WELD-MATIC SYNCHRO PULSE

MODEL NO. CP29

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CAT.

1 0 / 8 0

THE. INFOFOlATION CONTAINED I N THE FOLDER I S SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER I S KEPT I N A SAFE PLACE FOR FXADY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NO. O F THE MACHINE AND PART NO. O F THE ITEM REQUIRED. FAILURE TO SUPPLY THIS INFORPWTION WILL RESULT I N UNNECESSARY DELAYS I N SUPPLYING THE CORRECT PARTS.

WELDING INDUSTRIES O F AUSTRALIA PTY. LTD.

Melbourne 4 2 9 4 7 6 6 Sydney 534 2 1 4 4 Newcastle 6 1 1 6 6 8 Adelaide 3 5 2 3 0 2 2 P e r t h 3 6 1 7 0 8 8 B r i s b a n e 44 1 3 9 1 L a u n c e s t o n 3 1 7 0 0 4 Darwin 8 1 6 4 2 7 & 8 4 3 0 7 6

OPERATING AND MAINTENANCE’ INSTRUCTIONS ”

WELDMATIC SYNCHROPULSE 2 5 0 ( C P 2 9 )

INTRODUCTION - GENERAL

T h i s m a n u a l h a s b e e n p r e p a r e d e s p e c i a l l y f o r u s e i n fami l ia r - i z i n g p e r s o n n e l w i t h t h e d e s i g n , i n s t a l l a t i o n , o p e r a t i o n , ma in tenance , and t roub le shoo t ing o f t h i s equ ipmen t . A l l i n f o r m a t i o n p r e s e n t e d h e r e i n s h o u l d b e g i v e n c a r e f u l c o n s i d - e r a t i o n t o a s s u r e opt imum per formance of th i s equipment ,

- RF:CEIVING/HANDLING.

P r i o r t o i n s t a l l i n g t h i s e q u i p m e n t , c l e a n a l l pack ing material f r o m a r o u n d t h e u n i t a n d c a r e f u l l y i n s p e c t fo r any damage t h a t may have occu r red du r ing sh ipmen t . Any claims f o r l o s e s o r damage t h a t may h a v e o c c u r r e d i n t r a n s i t m u s t be f i l e d by t h e p u r c h a s e r w i t h W e l d i n g I n d u s t r i e s of A u s t r a l i a P t y . L t d . o r a u t h o r i s e d a g e n t i m m e d i a t e l y ( refer t o EQUIPMENT WARRANTY card e n c l o s e d w i t h O p e r a t i n g I n s t r u c t i o n M a n u a l ) .

When r e q u e s t i n g i n f o r m a t i o n c o n c e r n i n g t h i s e q u i p m e n t , i t i s e s s e n t i a l t o supp ly correct Model i d e n t i f i c a t i o n a n d m a c h i n e se r ia l number.

SAFETY

Befo re t he equ ipmen t i s p u t i n t o o p e r a t i o n , t h e SAFETY PRACTICES s e c t i o n a t t h e b a c k of t h i s m a n u a l MUST BE READ COMPLETELY. T h i s w ? l l h e l p a v o i d p o s s i b l e i n j u r y d u e t o m i s u s e o r i m p r o p e r w e l d i n g a p p l i c a t i o n s .

CONTENTS.

G e n e r a l D e s c r i p t i o n

I

PAGE NO.

1

S e t t i n g u p for Opera t ion 2

W e l d i n g O p e r a t i o n I n s t r u c t i o n s 3

M a i n t e n a n c e I n s t r u c t i o n s 4 & 5

Par ts L i s t CP29-0 I s s u e 1 6

Assembly Drawing CP29-0 I s s u e 1

Circu i t D iag ram - C P 2 9 - C l

Mobile K i t Assembly - AM117

S a f e t y Practices

Guarantee Card

7

8

1 STANDARD UNIT.

The "Weldmat i c" Synchro -Pu l se p l an t cons i s t s o f t h ree bas i c

a) CP29 'Synchro-Pulse ' Power Source b ) W17 type Semi-automatic wire f e e d e r ( f a c t o r y f i t t e d w i t h

v e r n i e r t y p e w i r e - f e e d e r c o n t r o l ) c) Welding gun and cable assembly.

i terns.

O p t i o n a l items i n c l u d e - - AI4117 Mobile k i t AM89 Ba lanc ing boom assembly.

1. POWER SOURCE FEATURES. - The W . I . A . CP29 "Synchro-Pulse" Power Source i s a d u a l p u r p o s e

machine which combines f a c i l i t i e s f o r s t a n d a r d G.M.A. w e l d i n g i n t h e C o n s t a n t P o t e n t i a l ' M I G ' mode, and Pulsed G.M.A. w e l d i n g i n t h e ' PULSE mode.

The c o r r e c t a p p l i c a t i o n o f t h e P u l s e f a c i l i t y e n a b l e s w e l d i n g t o o c c u r , i n s p r a y t r a n s f e r , a t a v e r a g e c u r r e n t s much lower t han n o r m a l l y a n t i c i p a t e d f o r a p a r t i c u l a r e l e c t r o d e m a t e r i a l / d i a m e t e r c o m b i n a t i o n . I n t h i s w a y , t h i n s e c t i o n materials may be welded w i t h r e d u c e d h e a t i n p u t i n t o t h e w o r k p i e c e .

I n t h e MIG mode, t h e w e l d i n g v o l t a g e i s a d j u s t a b l e t h r o u g h 30 s t e p s , as s e l e c t e d b y a 3 p o s i t i o n 'COARSE' swi t ch and a 10 p o s i t i o n ' F I N E ' s w i t c h .

I n t h e PULSE mode, t h e w e l d i n g p a r a m e t e r s are determined by a p p r o p r i a t e s e t t i n g of t h e f o l l o w i n g c o n t r o l s .

- 10 p o s i t i o n ' F I N E ' s w i t c h . - 4 p o s i t i o n B a c k g r o u n d c u r r e n t / O p e n c i r c u i t v o l t a g e

s w i t c h .

0 t h

5 p o s i t i o n Continuous

Pulse f requency swi tch (100 ,50 ,33 ,25 ,16HTZ) c o n t r o l o f t h e P u l s e W i d t h i n t h e r a n g e

0-9111s. e r f e a t u : r e s o f t h e P o w e r S o u r c e i n c l u d e t h e r m o s t a t i c p r o t e c t i o n

o f t h e r e c t i f i e r a s s e m b l y , p o w e r f u l s i n g l e p h a s e a x i a l c o o l i n g f a n , H.F. p r o t e c t i o n f o r s e m i c o n d u c t o r d e v i c e s , a n d p r o v i s i o n of l l O V ac f u s e d gas h e a t e r o u t l e t .

2 . INSTALLATION. - Supply and Welding Cables Note The e l e c t r i c a l connec t ion

t o tEe Mains Supply should on ly be under taken by a q u a l i f i e d e l e c t r i c i a n .

The CP29 Synchro-Pulse i s d e s i g n e d f o r c o n n e c t i o n t o a 415v, 5 0 Htz, 3g Supply. The recommended f u s e s i z e , p r imary cab le and we ld ing cable are as below.

- Fuse - 15 amp. wire t y p e - P r i m a r y c a b l e - 4 core 30/0.25 TRS - Weld ing cab le s - 1 1 2 1 / 0 . 2 0 TRS.

