WIA WELDMATIC 600 User manual

WELDMATIC

600

MODELNO. CP6

CAT.

7524/6

6/80

FROM SERIAL NO.

6035

THEINFORMATIONCONTAINED IN THE FOLDER

SET OUT TO ENABLE

YOU

TO PROPERLYMAINTAIN YOURNEW EQUIPMENT AND ENSURE THAT

YOU OBTAIN MAXIMUP4 OPERATINGEFFICIENCY.

PLEASE ENSURETHAT THIS FOLDER

KEPT

A SAFE PLACE FOR

READY REFERENCE WHEN REQUIREI?.

WHEN REQUESTINGSPAREPARTS, QUOTE THE MODEIi NO. AND SERIAL

NO. OF THEMACHINE AND THE PARTNO.OFTHEITEMREQUIRED.

FAILURETOSUPPLYTHISINFORMATIONWILLRESULT

UNNECESSARY

DELAYS

SUPPLYING THECORRECT PARTS.

WELDING INDUSTRIESOFAUSTRALIAPTY.LTD.

Melbourne

4294766

Newcastle

611668

Sydney

5342144

Adelaide

3523022

Brisbane

441391

Perth

3617088

Launceston

317004

Darwin

6427

843076

OPERATING

AND

MAINTENANCE

INSTRUCTIONS

WELDMATIC

600(CP6)

INTRODUCTION

GENERAL

Thismanualhasbeenpreparedespecially

for

use

familiar-

izingpersonnelwiththedesign,installation,operation,

maintenance,andtroubleshooting

this equipment.

All

inform-

ationpresentedhereinshould

givencarefulconsideration

assure optimumperformance

this

equipment.

RECEIVING/HANDLING.

Prior

toinstallingthisequipment,clean

all

packing

material

from. aroundtheunitandcarefullyinspectforany damage that

may haveoccurredduringshipment. Any

claims

for

loses

damage that m.ay haveoccurredintransit

must

filedbythe

purchaserwithWeldingIndustries

AustraliaPty.Ltd.

authorisedagentimmediately

(refer

EQUIPMENT

WARRANTY

card

enclosedwithOperatingInstructionManual).

When requesting irrbbrmation concerningthisequipment,

essential

supply

correct

Model identificationandmachine

serial

number.

SAFETY.

Before

theequipment

putintooperation,the

SAFETY

PRACTICES

section

the

back

this manual

MUST

READ

COMPLETELY.

This

will

kelp

avoid

possibleinjurydue

misuseorimproper

weldingapplications.

CONTENTS

PAGE

NO.

GeneralDescription

SettingupforOperation

2-3

WeldingOperationInstructions

MaintenanceInstructions

5-6

Welding

Data

Table

"C"

Parts

List

CP6-02 Issue

AssemblyDrawing CP6-02

Issue

CircuitDiagrams

CP6-C9 10

Mobile

Kit

Assem.bly

Safety

Practices

Guarantee

Card

STANDARD

UNIT

The construction of thestandard package planthas been designed

forinstallation and operating

wide variety of applications,

such

ashighproductionfactories and generalfabrication shops.

"WELDMATIC"

Plantsconsist of threebasic

units:-

ConstantPotentialRectifier Power Source.

Semi-Automatic Wire Feeder.

Welding

Gun

and Cable Assembly.

Separateoperating and maintenance instructionsare provided

forthewirefeeder andgun cables.

POWER

SOURCE

FEATURES

The standard

C.P.

rectifier power source

housed

drip-

proof enclosure.

Lifting

lugs

areprovidedforcranetrans-

portation. For

units

with

wheelmounting foursolidrubber

tyredwheelsareprovided:the two front wheels aresteerable

permittingeasy movement

restrictedfloorspace.

push

bar

provided

the

front

of the machine and

gascylinder

carrier

with

a supportbracket and chain

therear.

