WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LIMITED

ACN 004 547 l 1 1

Head Office and International Sales

5 Allan Street, Melrose Park

South Australia, 5039

South Australia, 5039

Telephone (08) 8276 6494 Facsimile (08) 8276 6327

www.weldingindustries.com.au

info@weldingindustries.com.au

OWNERS MANUAL

UTILITY CV1 3

MODEL UTCVI 3-0

05/98

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE (

The information contained in this manual has been prepared to enable you to properly maintain your new equipment and ensure that you obtain maximum operating efficiency.

Please ensure that this information is kept in a safe place for ready reference when required at any future time.

When requesting spare parts, please quote the model and serial number of the machine and part number of the item required. A11 relevant numbers are shown in lists contained in this manual. Failure to supply this information may result in unnecessary delays in supplying the correct parts.

SAFETY

Before this equipment is put into operation, the Safe Practices section at the back of this manual must be read completely. This will help to avoid possible injury due to misuse or improper welding applications.

CONTENTS

l .......................... Introduction .................................................... 3 2 .......................... Receiving.. ..................................................... 3 3 .......................... Specifications ................................................ 4 4 .......................... Power Source Controls .................................. 5 5 .......................... Connection to Mains Supply .......................... 6 6 .......................... Welding Polarity Selection ............................ 6 7 .......................... Shielding Gas ................................................ 6 8 .......................... Fitting Electrode Wire .................................... 7 9 .......................... Establishing a Weld Setting .......................... 7 10 ........................ Duty Cycle ..................................................... 9 11 ........................ General Maintenance .................................... 9 12 ........................ Fault Finding .................................................. I Q l 3 ........................ Circuit Diagram .............................................. l l 14 ........................ Parts Diagram ................................................ 12 15 ........................ Parts List ........................................................ l 3 16 ........................ Safe Practices Information ............................. l 4

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

UTILITY CV13 OWNERS MANUAL " "

l . INTRODUCTION

The UTILITY CV13 is a Gas Metal Arc power source designed for gas shielded welding using solid electrode wires, and self shielding flux cored wires. The consumable wire is fed to the welding gun by motor driven drive rollers. The arc is struck between the work piece and the end of the wire, which melts to form the weld deposit.

With solid consumable wires, the arc is protected by an envelope of shielding gas supplied via the gun from a separate gas cylinder.

"Self shielding" wires contain a core of flux which, during welding, generates gases to shield the arc and the weld pool. The flux also leaves a light protective slag over the cooling weld deposit. In this way a separate gas supply is not required.

The UTILITY CV13 is intended for use with 0.6mm and Q.8mm solid wires, and 0.8 and 0.9mm cored wires. Smaller wire sizes are recommended for welding at lower currents such as thin sheet-metal applications. Increasing the wire diameter permits thicker gauges to be welded. The UTILITY CV1 3 will accept l kg and 5kg spool types of electrode wire.

2. RECEIVING

Check the equipment received against the shipping invoice to make sure the shipment is complete and undamaged. If any damage has occurred in transit, please immediately notify your supplier.

The UTILITY CV13 package contains:

UTILITY CV13 Power Source Fitted welding torch Work lead and clamp Mobile mounting kit (wheels, handle and front prop) Spare welding tips (3 )

R Gas hose connector (This) Owners Manual

Optional items:

Gas regulator (Argon) ...................................................... GW251190

Consumable wires to suit the UTILITY CV13:

Carbon steel solid wire O.6mm, 0.9 kg ............................ ES606BP Carbon steel solid wire 0.8mm, 8.9 kg ............................ ES608BP

E Carbon steel solid wire 0.6mm, 5kg ................................ ES606M Carbon steel solid wire 0.8mm, 5kg ................................ ES608M

Carbon steel self-shielding wire 0.9mm, 8.9 kg ............... H021 BO91 KG Carbon steel self-shielding wire 0.9mm, 5 kg .................. H021 B09M

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

L

UTILITY CV13 OWNERS MANUAL

3. SPECIFICATIQNS

Model Number ......................................................................... U T ~ V l 3 - 0

Primary Supply .................................. 240 Volts AC Single Phase, 50 Hz