Access t o t h e s u p p l y c o n n e c t i o n t e r m i n a l s i n t h e m a c h i n e i s g a i n e d t h r o u g h t h e h i n g e d f l a p o n t h e R.H. S . cover o f t he mach ine . The e a r t h ( g r o u n d ) c o n n e c t i o n ( g r e e n / y e l l o w wire) m u s t b e s e c u r e l y f a s t e n e d t o t h e 'EARTH' t e r m i n a l a d j a c e n t t o t h e s u p p l y t e r m i n a l b l o c k . A clamp i s s u p p l i e d t o a n c h o r . t h e p r i m a r y c a b l e .

2

MACHINE ' SET-UP ' . - refer f i g . 1.

Ensure t h e CP29 Power Source i s t u r n e d OFF. Connect t h e c o n t r o l cable t o t h e wire feeder ( n o t e c o n n e c t i o n

c h a r t a d j a c e n t t o wire f e e d e r c o n n e c t o r s t r i p ) a n d p l u g i n t o t h e s o c k e t o n the CP29 f r o n t p a n e l .

Connect the gas hose f rom t h e g a s r e g u l a t o r / f l o w m e t e r t o t h e back of t h e wire feeder e n s u r i n g a l l c o n n e c t i o n s are f i r m l y t i g h t - e n e d . I n s e r t t h e gun c a b l e i n t o t h e s o c k e t of t h e wire feed dr ive c a s t i n g . C o n n e c t gas hose and gun swi t ch l eads o f t h e gun cable assembly t o t h e i r respective s o c k e t s o n t h e wire feeder f r o n t p a n e l .

Bo th s t anda rd ' M I G ' and 'PULSE' Mig we ld ing are DCRP p r o c e s s e s , t h a t i s the e l e c t r o d e wire i s POSITIVE w i t h r e s p e c t t o t h e w o r k p i e c e . T h e r e f o r e , c o n n e c t t h e 'WORK' lead t o common n e g a t i v e ( - 1 o u t p u t s o c k e t , a n d t h e gun c a b l e l e a d t o t h e a p p r o p r i a t e p o s i t i v e (+) o u t p u t socket. I n s e r t t h e w e l d i n g l e a d p l u g f u l l y i n t o t h e s o c k e t , and twist c lockwise t o l o c k .

E

FUNCTION CHECK.

1) Switch the Power Source ' O N ' . Check 'POWER O N ' l i q h t s a t b o t h t h e Power Source and the Wire Feede r . Check ?or fan o p e r a t i o n .

2) Test 'GAS PURGE' and ' INCH' f a c i l i t i e s a t t h e wire feeder. Set the gas f low rate a c c o r d i n g t o t h e weld pa rame te r s r e q u i r e d , b u t u s u a l l y i n t h e r a n g e o f 8 - 10 l i t r e s / m i n u t e . Note t h a t p a r t i c u l a r l y when ' P u l s e ' w e l d i n g , e x c e s s i v e g a s f low can adversely a f fec t t h e w e l d i n g r e s u l t .

3) Test f o r t h e correct o p e r a t i o n of t h e gun s w i t c h , i . e . s h i e l d - i n g g a s , wire f eed and mach ine con tac to r .

4) Set t h e f e e d r o l l e r p r e s s u r e . T h i s s h o u l d be set w i t h j u s t s u f f i c i e n t r o l l e r p r e s s u r e t o achieve p o s i t i v e w i r e feed.

3

WELDING OPERATION INSTRUCTIONS.

C o n s t a n t P o t e n t i a l "IC' Welding (GMAW) . E n s u r e t h a t t h e gun cable l e a d i s c o n n e c t e d t o t h e correct

o u t p u t s o c k e t , t h a t t h e d e s i r e d s h i e l d i n g g a s i s s u p p l i e d . S e t t h e ' C O A R S E ' s w i t c h t o e i ther p o s i t i o n 1 , 2 & 3 . The 'PULSE CONTROLS' w i l l have no e f fec t i n t h i s mode.

F o r a n y p a r t i c u l a r w e l d i n g e l e c t r o d e wire d i a m e t e r , t h e we ld ing c u r r e n t i s b a s i c a l l y se t by t h e wire feed ra te . To achieve optimum w e l d i n g c o n d i t i o n s , i t i s n e c e s a r y t o a d j u s t t h e w e l d i n g v o l t a g e t o ma tch t he wire feed r a t e . I f t h e v o l t a g e i s t o o low f o r t h e a p p l i c a - t i o n , wire ' s t u b b i n g ' w i l l o c c u r , p a r t i c u l a r l y a t t h e s t a r t o f the w e l d . I n a d d i t i o n , t he weld c o n t o u r w i l l be v e r y c o n v e x . I f t h e v o l t a g e i s t o o h i g h , metal t ransfer w i l l be e r r a t i c , a n d t h e r e w i l l be e x c e s s a r c s p a t t e r . With t h e w e l d i n g c u r r e n t a n d v o l t a g e matched, t h e r e s u l t w i l l be smooth running a rc , w i t h a minimum s p a t t e r loss.

The s h i e l d i n g g a s e s n o r m a l l y u s e d are: 1 0 0 % Carbon Dioxide, o r a Carbon Dioxide/Argon mixture.

PULSE ' M I G ' WELDING.

Ensure t h a t the gun c a b l e lead i s c o n n e c t e d t o t h e 'PULSE' o u t p u t s o c k e t . F o r P u l s e w e l d i n g , Argon ( p r e . f e r a b l y a High Pu r i ty g rade ) i s t h e r e q u i r e d s h i e l d i n g g a s . Note t h a t s p r a y t r a n s f e r w i l l n o t o c c u r i f Ca rbon D iox ide sh i e ld ing gas i s used .

I n P u l s e ' M I G ' Weld ing , the arc' c u r r e n t i s n o t c o n s t a n t , b u t i s modulated by the Power Source between two d i s t i n c t d i f f e r e n t v a l u e s . These two c u r r e n t levels are known as:-

a) The Background cur ren t - the lower v a l u e . b ) The P u l s e c u r r e n t - t h e h i g h e r v a l u e .

The Background cur ren t serves t o m a i n t a i n t h e a rc between p u l s e c u r r e n t p e r i o d s , a n d w i t h t h e CP29 i s t y p i c a l l y b e t w e e n 9 - 20 Amps.

The P u l s e c u r r e n t , w h i c h i s o f t h e o r d e r o f 300 Amps. peak , i s r e s p o n s i b l e f o r t h e t r ans fe r of e l e c t r o d e material i n t o t h e weld poo l .

I n a c o r r e c t l y a d j u s t e d P u l s e M I G arc , o n e d r o p l e t of mol ten e l e c t r o d e material i s d e p o s i t e d o n t h e work -p iece fo r each c u r r e n t pu lse . Because o f t h i s ' o n e d r o p l e t p e r p u l s e ' r e l a t i o n s h i p , t h e wire feed ra te , and t h e p u l s e f r e q u e n c y ra te a rc i n t e r - d e p e n d a n t . For any p a r t i c u l a r p u l s e f r e q u e n c y , t h e r e i s a ' r ange o f wire f e e d ra tes o v e r w h i c h s a t i s f a c t o r y r e s u l t s w i l l b e o b t a i n e d , b u t i n g e n e r a l , a low p u l s e f r e q u e n c y r e q u i r e s a low wire-feed r a t e , a n d v i c e versa.