110

voltplugsocket is located

therear panel

for

connection

of gaspreheater when welding

with

C02

gasshield. Located

thefrontpanelare

coarsevoltageselectionswitch,fine

voltageselectionswitch, power

ON/OFF

switch,controlfuses,

wirefeeder

plug

socket and rectifier power outletsockets.

CONSTRUCTION

Thepower source

a ConstantPotentialSilicon Diode Rectif-

ier

B.C.

Welder,

with

a threephasetransformer and

three

phase rectifierbridge. Connected

the

outputcircuit

inductance

unit

providingthe"inductance"ordegree of slope

necessaryforvariousweldingcurrents.Cooling

thesili-

con diodes,transformerwindings and inductance

unit

isby a

singlephaseaxialfan. Thepower source

protectedagainst

fanfailure and overheating

thermostats mountedon diode

heatsinks.

WELDING

PROCESS

Gas metalarcwelding

within

thecapacity

the power source

can be carried

out

with

tke

followingequipment:-

a) Semi-automatic wirefeeder model

W14.

Semi-automatic wirefeeder

with

spottimer

W14-20.

c) "Hobart"spool gun welding

unit

model

SP9

with

CV2

"Mini-mig" push and

pull

gun

and control.

controller.

WELDING

CAPACITY

Power SourceCapacity

asfollows:-

600

Amps,42 volts,

100%

duty

cycle.

-1

-2-

SUPPLY

AND

WELDING

CABLES.

Power

Sources

are

suitableforconnection

415 volt 50

Hertz

phasesupply.

Therecommended fuse

size,

primary

cable

sizeandwelding

cable

size

are

follows:-

Fuse

amp.

Primary

Cable

4 core 77/0.40

T.R.S.

Welding

Cable

998/0.30

T.R.S.

SHIELDING

GASES.

a) Welding

Grade

C02

for

a11

mild

andalloy

steel

weldingin

thicknessesranging

from

lmm

upwards.

Argon/C02

Argon/Oxygen mixtures

for

all

applicationson

low

currentsrequiring minimum

spatteronsheet

steel

and

for

stainless

steel

welding.

Argon/Oxygenand

Argon/C02

mixtures

for

prime

quality

weld-

ing

stainless

steel.

Argon (pure)

for

all

aluminium.welding.

§ETTING

UNIT

FOR

OPERATION.

General

Assembly

Packaqed

Plant

(Refer

Drawing

AM1.16)

The

Rectifier

Welder

shipped

with

the

skids

wheels

unbol-

ted.

Bolt

the

wheel

assemblies

with

the

steerable

(swivel)

wheelsnearestthefrontpanelandpush

bar.

"Mini-Boom"

wire

feedermounting

supplied,

locate

thevertical

boom

post

the

special

swivel mount

the

rear

themachine.

Locate

the

Wire

Feederontheswivelmount,ensuringthatthe

fibre

thrustwasher

on the

pivot

pin.

Check

that

the

"Wire

Feeder"

free

toswivelin

all

directions.

necessary

apply

small

am.ount

graphite

grease

shaft.

Connection

MainsSupply.

Note:

This

work

shouldonly

doneby

qualifiedelectrician.

Thepowersource

designed

for

connection

415 volt,

hertz,

phase

supply

and

the

supplyvoltageshould

ascert-

ained

before

connectingthemachine.

Access

supplyconnec-

tion

terminals

machine may

gainedbydoorinrighthand

side

panel.

Use

flexible 4

core

primary

cable

for

portable

machinesand

clamp

cable

ensurethat

there

nostrainon

cable

connections.The

earth

(or

ground)connection(green/

yellow)must

securelyfastenedto

the

'earth'

terminal

themachineadjacent

thesupplyconnectionterminals.

CAUTION

Before

insertingprimary

cable

pluginmainssupply

socket:

ensurethat

switch

both

plug

socket

andwelding

machine

'OFF'

position.

CONNECTION

CABLES/HOSES,

ETC.