Rated Input current. .................................................................... I O Amps

Supply Flexible Cable ..... 10 Amps, type Y attachment (see note below)

Maximum Rated Input Current.. .............................................. . l 5 3 Amps

Open Circuit Voltage ..................................................... 57 Volts DC (pk)

Rated Output ........................................... 100 Amps, l 9 Volts, 25% Duty

Degree of Protection ........................................................................ IP22

Electrical Approvals Number.. ......................................... .S1221 /UTCV13

NOT]

If the supply flexible cable is damaged, it must be replaced by the manufacturer or it's service agent or similarly qualified person in order to avoid a hazard.

QUALlTY WELDING PRODUCTS, SYSTEMS AND SERVlCES

UTILITY CV13 OWNERS MANUAL Page 5

4. POWER SOURCE CONTROLS

WIRESPEED CONTROL

VOLTAGE CONTROL SWITCHES

POWER SWITCH

NEGATIVE OUTPUT TERMINAL

POSITIVE OUTPUT TERMINAL

POWER ON/OFF SWITCH A rocker type switch is located on the front panel. Select the ON position to energise the power source. An indicator lamp within the on/off switch is lit when the machine is energised.

WIRESPEED CONTROL This control is used to set the feeding rate of the consumable electrode wire. Rotating the dial clockwise increases the wirespeed, so increasing the welding current. An increase of wirespeed will usually require an increase of welding voltage to maintain stable welding conditions.

VOLTAGE CONTROLS The three voltage control switches together provide 6 steps of welding voltage adjustment, arranged as 3 steps in LO range, and 3 steps in HI range. For voltage steps 2 and 3 , also select position A.

OUTPUT TERMINALS The welding output current is available on these terminals. Refer to Section 6 for information regarding the correct connection of the welding leads.

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

Paae B UTILITY CV13 OWNERS MANUAL

5. CONNECTION TO ELECTRICAL MAIMS POWER SUPPLY

The UTILITY CV1 3 is fitted with a 10 Amp mains power supply cable, and is suitable for connection to a standard domestic 10 Amp power outlet.

If the machine is to be used in conjunction with an extension power cable, the cable must be of sufficient capacity to avoid excessive voltage drop, which could limit the output capacity of the welder.

The rated input current of the UTILITY CV1 3 is 10 Amps, and so a fuse or circuit breaker rated at 20 Amps may be installed to avoid nuisance tripping.

6. WELDING POLARITY SELECTION

POSITIVE GUN

welding gun Positive (+) polarity, and the work piece Negative (-) polarity.

the photograph on page 5. NEGATIVE GUN

welding gun Negative (-) polarity, and the work piece Positive (c ) polarity.

terminal, and the Gun lead to the (-) terminal.

7. SHIELDING GAS

Gas shielded Mig welding with a solid consumable wire is carried out with the

To set the machine for this condition, connect the Gun and Work leads as shown in

Mig welding with a self shielded flux cored consumable wire is carried out with the

To set the machine for this condition, connect the Work lead to the (+) output

When welding using solid consumables wires, a shielding gas is required to protect the arc and molten weld pool from the effects of atmospheric gases. A suitable gas pressure regulator / flow gauge must be fitted to the gas cylinder, and the CV13 gas supply hose connected to the regulator.

The choice of shielding gas type is determined by the application, and the welding consumable to be used. In general the following applies, consult your gas supplier for more specific information.

Carbon Steel ................................. Argon + 5 to 18% CO2

E Aluminium ...................................... 100% Argon . Stainless Steel .............................. Argon + 1 to 2% Oxygen Set the gas regulator for a flow rate of I O to 15 litreslmin. In windy or outside

locations it may be necessary to increase this setting to avoid weld porosity resulting from insufficient gas coverage.