The 'PULSE W I D T H ' c o n t r o l i s u s e d t o a d j u s t the e n e r g y v a l u e o f t h e c u r r e n t p u l s e . I f t h i s s e t t i n g i s t o o l o w , s p r a y t r a n s f e r canno t occu r , and t he we ld w i l l be a series o f e x p l o s i v e s h o r t c i r c u i t s . I f the p u l s e w i d t h i s set t o o h i g h , t h e arc w i l l be too l ong , and t h e weld d e p o s i t e r r a t i c . The i d e a l s e t t i n g w i l l achieve f u l l s p r a y t r a n s f e r , w i t h a s h o r t arc l e n g t h . The P u l s e W i d t h c o n t r o l s h o u l d b e a l tered s lowly when approach ing a s a t i s f a c t o r y s e t t i n g .

4

If d e s i r e d , the arc l e n g t h may a l s o be a l te red by changing t h e w i r e - f e e d r a t e . R e d u c i n g t h i s w i l l l e n g t h e n t h e a r c , and i n c r e a s i n g it w i l l s h o r t e n t h e arc . N o t e t h a t f o r a n y p a r t i c u l a r p u l s e f r e q u e n c y , t h e r e i s a minimum w i r e - f e e d ra te , below which there i s i n s u f f i c i e n t e l e c t r o d e m a t e r i a l a v a i l a b l e t o form "one d r o p l e t p e r p u l s e " , w i t h a subsequen t loss o f c o n t r o l o f the arc ,

The s e t t i n g o f t h e 'F INE VOLTAGE' s w i t c h a f fec ts t h e p e a k p o t e n t i a l c u r r e n t o f t he p u l s e . For most work t h i s swi tch may be se t t o '10'.

The 'BACKGROUND CURRENT' s w i t c h may norma l ly be set t o ' A ' , b u t c a n be se t h i g h e r s h o u l d t h e work-piece be comtaminated w i t h o i l o r grease, o r f o r h i g h e r w e l d i n g c u r r e n t s e t t i n g s .

S o f t S t a r t Con t ro l . Dur ing the weld commencement p e r i o d t h e o u t p u t charac te r i s t ics of t h e Power Source are mod i f i ed t o provide improved arc i n i t i a t i o n . The ' S o f t S t a r t c o n t r o l sets t h e time s p a n o f t h e m o d i f i e d c h a r a c t e r i s t i c s . If t h e c o n t r o l i s s e t f o r a p e r i o d t o o l o n g , t h e a rc w i l l t e n d t o r u n u p t o t h e t i p . I f the c o n t r o l i s se t f o r a p e r i o d t o o s h o r t , there w i l l t e n d t o be a series o f e x p l o s i v e s h o r t c i r c u i t s a t arc s t a r t - u p .

SAFETY DEVICES.

I n t h e e v e n t o f t h e power sou rce becoming ove rhea ted t he t he rmos ta t s on t h e diode and S C R heat s i n k s w i l l o p e r a t e p r e v e n t i n g f u r t h e r weld- i n g . The thermostats w i l l a u t o m a t i c a l l y reset and wi th t h e c o o l i n g f a n o p e r a t i n g t h i s w i l l take approx ima te ly LO minu tes . A check shou ld be made t o a s c e r t a i n t h e r e a s o n for t h e o v e r h e a t i n g s u c h as f a n n o t o p e r a t i n g or a i r f l o w r e s t r i c t e d . F u s e s p r o v i d e d f o r a l l c i r c u i t s are as fo l lows and are i n d i c a t e d on t h e f r o n t p a n e l : -

Fuse E l - 3 amps. (Delayed a c t i o n ) Fuse E 2 - 3 amps. ( II 'I ) Fuse E 3 - 5 amps. ( 1 Fuse E 4 - 5 amps. ( 'I If )

MAINTENANCE.

a) Power Source.

Apar t f rom t h e f a n t h e rect i f ier has no rotary componments . To ach ieve comple t e d i s s ipa t ion o f hea t f rom the ac t ive componen t s , t h e r e c t i f i e r shou ld be thorougly blown off w i t h d r y compressed a i r a f t e r 6 months ' ope ra t ion . C lean ing shou ld be car r ied o u t a t s h o r t e r i n t e r - v a l s i f d u s t a c c u m u l a t i o n i s c o n s i d e r a b l e .

P r i o r t o c l e a n i n g , r emove t he un i t cove r by de t achmen t o f l ugs a n d t h e f i x i n g screws. Thus a l l the components o f the power source w i l l be a c c e s s i b l e .

b) The wire-feed motor/gearbox i s pre-packed w i t h grease and needs n o o t h e r l u b r i c a t i o n . Change the grease a f te r approx ima te ly 4 , 0 0 0 s e r v i c e h o u r s . (see Wire Feeder I n s t r u c t i o n M a n u a l ) .

The d r ive rollers and t h e i n n e r wire g u i d e s s h o u l d b e k e p t c l e a n . If n e c e s s a r y , blow o f f t h e i n s i d e o f t h e wire feeder w i t h compressed a i r .

c) - Gun and Cable

P a r t i c u l a r l y when w e l d i n g i n t h e 'PULSE' mode, smooth and c o n s t a n t wire f e e d i s e s s e n t i a l t o a c h i e v i n g s a t i s f a c t o r y w e l d i n g c o n d i t i o n s .

Remove a n y s p a t t e r w h i c h m i g h t a d h e r e t o t h e n o z z l e bore SO t h a t t h e s h i e l d i n g gas o u t f l o w i s not impeded. The c o n d i t i o n o f t he c o n t a c t t u b e s s h o u l d b e r e g u l a r l y checked. Damaged, b u r n t o r w o r n t u b e s are an impediment t o t r o u b l e - f r e e w e l d i n g o p e r a t i o n a n d s h o u l d be r ep laced immedia t e ly .

T r o u b l e - f r e e o p e r a t i o n a l so depends t o a l a r g e e x t e n t on t h e g o o d c o n d i t i o n a n d c l e a n l i n e s s o f t h e i n n e r wire l i n e r ( S e e I n s t r u c - t i o n s o n Gun C a b l e s ) .

WELDING - OPERATION

Never o b s e r v e t he a rc w i t h u n p r o t e c t e d e y e s . I t i s of impor- t a n c e t h a t t h e we lde r wear p r o t e c t i v e c l o t h i n g p r o v i d i n g s u f f i c i e n t s a f e t y .

- S W P P A G E S AND THEIR ELIMINATION

The machine should be checked on ly by a f u l l y s k i l l e d elec- t r i c i a n .

If t h e u n i t s t o p s w o r k i n g , f i r s t de te rmine whe the r s toppages are i n i t i a t e d by t h e mains ( f o r i n s t a n c e , b u r n t f u s e ) o r by t h e supply

the u n i t p r o p e r .

on the p r i m a r y t e r m i n a l

u n i t i t s e l f .

w i l l f a c i l i t a t e t h e

(Voltmeter r e a d i n g ) t h e

cable ( l o o s e c o n n e c t i o n , cable break) o r by

If t h e three t e r m i n a l s L 1 , L2 and L3 b o a r d are c o r r e c t l y c o n n e c t e d t o t h e m a i n s cause o f t h e s toppage mus t be s o u g h t i n t h e

The w i r i n g d i a g r a m on t h e n e x t p a g e s l o c a t i o n o f t h e d e f e c t .