Withunitswitched

'OFF'

connectcontrol

cable

pinplug)

from

power

sourceto

wire

feeder.

Connect

gas

hosefrom

wire

feeder

gas

regulator/flowmeter,ensuring

all

connections

are

tightenedfirmly.

C02

Gas

Shield

beingused,plug

heater

into

110

volt

socket

rear of

unit.

insert gun

cable

into

socket

wire

feeder

outputguideandretaininplace

with

set

screw

provided.

Set

screw

shouldnot

tightened

preventgun

cable

fromswivelling.Connect

"Gas

Hose"

and "Gun Switch"

leads

respectivesockets.

WELDING

CABLES.

All

G.M.A.

welding

done

with

electrode

wire

connectedto

"positive"

pole

comrn.only known

D.C.

reversepolarity

(D.C.R.P.)

therefore,connecttheshortjumper

lead

from

'I+''

socketon

machine

toterminallugongun

cable.

Thework lead

("negative")should

pluggedinto

the

'I-''

socketon

the

machine.Theplugsofthewelding

cables

must

fullyinserted

inthe

sockets,

preventaccidentaldisconnection.

avoid

error,

weldingshouldnot

attempted

untilallconnections

have

been

secured.The

wire

feeder may

installed

remote

from

the

power

source,in

which

case,

extension

lead

sets

comprising

power

cable,

gas

hose

andcontrol

cable

(four

core)

arerequired

inaccordance

with

the

desired

length.Standardlength

avail-

able

from

stock

m.etres.

WIRE

FEEDER

AND

GUN

CABLE.

Fit

spool

wire

the

wire

feeder

(see

notesin

"Wire

FeederInstructionManual").Tightenthe

"brake"

screw

until

slightbraking

effect

felt when turningthe

wire

spool

hand

prevent"over-run" when

wire

feed

stops.

The

wire

drive

rolls

and

inlet

wire

guideshould

selected

inaccordance

with

the

diameter

andtype

wire

beingused.

Refer

current

wire

feedermanual

for

correct

selection

wire

feed

rolls

andinput

guides.

0.8mm.

0.030"

1.6m

1/16"

0.9mm

0.035"

2.4m

3/32"

1.2mm

0.045"

3.2m

1/8"

The

gun

cable

andgun

are

normally delivered with thecontact

tip

and

liner spring

for

wire

size nominated,but

check

that

both

are

correct

sizefor

wire

beingused.

-4-

WELDING

OPERATION

INSTRUCTIONS

SINGLE

FUNCTION

CHECK

Unit

now

ready

for

operation,but

prior

commen

ina,

thefollowins"functionscheck''

recommended,cing

weld-

switchon

poGersourceandcheck

air

flow.

See

that

all

weldinglead

plugs

are

inserted

the

correct

polarity

sockets

electrode

"positive"

work

"negative". Check

all

weldingconnections

andplugsfortightnessparticularly"work"

clamp.

ensurethat

all

control

cables

and

gas

hoses

are

securely

connectedandthat

Gas

Heater

(for

C02

only)

pluggedinto

socket

rear

power

source.Switchon

wire

feeder,

indic-

ator

lightshould now

show

"Power On".Open

Gas

cylinderfully

andcheckcontentsgauge

for

adequategassupply.

Press

"Gas

Purge"switchand

set

gasflowinaccordancewith

weldingrequirements,

the

same

time

checkthat

gas

flow

adequate

from

gunnozzle,

Set

"wire

speed"control

desired

wire

speed.

Press

"wire

inch"switchandcheck

wire

feed

for

correct

pressureondrive

rolls.

Pressureshould

sufficient

preventany''slip" when feedingthroughgunandcable.

Next,

gunswitchmomentarily

for

wire

feed,

gas

flow

and

welding

power

check.

Set

thevoltage

selector

switchesin

accordance

with

required

voltage

(see

welding

table),

unit

now ready

for

welding.

The

weldingcurrent

determinedautomaticallyby

"Wire

Speed".