QUALlTY WELDlNG PRODUCTS, SYSTEMS AND SERVIES

UTILITY CV13 OWNERS MANUAL Page 7

8. FITTING THE ELECTRODE WIRE PRESSURE SPRING

. I _ _ r ,,. ,. PRESSURE ROLL ARM

DRIVE

Place the spool of electrode wire onto the spool holder. Replace the wing nut, and tighten sufficiently to apply some braking force on the wire spool. Both 1 kg and 5 kg spools can be fitted.

allowing the upper pressure roll arm to be lifted away from the lower drive roll. Open the wire drive mechanism by rotating the pressure spring outwards,

Check that the drive roller groove is correct for the wire in use. The drive roller has two groove sizes, refit as required to select the appropriate groove.

Check also that the appropriate size tip is fitted to the welding gun, replace if necessary.

Straighten a short length of the consumable wire, and pass it through the inlet

Close the pressure arm and spring mechanism, check that the consumable wire

guide, over the driven roller and into the gun wire guide.

is seated in the drive roller groove.

With the machine power on, close the gun switch to feed wire to the gun.

Adjust the compression of the spring assembly to just provide sufficient clamping of the drive rolls to achieve constant wirefeed. Do not over tighten as the consumable wire can be damaged leading to erratic wirefeed.

9. ESTABLISHING A WELD SETTING

Page 8 UTILITY C W 3 OWNERS - MANUAL

WELDING RESULT The welding current should be established to suit the thickness of the metal to be

welded. It is important to check that the deposited weld provides sufficient strength to suit the application.

‘GOOD’ WELD ‘BAD‘ WELD

A ‘good’ weld will have the Characteristics illustrated above. The weld has penetrated into the parent metal, fusing the root of the weld where the two plates meet, and the weld blends smoothly into the side walls.

The characteristics of a ‘bad’ weld are also shown above. Here the weld has not penetrated the root joint, and there is poor side wall fusion. This lack of fusion would normally be corrected by increasing the arc voltage, or increasing both wirespeed and voltage to achieve a higher welding current.

GUN POSITION For ‘down hand’ fillet welding with gas shielded solid wire consumables, the gun is

normally positioned as in the figures below, with the nozzle pointing in the direction of travel.

If using self shielded wires, the gun is normally positioned with the nozzle pointing away from the direction of travel, referred to as ‘dragging’ the weld. Self shielded wires should be operated with approximately 15mm of wire ‘stick-out’ from the end of the contact tip,

GAS-SHIELDED WIRE

SELF-SHIELDED WIRE

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

I O . DUTY CYCLE

The term ‘duty cycle’ indicates the percentage welding time available from the equipment when operating at the rated output current.

The UTILITY CV13 is rated at 100 Amps, ‘l9 Volts, 25% duty cycle. If the machine is operated at a lower welding current, greater duty cycle percentage is available.

The machine is protected by in-built temperature protection devices. These will trip if the machine is operated in excess of its current and duty cycle rating, preventing damage to internal components. If this occurs, an indicator light on the front panel will be lit, and the machine will not deliver welding current until it has cooled sufficiently.

1 l. GENERAL, MAINTENANCE

DUST BUILD-UP Excessive dust build up can reduce the effectiveness of the internal cooling fan,

leading to reduced operating duty cycle. It is recommended that at regular intervals, according to the prevailing conditions, the machine covers be removed and any accumulated dust be removed using dry, low pressure compressed air.

Ensure that the internal Earth wire is reconnected to the cover before the cover is refitted.

Inspect the visible components for any signs of overheating or other damage. Report any observed problems to qualified service personnel.

WIREFEED In Mig welding, satisfactory welding results can only be obtained when the wirefeed

to the welding gun is smooth and constant. It is important to regularly monitor the following points;

Keep the gun cable wire guide clear of dust and swarf build-up. Accumulated dust may be partially cleared by purging the wire guide with compressed air, however it will require occasional replacement.

Replace the welding tip as it becomes worn or damaged. Welding current is transferred to the wire at the tip, and any tendency to poor contact will affect welding results.

Keep.the wirefeeding mechanism clean. Periodically check the drive roller groove for wear or clogging, and replace the roller when necessary.

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

L

UTILITY CV13 OWNERS MANUAL Paae 9

L L A L Pa e10 -

112. FAULT FINDING

NO WELDING CURRENT Check that mains supply is available at the Power Source, ie. that the fan is

running and the POWER ON indicator is lit. Check for co.ntinuity of the welding current circuit, ie. work lead, work damp and

electrode holder: Check that the electrode and work leads are correctly connected for the welding process in use.