5a

WELDING DATA - TYPICAL VALUES

S h i e l d i n g Gas i s we ld ing Grade C 0 2 used w i t h a Gas P r e h e a t e r . C o n t a c t Tip l , t imm i n s i d e sf Gas Nozzle. Wire "St ick O u t " 6 - 9mmup t o 200 amps. 9 - 12mmover 200 amps. These Tables a re a g u i d e o n l y € o r i n i t i a l m a c h i n e s e t t i n g a n d f i n e r a d j u s t m e n t s may he n e c e s s a r y to achieve opt imum welding character is t ics fo r t h e a p p l i c a t i o n . Recommended m a c h i n e s e t t i n g m e t h o d i s t o s e t Voltage Swi tches , Induc tance and Gas Flow as per Table t h e n a d j u s t wire speed t o o b t a i n r e c m e n d e d c u r r e n t .

Volts Amps. 2.5(metres/min) 18.0 L00

18.5 l30 19.0 1.48 20.0 160 23.0 200

23.0 230 28.0 250

12.1 ' I

16.8 I'

NOTE: Wire speed i s shown i n rnetres/minute and are n o t d i a l c a l i b r a t i o n s e t t i n g s .

- I TEb NO.

1 2 3 4 5 6 7 8 9 LO 11 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2

' 2 3 2 4 2 5 2 6 2 7 2 8 29 30 31 3 2 3 3 3 4 35 36 37 3 8 39 4 0 41 4 2 4 3 44 4 5 4 6

- PART NO.

CP29-32 C P 2 9 - 1 1 CP28-17 C P 1 5 - l 4 C P 2 9 - l 8 CP29-0/6 CP29-0/7 CP15-0/7 CP2-0/13 CP2-0/13 CP3-0/30 CP3-0/35 CP3-0/47 Wl-22 W 1 - 2 3 CP25-0/18 CP29-0/18 CP28-0/17 CP29-0/20 CP15-0/14 CP28-0/20 C P 2 8 - 0 / 2 1 I

CP28-0/22 CP29-20 CP29-23 CP29-24 CP29-19 2P25.146 2P35-13 ZP35-14/1, 3 ' 3 5 - 1 4 / 2 ? P 2 9 - 2 1 4IN44 iIC14-1/14 U N 8 1 IM16 1P35-18 P 2 5 - 4 7 :P29-0/39 J5-10/19

1P29-0/46 lP29-26 !P29-25 !P29-33 !P2-0/13

6

DRAWING NO. CP29-0 PARTS L I S T .

DESCRIPTION

BASE FF3U4E ASSEMBLY T R A N S F O M R ASSEDBLY COMMUTATING INDUCTANCE INDUCTANCE ASSEMBLY RECTIFIER ASSEMBLY FAN BLADE FAN MOT.OR HEATER PLUG SOCKET WELDING CONTACTOR SOFT START CONTACTOR AMMETER SHUNT 0-400A AE4METER 0-400A. 'VOLTPETER 0-60V. INDICATOR LIGHT FUSE HOLDER FINE SELECTOR SWITCH COARSE SELECTOR SWITCH BACKGROUND SELECTOR SWITCH OFP/ON SWITCH CONTROL PLUG VERNIER POTENTIOMETER DIAL 10 TURN POTENTIOMETER 10K OHM. FREQUENCY SELECTION SWITCH PRINTED CIRCUIT BOARD ASSEMBLY BACKGROUND CURRFNT RESISTOR ZURRENT LIMITING RESISTOR FRONT PANEL BACK PANEL

LEFT HAND SIDE COVER RIGHT HAND SIDE COVER 3AFFLE & CONTACTOR MOUNT PYPE NO. /SERIAL NO. PLATE SUPPLY TERMINAL BLOCK CERMINAL CONNECTION PLATE IUTPUT TERMINALS 'IE BAR PAN MOUNTING BRACKET ;OFT START POTENTIOMETER 'OTENTIOmTER KNOB :YE NUT LOOM ASSEMBLY PRINTED CIRCUIT BOARD MOUNTING PLATE SCHADOW SWITCH MTG. PLATE CONTACTOR LINKS

rop COVER

MIG - PULSE CONTACTOR

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WELDMATIC 250

The W.I.A. CP29 "Synchro-Pulse'' Power Source is a dual purpose machine which combines facilities for standard G.M.A. welding in the Constant Potential 'MIG' mode, and Pulsed G.M.A. welding in the 'PULSE' mode. The flexibility of operation gives increased machine loading with a wider range of jobs possible. The correct application of the pulse facility permits spray transfer welding at average currents much lower than normally anticipated for a particular electrode material/diameter combination. This allows thin section material, both ferrous and non ferrous (for example 1.6 mm aluminium), to be welded with a narrower heat affected zone and eliminating the necessity to use other equipment or processes. By simply adjusting a switch and reconnecting an output lead, the SYNCHRO-PULSE can be used for all standard MIG (Gas Metal Arc) welding applications, where a 250 amp machine is required.

, . . , I . , I

The "Weldmatic" Synchro-Pulse plant consists of three basic items. (a) CP 29 'Synchro-Pulse' Power Source (b) W17 type Semi-automatic wire feeder (factory fitted with

vernier type wire-feeder control) (c) Welding gun and cable assembly.

Optional items include: AM117 Mobile kit (shown fitted to the machine) AM89 Balancing boom assembly.

~ . ~, - , . , .

' j . ' ; f ' . > $ 1 ;

In Pulse 'MIG' Welding, the arc current is not constant, but is modulated by the Power Source between two distinctly different values. These two current levels are known as:-

(a) The Background current - the lower value. tl (b) The Pulse current - the higher value. t2

The Background current serves to maintain the arc between pulse current periods, and with the CP29 is typically between 9-20 Amps. The Pulse current, which is of the order of 300 amps peak, is res- ponsible for the transfer of electrode material into the weld pool. The 'PULSE WIDTH' control is used to adjust the energy value of the current pulse. The setting of the 'FINE VOLTAGE' switch affects the peak potential current of the pulse. In a correctly adjusted Pulse MIG arc, one droplet of molten elec- trode material is deposited on the work-piece for each current pulse. Because of this 'one droplet per pulse' relationship, the wire feed rate; and the pulse frequency rate are interdependant. For any

which satisfactory results will be obtained, but in general, a low particular pulse frequency, there is a range of wire feed rates over

pulse frequency requires a low wire feed rate, and vice versa. For Pulse welding, Argon (preferably a High Purity grade) is the

Carbon Dioxide shielding gas is used. required shielding gas. Note that spray transfer will not occur if

:;,//: 1 ;I;I;,~I;: : ~ , \ ~ : J i ~ , ; ~

In the MIG mode, the welding voltage is adjustable through 30

position 'FINE' switch. steps, as selected by a 3 position 'COURSE' switch and a 10

In the PULSE mode, the welding parameters are determined by appropriate setting of the following controls.