The welding power source incorporates in built thermal protection devices which will trip if the unit is used in excess sf its duty cycle. In this event, the machine will not deliver welding current, and the front panel Over temperature indicator will be lit. Leave the machine energised with the fan running to achieve the maximum cooling rate.

If equipment failure is suspected, forward the unit to your nearest WIA Sales and Service Branch or qualified service agent.

UNSATISFACTORY WELDING RESULTS The most frequent cause sf erratic welding conditions is poor wirefeeding. Check

the condition of the gun cable liner, the drive roller and groove, and the welding tip. Replace worn or damaged items.

WELDING CIRCUIT Ensure that the work clamp is securely tightened onto the work-piece so that good electrical contact is achieved.

Surface contamination of the work piece by water, oil, grease, galvanising, paint, or oxide layers can severely disturb the welding are resulting in a poor weld. Best results will be obtained if the surface is clean and dry.

WIREFEED I ARC VOLTAGE RELATIONSHIP If the consumable wire is stubbing into the work piece and a steady arc cannot be

obtained, it is likely that the wirespeed is set too high to suit the welding voltage. To correct this situation, decrease the wirespeed setting. If the arc length is too long, increase wirespeed setting.

L

UTILITY CV13 OWNERS MANUAL Page l l

QUALITY WELDlNG PRODUCTS, SYSTEMS AND SERVlCES

Paae 12 UTILITY CV13 OWNERS MANUAL

’14. PARTS DIAGRAM

l”

SIDE COVERS. HANDLE AND LEADS OMITTED FROM THESE VIEWS

SIUE COVER OMITTED FROM THIS VIEW

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES

- UTILITY CV13 - OWNERS MANUAL Page-

115. PARTS LIST

Item Part Number Descriptiom

1 ....................... E21 62501 3 . . ................. Wheel 2 ....................... E21690012 ................... Spool holder retaining ring 3 ....................... E21690011 ................... Fixed spool holder 4 ....................... E33805001 ................... Wire feed drive roll 0.6 / 0.8mm 5 ....................... SA32-0/1 ...................... Plug 6 ....................... SA14 0-0/2 .................... Socket 7 ....................... E230Q0040 ................... Porch complete 9a ..................... WGUYI ........................ Welding tip 06mm 9b. .................... WGUY2 ........................ Welding tip Q.8mm 9c ..................... WGUY3 ........................ Welding tip 0.9 / l .Omm 10. .................... WGUY4 ........................ Gas nozzle 1 l ..................... WGWVCI .............. work clamp 12.. ................... S1 40-011 ....................... Handle 13 ..................... E44400002 ................... Wirefeed mechanism 14 ..................... E22810002 ................... Wire feed motor 15 ..................... E2271 001 5 ................... Wirefeed printed circuit board 16.. ................... UPCVl3-0/2 ................. On/off switch cover 17 ..................... E22200Q23 ................... On/off switch with light 18.. ................... E441 28032 ................... Welding transformer UTCVI 3 19 ..................... E2221 0013 ................... Rectifier thermostat 8OoC 20 ..................... E22800010 ................... Fan motor and blade 21 ..................... E22210016 ................... Transformer thermostat 127OC 22.. ................... E3372501 5. . ................. Handle extension 23 ..................... hlTCVl3-0/1 ................. Mains cable l OAmp

25 ..................... E22400038 ................... Welding rectifier

27 ..................... UTCVI 3-0/3 ................. Welding voltage selection switch cover (3) 28 ..................... E22200006 ................... Welding voltage switch (3)

32 ..................... E21800036 ................... Spool holder knob 33 ..................... E33800004 ................... Spool retainer spring

24.. ................... E441 3500.4 ................... Welding inductance UTGVI 3

26 ..................... E21690018 ................... Wirespeed knob

29 ..................... E21690001 ................... Panel grommet

34 ..................... E21600006 ................... Handle Grip

QUALlTY WELDiNG PRODUCTS, SYSTEMS AND SERVICES

g MANUAL

96. SAFE PRACTICES tN USING WELDING EQUIPMENT

These notes are provided in the interests of improving operator safety. They should be considered only as a basic guide to Safe Working Habits. A full list of Standards pertaining to industry is available from the Standards Association of Australia, also various State Electricity Authorities, Bepartments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements. W I A Technical Note TN7-98 also provides a comprehensive guide to safe practices in welding.

EYE PROTECTION NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or

glasses with side shields underneath, with appropriate filter lenses protected by clear cover lens. This is a MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal. Replace the cover lens when broken, pitted, or spattered.

Recommended shade filter lens. Amps TIG MMAW MIG Pulsed MIG Q-100 ............ 10 ................. 9 ................... 10 ................. 12-13 100-150 ......... 11 ................. 10 ................. 10 ................. 12-13 150-200 ......... 12 ................. 10-11 ............ 11-12 ............ 12-13 200-300 ......... 13 ................. 11 ................. 12-13 ............ 12-1 3 300400 ......... 14 ................. 12 ................. 13 ................. 14 400400 ............................ I_ 13 ................. 14 ................. 14 500 + .................................................. " " t 4 ................. 14

BURN PROTECTION. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight

clothing, reflect from light-coloured surfaces, and burn the skin and eyes. Burns resulting from gas- shielded arcs resemble acute sunburn, but can be more severe and painful.

Wear protective clothing - leather or heat resistant gloves, hat, and safety-toe boots. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.

Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and work pieces should never be handled without gloves.

Ear plugs should be worn when wetding in overhead positions or in a confined space. A hard hat should be worn when others are working overhead.

Flammable hair preparations should not be used by persons intending to weld or cut.

TOXIC FUMES. Adequate ventilation with air is essential. Severe discomfort, illness or death can result from fumes,

vapours, heat, or oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen. Lead, cadmium, zinc, mercury, and beryllium bearing and similar materials when welded or cut may

produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.

Work in a confined space only while it is being ventilated and, if necessary, while wearing air- supplied respirator.

Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and lung and eye irritating products. The ultra-violet (radiant) energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene. Bo not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or perchlorethylene.

QUALITY WELDlNG PRODUCTS, SYSTEMS AND SERVICES

L UTILITY CV13 OWNERS MANUAL

FIRE AND EXPLOSION PREVENTION. Be aware that flying sparks or falling slag can pass through cracks, along pipes, through windows or

doors, and through wall or floor openings, out of sight of the operator. Sparks and slag can travel up to 10 metres from the arc.

Keep equipment dean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.

If combustibles are present in the work area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work can not be moved, move combustibles at least 10 metres away out of reach of sparks and heat, or protect against ignition with suitable and snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on or cut. Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if;

- Combustibles (including building construction) are within I O metres.

~ Combustibles are further than 10 metres but can be ignited by sparks.

- Openings (concealed or visible) in floors or walls within 10 metres may expose combustibles to sparks.

- Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.

After work is done, check that area is free of sparks, glowing embers, and flames.

Any tank or drum which has contained combustibles can produce flammable vapours when heated. Such a container must never be welded on or cut, unless it has first been cleaned as described in AS1674-1974, the S.A.A. Cutting and Welding Safety Code. This includes a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible's solubility), followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AS1674- 1974. Water-filling just below working level may substitute for inerting.

Hollow castings or containers must be vented before welding or cutting. They can explode. Never weld or cut where the air may contain flammable dust, gas, or liquid vapours.

SHOCK PREVENTION. Exposed conductors or other bare metal in the welding circuit, or ungrounded electrically alive

equipment can fatally shock a person whose body becomes a conductor. Ensure that the machine is correctly connected and earthed. If unsure have machine installed by a qualified electrician. On mobile or portable equipment, regularly inspect condition of trailing power leads and connecting plugs. Repair or replace damaged leads.

Fully insulated electrode holders should be used. Do not use holders with protruding screws. Fully insulated lock-type connectors should be used to join welding cable lengths.

Terminals and other exposed parts of electrical units must have insulated knobs or covers secured before operation.

QUALITY WELDING PRODUCTS, SYSTEMS AND SfZRVlCES