- 10 position 'FINE' switch

- 5 position Pulse frequency switch (100, 50, 33, 25, 16 hz) - 4 position Background current/Open circuit voltage switch

- Continuous control of the Pulse Width in the range 0-9mS. Another feature of the Power Source is the thermostatic protection of the rectifier assembly.

stats on the diode and SCR heat sinks will operate preventing In the event of the power source becoming overheated the thermo-

further welding. The thermostats will automatically reset and with the cooling fan operating this will take approximately 10 minutes.

visions of l lOV AC fused gas heater outlet, It also has H.F. Protection for semiconductor devices, and pro-

0 W17 2 ROLL DRIVE MOTOR - U W17 WIREFEEDER FRONT PANEL

W18 WIREFEEDER SIDE VIEW

I'] AM117 MOBILE KIT

W. LA. wirefeeders . . . . , , I , . . , , , . . . . . .

MODEL: W1 7 POWER SUPPLY: 30 Volts 50Hz WIRE SPEED RANGE: 1-16 m/min GEAR BASE RATIO: 25:l WIRE SIZE RANGE: 0.8-2.4 mm DIMENSIONS: Length 420 mm

Width 310 mm Height 305 mm

WEIGHT: 15.5 kg

. , . .. . . . , . _ ,

, I .

MODEL: POWER SUPPLY: WIRE SPEED RANGE: GEAR BOX RATIO: WIRE SIZE RANGE: DIMENSIONS:

WEIGHT:

! I ,

W1 8 30 Volts 50Hz 1-16 m/min 50:l 0.8-3.2 mm

Width: 310 mm Length: 420 mm

Height: 305 mm 16Kg

OPTIONAL ACCESSORiES j Electronic digital wire feed meter which

displays wire speeds in metres per minute - (AM 129) 1 Spot welding and cycle arc timing con-

) Push & Pull wire feed aun and cable trols - (AM128)

1 Cable extension kits for remote mounting

j Wire coil bracket and mounting kit - ) Pre weld and post weld control of gas

flow for critical weld situations - (AM126) .3 Soft start and crater fill controls -

(AM127) ... 3 Telaboom for suspension mounting -

system for aluminium wires

of wire feeder

(W1 -48)

(2375 + Wl l -14 ) Bulk wire dereeling facilities for high volume applications - (AM38)

~3 Balancing boom mounting reduces opera- tor fatigue by supporting gun cable - (AM89)

-..l Mobile Kit - (AM117).

When you purchase W.I.A. products, you obtain

of Australia's own Welding Organization, quality, reliability and the dependable service

WELDIN6 CURRENT RATING: 250 Amps 30 volts 100% duty cyek 300 Amps 32 volts 60% duty cycle

OPEN CJVGUIT VOLTAGE:

BACKGROUNDCURRENT: PULSE FREQUENCY PULSE WIDTH: PRIMARY SUPPLY: FUSE RATING: SUPPLY CABLE: INSULATION: WELDING WIRE SIZE: SHIELDING 6AS: DIMENSIONS:

WEIGHT: STANDARD PACKAGE COMPRISES:

16-40 volts regulated through 3 coarse

voltage settings. ranges and 10 fine steps giving 30 progressive

12-20 amps adjustable in 4 steps 16,25,33, 50, IOOHz 0-9ms 415 volt 50Hz 3 phase 15 Amp 4 core 30/0.25 TRS Class B 90°C Temperature Rise 0.8, 0.9, 1.2, 1.6mm hard or soft wires C02, Argon or mixed gases. Length 785 mm x Width 560 mm Helght 665 mm (Skid mounted) 220 kg GP29 Power Source W17 Wirefeeder fitted with AM130 Vernler Speed Bernard Ezi-Feed 300 Amp Welding Gun Control TL4310 Gun Cable AMI 13 Accessory Lead Kit K2 Regulator/Flowmeter K4 Argon Gas Elbow AM111 Swlvel Mounting W14-16 Mounting Bracket

WELDMATIC SYNCHRO PULSE

MODEL NO. CP29 - 1 0 0 s

"""""""""""

CAT.

0 1 / 8 2

THE INFORMATION CONTAINED I N THE FOLDER I S SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE, THAT YOU OBTAIN M A X I M U M OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER I S KEPT I N A SAFE PLACE FOR W A D Y REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NO.

SUPPLY THIS INFOFNATION WILL RESULT I N UNNECESSARY DELAYS I N SUPPLYING THE CORRECT PARTS.

OF THE MACHINE AND PART NO. O F THE ITEM REQUIRED. FAILURE: TO

WELDING INDUSTRIES O F AUSTRALIA PTY. LTD.

Melbourne 429 4 7 6 6 Sydney 5 3 4 2 1 4 4 Newcastle 61 1 6 6 8 Adelaide 3 5 % 3 0 2 2 P e r t h 3 6 1 7 0 8 8 Brisbane 4 4 1 3 9 1 Eauneeston 317 004 Darwin 81 6427 & 8 4 3076

U

OPERATING AND MAINTENANCE INSTRUCTIONS

WELDMATIC SYNCHROPULSE 2 5 0 (GP29 - 100s) - INTRODUCTION - GENERAL

T h i s m a n u a l h a s b e e n p r e p a r e d e s p e c i a l l y f o r u s e i n fami l ia r - i z i n g p e r s o n n e l w i t h t h e d e s i g n , i n s t a l l a t i o n , o p e r a t i o n , ma in tenance , and t roub le shoo t ing of t h i s e q u i p m e n t . A l l i n f o r m a t i o n p r e s e n t e d h e r e i n s h o u l d b e g i v e n c a r e f u l c o n s i d - e r a t i o n t o a s s u r e optimum performance of t h i s e q u i p m e n t ,

- RECEIVING/HANDLING.

P r i o r t o i n s t a l l i n g t h i s e q u i p m e n t , c l e a n a l l p a c k i n g m a t e r i a l f r o m a r o u n d t h e u n i t a n d c a r e f u l l y i n s p e c t €or any damage t h a t may have occu r red du r ing sh ipmen t . Any c l a i m s for l o s e s o r damage t h a t may h a v e o c c u r r e d i n t r a n s i t must be f i l e d by t h e p u r c h a s e r w i t h W e l d i n g I n d u s t r i e s o f A u s t r a l i a P t y . L t d . o r a u t h o r i s e d a g e n t i m m e d i a t e l y ( r e f e r t o EQUIPMENT WARRANTY c a r d e n c l o s e d w i t h O p e r a t i n g I n s t r u c t i o n M a n u a l ) .

When r e q u e s t i n g i n f o r m a t i o n c o n c e r n i n g t h i s e q u i p m e n t , it i s e s s e n t i a l t o supp ly correct Model i d e n t i f i c a t i o n a n d m a c h i n e se r ia l number.

SAFETY

Befo re t he equ ipmen t is p u t i n t o o p e r a t i o n , t h e SAFETY PRACTICES s e c t i o n a t t h e b a c k of t h i s manual MUST BE READ COMPLETELY. Th i s w i l l h e l p avoid p o s s i b l e i n j u r y d u e t o m i s u s e o r i m p r o p e r w e l d i n g a p p l i c a t i o n s .

CONTENTS.

G e n e r a l D e s c r i p t i o n

PAGE NO.

1

S e t t i n g u p f o r O p e r a t i o n 2

W e l d i n g O p e r a t i o n I n s t r u c t i o n s 3

~ 4 a i n t e n a n c e I n s t r u c t i o n s 4 & 5

Pa r t s L i s t CP29-0 I s s u e 1 6

7 Assembly Drawing CP29-0 I sSue 1

Circu i t D iag ram - CP29-CS 8

Mobile K i t Assembly - AM117

S a f e t y Practices

Guarantee Card

v e r n i e r t y p e w i r e - f e e d e r c o n t r o l ) c) Welding gun and cable assembly.

O p t i o n a l items i n c l u d e - - AM1 1 7 Mobile k i t AM8 9 Ba lanc ing boom assembly.

1. POWER SOURCE FEATURES.

The W . I . A . CP29 "Synchro-Pulse" Power Sol lrce i s - a d u a l p u r p o s e machine which combines f a c i l i t i e s f o r s t a n d a r d G.M.A. weld ing i n t h e C o n s t a n t P o t e n t i a l ' M I G ' mode, and Pulsed G.M.A. w e l d i n g i n t h e I PULSE mode.

The c o r r e c t a p p l i c a t i o n of t h e P u l s e f a c i l i t y e n a b l e s w e l d i n g t o o c c u r , i n s p r a y t r a n s f e r , a t a v e r a g e c u r r e n t s much lower t h a n n o r m a l l y a n t i c i p a t e d f o r a p a r t i c u l a r e l e c t r o d e m a t e r i a l / d i a m e t e r combina t ion . In t h i s way , t h i n s e c t i o n materials may be welded w i t h r e d u c e d h e a t i n p u t i n t o t h e work p i e c e .

I n t h e MIG mode, t h e w e l d i n g v o l t a g e i s a d j u s t a b l e t h r o u g h 30 s t e p s , as s e l e c t e d b y a 3 p o s i t i o n 'COARSE' swi tch and a 1 0 p o s i t i o n ' F I N E ' s w i t c h .

I n t h e PULSE mode, t h e w e l d i n g p a r a m e t e r s are determined by a p p r o p r i a t e s e t t i n g o f t h e f o l l o w i n g c o n t r o l s .

- LO p o s i t i o n ' F I N E ' s w i t c h . - 4 p o s i t i o n B a c k g r o u n d c u r r e n t / O p e n c i r c u i t v o l t a g e

- 5 p o s i t i o n P u l s e f r e q u e n c y s w i t c h (LOO , 50 ,33 ,25 , 16HTZ) - C o n t i n u o u s c o n t r o l of t h e P u l s e W i d t h i n t h e r a n g e

s w i t c h .

0-9mS.

O t h e r f e a t u r e s o f t h e P o w e r S o u r c e i n c l u d e t h e r m o s t a t i c p r o t e c t i o n o f t h e r e c t i f i e r a s s e m b l y , p o w e r f u l s i n g l e p h a s e a x i a l c o o l i n g f a n , H . F . p r o t e c t i o n f o r s e m i c o n d u c t o r d e v i c e s , a n d p r o v i s i o n of l l O V ac f u s e d g a s h e a t e r o u t l e t .

2 . INSTALLATION.

Supply and Welding Cables Note The e l e c t r i c a l connec t ion t o tEe Mains Supply should on ly be under taken by a q u a l i f i e d e l e c t r i c i a n .

The CP29 Synchro-Pulse i s d e s i g n e d f o r c o n n e c t i o n t o a 415v, 50 H t z , 3$l Supply. The recommended f u s e s i z e , p r imary cab le and w e l d i n g c a b l e are as below.

- Fuse - 15 amp. wire t y p e - Pr imary cab le - 4 core 30/0.25 TRS - Weld ing cab le s - 1 1 2 1 / 0 . 2 0 TRS.

Access t o t h e s u p p l y c o n n e c t i o n t e r m i n a l s i n t h e m a c h i n e i s g a i n e d t h r o u g h t h e h i n g e d f l a p o n t h e R. H . S . cove r of the machine . The e a r t h ( g r o u n d ) c o n n e c t i o n ( g r e e n / y e l l o w wire) m u s t b e s e c u r e l y f a s t e n e d t o t h e 'EARTH' t e r m i n a l a d j a c e n t t o t h e s u p p l y te rmina l b l o c k . A clamp i s s u p p l i e d t o a n c h o r t h e p r i m a r y c a b l e .

2

MACHINE 'SET-UP' . - refer f i g . 1.

Ensure t h e CP29 Power Source i s t u r n e d OFF. C o n n e c t t h e c o n t r o l c a b l e t o t h e wire f e e d e r ( n o t e c o n n e c t i o n

c h a r t a d j a c e n t t o wire f e e d e r c o n n e c t o r s t r i p ) a n d p l u g i n t o t h e s o c k e t on t h e CP29 f r o n t p a n e l .

Connect the gas hose f rom t h e gas r e g u l a t o r / f l o w m e t e r t o t h e b a c k o f t h e wire f e e d e r e n s u r i n g a l l c o n n e c t i o n s are f i r m l y t i g h t - e n e d . I n s e r t t h e gun c a b l e i n t o t h e s o c k e t o f t h e wire f e e d d r i v e cas t ing . Connect gas hose and gun swi tch l eads of t h e gun c a b l e a s s e m b l y t o t h e i r r e s p e c t i v e s o c k e t s on t h e wire f e e d e r f r o n t p a n e l .

Bo th s t anda rd ' M I G ' and 'PULSE' Mig we ld ing are DCRP p r o c e s s e s , t h a t i s t h e e l e c t r o d e wire is POSITIVE w i t h r e s p e c t t o t h e w o r k p i e c e . T h e r e f o r e , c o n n e c t t h e 'WORK' l e a d t o common n e g a t i v e ( - 1 o u t p u t s o c k e t , and t h e gun c a b l e l e a d t o t h e a p p r o p r i a t e p o s i t i v e (+) o u t p u t s o c k e t . I n s e r t t h e w e l d i n g lead p lug f u l l y i n t o t h e s o c k e t , and twist c lockwise t o l o c k .

REGULATOR FIGURE 1

,* 1 E

GUN CABLE LEAD

WORK LEAD

FUNCTION CHECK.

1) S w i t c h t h e Power Source ' O N ' . Check 'POWER O N ' l i g h t s a t b o t h t h e Power Source and t h e Wire Feede r . Check f o r f a n o p e r a t i o n .

2 ) Test 'GAS PURGE' and ' I N C H ' f a c i l i t i e s a t t h e wire f e e d e r . S e t t h e g a s flow r a t e a c c o r d i n g t o t h e w e l d p a r a m e t e r s r e q u i r e d , b u t u s u a l l y i n t h e r a n g e of 8 - 10 l i t r e s / r n i n u t e . N o t e t h a t p a r t i c u l a r l y when ' P u l s e ' w e l d i n g , excessive gas flow c a n a d v e r s e l y a f f e c t t h e w e l d i n g r e s u l t .

3 ) Test f o r t h e c o r r e c t o p e r a t i o n of t h e gun s w i t c h , i.e. s h i e l d - i n g g a s , wire feed and machine contac tor .

4) Set t h e f e e d r o l l e r p r e s s u r e . T h i s s h o u l d b e se t w i t h just s u f f i c i e n t r o l l e r p r e s s u r e t o a c h i e v e p o s i t i v e wire f e e d .

3

E n s u r e t h a t t h e gun c a b l e l e a d i s c o n n e c t e d t o t h e c o r r e c t o u t p u t s o c k e t , t h a t t h e d e s i r e d s h i e l d i n g gas i s s'izpplied. S e t t h e 'COARSE' s w i t c h t o e i t h e r p o s i t i o n 1,2&3. The 'PULSE CONTROLS w i l h a v e n o e f f e c t i n t h i s mode.

1

F o r a n y p a r t i c u l a r w e l d i n g e l e c t r o d e wire d i a m e t e r , t h e w e l d i n g c u r r e n t i s b a s i c a l l y se t b y t h e wire f e e d r a t e . To a c h i e v e optimum w e l d i n g c o n d i t i o n s , i t i s n e c e s a r y t o a d j u s t t h e w e l d i n g v o . l t a g e t o match the wire f e e d rate. If t h e v o l t a g e i s t o o l o w f o r t h e a p p l i c a - t i o n , wire " s t u b b i n g ' w i l l o c c u r , p a r t i c u l a r l y a t t h e s t a r t of t h e w e l d . I n a d d i t i o n , t h e weld contour w i l l b e v e r y convex. If t h e v o l t a g e i s too h i g h , metal t r a n s f e r w i l l be e r r a t i c , a n d t h e r e w i l l be excess a rc s p a t t e r . W i t h t h e w e l d i n g c u r r e n t a n d v o l t a g e m a t c h e d , t h e r e s u l t w i l l be smooth running a rc , w i t h a minimum s p a t t e r loss.

The s h i e l d i n g g a s e s n o r m a l l y u s e d are: 1 0 0 % Carbon Dioxide , o r a Carbon Dioxide/Argon mixture.

PULSE ' M I G ' WELDING.

Ensure t h a t t h e gun c a b l e l e a d i s c o n n e c t e d t o t h e 'PULSE' o u t p u t s o c k e t . For P u l s e w e l d i n g , A r g o n ( p r e f e r a b l y a High Pu r i ty g rade ) i s t h e r e q u i r e d s h i e l d i n g g a s . N o t e t h a t s p r a y t ransfer w i l l n o t o c c u r i f Ca rbon D iox ide sh i e ld ing gas i s used.

I n P u l s e ' M I G ' Weld ing , the a rc c u r r e n t i s n o t c o n s t a n t , b u t i s modula ted by the Power S o u r c e b e t w e e n t w o d i s t i n c t d i f f e r e n t v a l u e s , These t w o c u r r e n t levels are known as:-

a) The Background cur ren t - t h e l ower va lue . b) The P u l s e c u r r e n t - t h e h i g h e r v a l u e .

The Background current serves t o m a i n t a i n t h e a rc between p u l s e c u r r e n t p e r i o d s , a n d w i t h t h e CP29 i s t y p i c a l l y b e t w e e n 9 - 20 Amps.

The P u l s e c u r r e n t , w h i c h i s o f t h e o r d e r o f 300 Amps. peak, i s r e s p o n s i b l e f o r t h e t r a n s f e r of e l e c t r o d e material i n t o t h e w e l d p o o l .

I n a c o r r e c t l y a d j u s t e d P u l s e M I G a rc , o n e d r o p l e t of molten e l e c t r o d e material i s depos i t ed on t he work -p iece f o r e a c h c u r r e n t pu lse . Because of t h i s ' o n e d r o p l e t p e r p u l s e ' r e l a t i o n s h i p , t h e wire f e e d ra te , a n d t h e p u l s e f r e q u e n c y ra te arc i n t e r - d e p e n d a n t . For any p a r t i c u l a r p u l s e f r e q u e n c y , t h e r e i s a r ange o f wire f e e d ra tes o v e r w h i c h S a t i s f a c t o r y r e s u l t s w i l l be o b t a i n e d , b u t i n g e n e r a l , a low p u l s e f r e q u e n c y r e q u i r e s a low wi re - f eed r a t e , a n d v i c e v e r s a .

The 'PULSE W I D T H ' c o n t r o l i s used t o a d j u s t t h e e n e r g y v a l u e of t h e c u r r e n t p u l s e . If t h i s s e t t i n g i s too l o w , s p r a y t r a n s f e r c a n n o t o c c u r , a n d t h e w e l d w i l l be a series o f e x p l o s i v e s h o r t c i r c u i t s . If t h e p u l s e w i d t h i s s e t t o o h i g h , t h e arc w i l l b e t o o l o n g , a n d t h e w e l d d e p o s i t e r r a t i c . The i d e a l s e t t i n g w i l l a c h i e v e f u l l s p r a y t r a n s f e r , w i t h a s h o r t a rc l e n g t h . The P u l s e W i d t h c o n t r o l s h o u l d b e a l t e r e d s l o w l y when approach ing a s a t i s f a c t o r y s e t t i n g .

I n t h e e v e n t o f t h e power sou rce becoming ove rhea ted t he t he rmos ta t s on t h e d i o d e a n d S C R h e a t s i n k s w i l l o p e r a t e p r e v e n t i n g f u r t h e r w e l d - i n g . The t h e r m o s t a t s w i l . 1 a u t o m a t i c a l l y reset a n d w i t h t h e c o o l i n g f a n o p e r a t i n g t h i s w i l l t a k e a p p r o x i m a t e l y 10 minu tes . A check shou ld be made t o a s c e r t a i n t h e r e a s o n f o r t h e o v e r h e a t i n g s u c h as f a n n o t o p e r a t i n g o r a i r f l o w r e s t r i c t e d . F u s e s p r o v i d e d f o r a l l c i r c u i t s are as fo l lows and are i n d i c a t e d on t h e f r o n t p a n e l : -

Fuse E l - 3 amps. (Delayed ac t ion) Fuse E 2 - 3 amps. ( 'I 'I ) Fuse E 3 - 5 amps. ( I' 1 Fuse E 4 - 5 amps. ( " 'I 1

MAINTENANCE.

a ) Power Source.

A p a r t f r o m t h e f a n t h e r e c t i f i e r h a s n o r o t a r y componments. T o a c h i e v e c o m p l e t e d i s s i p a t i o n o f h e a t f r o m t h e a c t i v e c o m p o n e n t s , t h e r e c t i f i e r s h o u l d b e t h o r o u g l y b l o w n o f f w i t h d r y c o m p r e s s e d a i r a f t e r 6 mon ths ' ope ra t ion . C lean ing shou ld be c a r r i e d o u t a t s h o r t e r i n t e r - v a l s i f d u s t a c c u m u l a t i o n i s c o n s i d e r a b l e ,

P r i o r t o c l e a n i n g , r e m o v e t h e u n i t c o v e r b y d e t a c h m e n t o f l u g s a n d t h e f i x i n g screws. Thus a11 the components of t h e power source w i l l b e a c c e s s i b l e e

b) The wire- feed motor /gearbox i s p re -packed w i th g rease and needs n o o t h e r l u b r i c a t i o n . Change t h e grease a f t e r a p p r o x i m a t e l y 4 , 0 0 0 service hours . (see Wire F e e d e r I n s t r u c t i o n M a n u a l ) .

4

If d e s i r e d , t h e a rc l e n g t h may a l so b e a l t e r e d by changing t h e w i r e - f e e d r a t e . Reducing t h i s w i l l l e n g t h e n t h e a rc , and i n c r e a s i n g i t w i l l s h o r t e n t h e arc. Note t h a t f o r a n y p a r t i c u l a r p u l s e f r e q u e n c y , t h e r e i s a minimum wi re - f eed r a t e , below which there i s i n s u f f i c i e n t e l e c t r o d e material a v a i l a b l e . . t o f o r m " o n e d r o p l e t p e r p u l s e " , w i t h a subsequen t loss of c o n t r o l of t h e arc.

The s e t t i n g o f t h e ' F I N E VOLTAGE' s w i t c h a f f e c t s t h e p e a k p o t e n t i a l c u r r e n t o f t h e p u l s e . F o r m o s t work t h i s s w i t c h may be set t o '10'.

The 'BACKGROUND CURRENT' s w i t c h may norma l ly be s e t t o ' A ' , bu t can be se t h i g h e r s h o u l d the work-p iece be comtaminated w i t h o i l o r g r e a s e , o r f o r h i g h e r w e l d i n g c u r r e n t s e t t i n g s .

S o f t S t a r t C o n t r o l . D u r i n g t h e w e l d commencement p e r i o d t h e o u t p u t c h a r a c t e r i s t i c s of t h e Power Source are mod i f i ed t o p rov ide improved a rc i n i t i a t i o n . The ' S o f t S t a r t c o n t r o l sets t h e time s p a n o f t h e m o d i f i e d c h a r a c t e r i s t i c s . If t h e c o n t r o l i s set f o r a p e r i o d t o o l o n g , t h e a rc w i l l t e n d t o run up t o t h e t i p . I f t h e c o n t r o l i s s e t f o r a p e r i o d too s h o r t , t h e r e w i l l t e n d t o b e a series o f e x p l o s i v e s h o r t c i r c u i t s a t a r c s t a r t - u p .

SAFETY DEVICES.

5

c) Gun and Cable

P a r t i c u l a r l y when w e l d i n g i n t h e 'PULSE' mode, smooth and c o n s t a n t wire f e e d i s e s s e n t i a l t o a c h i e v i n g s a t i s f a c t o r y w e l d i n g c o n d i t i o n s .

Remove a n y s p a t t e r w h i c h m i g h t a d h e r e t o t h e n o z z l e b o r e so t h a t t h e s h i e l d i n g g a s o u t f l o w i s not impeded. The c o n d i t i o n of t h e c o n t a c t t u b e s s h o u l d b e r e g u l a r l y c h e c k e d . Damaged, b u r n t o r worn t u b e s are an impediment t o t r o u b l e - f r e e w e l d i n g o p e r a t i o n a n d s h o u l d b e r e p l a c e d i m m e d i a t e l y .

T r o u b l e - f r e e o p e r a t i o n a l s o d e p e n d s t o a l a r g e e x t e n t on t h e good c o n d i t i o n a n d c l e a n l i n e s s of t h e i n n e r wire l i n e r (See I n s t r u c - t i o n s o n Gun Cables) .

W E L D I N G - OPERATION

Never obse rve t he a rc w i t h u n p r o t e c t e d e y e s . I t i s of impor- t a n c e t h a t t h e welder wear p r o t e c t i v e c l o t h i n g p r o v i d i n g s u f f i c i e n t s a f e t y .

STOPPAGES AND THEIR ELIMINATION

The machine should be checked only by a f u l l y s k i l l e d elec- t r i c i a n .

If t h e u n i t s t o p s w o r k i n g , f i r s t de te rmine whe the r s toppages are i n i t i a t e d b y the mains ( f o r i n s t a n c e , b u r n t f u s e ) o r by t h e s u p p l y cable ( l o o s e c o n n e c t i o n , c a b l e b r e a k ) o r by t h e u n i t p r o p e r .

If t h e t h r e e t e r m i n a l s L1, L2 and L 3 on t h e p r i m a r y t e r m i n a l board are c o r r e c t l y c o n n e c t e d t o t h e m a i n s ( V o l t m e t e r r e a d i n g ) t h e c a u s e o f t h e s t o p p a g e m u s t b e s o u g h t i n t h e u n i t i t s e l f .

The w i r i n g diagram o n t h e n e x t p a g e s w i l l f a c i l i t a t e t h e l o c a t i o n of t h e d e f e c t .

- I TE P NO.

1 2 3 4 5 6 7 8 9 10 11 1 2 13 1 4 15 1 6 1 7 1 8 1 9 20 2 1 2 2

' 2 3 2 4 2 5 2 6 2 7 2 8 29 30 31 3 2 33 3 4 3 5 36 3 7 3 8 39 40 4 1 42 4 3 44 4 5 4 6 47 4 8

PART NO.

CP29-32 C P 2 9 - l 1 CP28-17 CP15-14 CP29-18 CP29-0/6 CP29-0/7

CP2-0/13 CP2-0/13 CP3-0/30 CP3-0/35 CP3-0/47 w1-22 W1-23 CP25-0/18 CP29-0/18 CP28-0/17 CP29-0/20 CP15-0/14 CP28-0/20 CP28-0/21 L

CP29-20 ZP29-23 ZP29-24 2P29-19 :P25246 3P35-13 ZP35-14/1, :P35-14/2 :P29-21 U N 4 4 ?C14-1/14 U N 8 1 iM16 JP35-18 P 2 5 - 4 7 :P29-0/39 !5-10/19

:P29-0/46 lP29-26 IP29-25 lP29-33 !P2-0 /13 5 - 1 0 / 9 1-35/1

CPP5-0/7

2P28-0/22

6

DRAWING NO. CP29-0 PARTS L I S T . -__-

DESCRIPTION

BASE FRNm ASSEMBLY TRANSFORMER ASSEPBLY COMMUTATING INDUCTANCE INDUCTANCE ASSEMBLY RECTIFIER ASSEMBLY FAN BLADE FAN MOTOR HEATER PLUG SOCKET WELDING CONTACTOR SOFT START CONTACTOR AMMETER SHUNT 0-400A AMMETER 0-400A. VOLTMETER 0-60V. INDICATOR LIGHT FUSE HOLDER FINE SELECTOR SWITCH ZOARSE SELECTOR SWITCH 3ACKGROUND SELECTOR SWITCH 3FF/ON SWITCH JONTROL PLUG JERNIER POTENTIOMETER DIAL LO TURN POTENTIOMETER LOK OHM. ?REQUENCY SELECTION SWITCH ?RINTED CIRCUIT BOARD ASSEBIIBLY 3ACKGROUND CURmNT RESISTOR :URRENT LIMITING RESISTOR PRONT PANEL iACK PANEL -0P COVER

UGHT HAND SIDE COVER IAFFLE & CONTACTOR MOUNT 'YPE NO./SERIAL NO. PLATE

,EFT HAND SIDE COVER

'UPPLY TERMINAL BLOCK 'ERMINAL CONNECTION PLATE lUTPUT TERMINALS 'IE BAR 'AN MOUNTING BRaCKET OFT START POTENTIOMETER OTENTIOMETER KNOB YE NUT LOOM ASSEMBLY PRINTED CIRCUIT BOARD MOU'NTING PLATE SCHADOW SWITCH MTG. PLATE CONTACTOR LINKS C?IG - PULSE CONTACTOR ?ULSE DISABLE SWITCH ?ULSE CONTROL PLUG

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