Theelectrode

wire

fed

thepre-selected

speed

bythe

driverollsthroughthegun

cable

the

arc

constant

speed,

unchanged

except

when

reset

bythe

"Wire

Speed"

control. The

higherthe

wire

speed,

thehighertheweldingcurrent,

will

indicatedby

the

ammeter.

The

outputvoltage

the power

source,indicatedbythevoltmeter when

the

gunswitch

closed,

dividedinto

number

steps

Coarse

Selector

andFine

Selector

switches.

The CP6

has

Coarse

Voltage

and

FineVoltageSwitches,eachwith

six

steps,

giving

voltage

settingsforthemachine.The

inductanceterminal

sockets

are

numbered

''1

4".

No.1

socket

should

not

usedforweldingcurrents

over

300

amps.

Depend-

ingonthetype

weldingconditions,variousinductancevalues

are

required.Thetypical

weld

settingchartindicatesthe

recommended socketsforvariousweldingconditions.

general

rule,lowweldingcurrentsrequireinductance

No.

For

aluminiumandtubularfluxcored

wires,

inductancesocket

No.

usedexclusively.

-5-

The followingsequence

weld setting

recommended:-

a) Consulttypical weld settingchart.

Selectweldingcurrent most suited

theapplication

followingthesettings of wire speed and voltage shownon the

settingchart.

"tune"each weld setting,adjustwire

speed only.

c)Ifvoltage

too low fortheapplication,wire"stubbing"

will

occur,particularlyatstart of weld and weld contour

will

be very convex.

thevoltage

toohigh,metal

transfer

will

be erratic

with

excessspatter.

With

weldingcurrent and voltage matched theresult

will

beanoptimum tunedweldingcondition

with

a smooth spatter-

freearc.

10.

SAFETY

DEVICES

theevent

the power source becoming overheatedthether-

mostats on thediodeheatsinks

will

operatepreventingfurther

welding. The thermostats

will

automaticallyreset and

with

thecoolingfanoperating

this

will

takeapproximately

min-

utes.

check should be made toascertainthereasonforthe

over-heating such

fannotoperatingorairflowrestricted.

Fusesprovidedfor allcircuitsareasfollows and are

indicated on thefrontpanel:-

Fuse

amps (Delayed action)

Fuse

amps

(

Fuse

amps

(

Fuse

amps

(

ENT

ENANCE

Power Source

Apart from thefantherectifier has no rotary components.

To achievecompletedissipation of heat from theactive com-

ponents,therectifier should be thoroughly blown off

with

dry

compressed airafter

months' operation.Cleaningshould

be carriedoutatshorterintervalsif

dust

accumulation

considerable.

Prior

cleaning, remove the

unit

cover

detachment

lugs

and

thefixing screws. Thus

a11

the components of the power

source

will

accessible.

The wirefeedmotor/gearbox

pre-packed

with

grease and

needs no otherlubrication. Change thegreaseafter approx-

im.ately

14,000

servicehours.(see Wire Feeder Instruction

Manual

The driverollers

and

theinner

wire

guides

should

be kept

clean.

necessary,

blow

off

theinside

the

wirefeeder

with

compressed air.

-6-

Gun and

Cag

Remove any

spatter

which

might

adhere

the

nozzle

bore

that

the

shieldinggasoutflow

not

impeded.

The

condition

the

contacttubesshould

regularlychecked.

Damaged

and/orburnt

tubes

are

animpediment

trouble-freewelding

operationandshould

replacedimmediately.

Trouble-freeoperation

depends

largeextenton

the

good

conditionandcleanliness

theinner

wire

liner

(See

Instr-

uctionson Gun

Cables).

12.

WELDING

OPERATION

Neverobserve

the

arc

with

unprotectedeyes.

ofimpor-

tancethatthe

welder

wear

protectiveclothingproviding

sufficientsafety.

13.

STOPPAGES

AND

THEIR

ELIMINATION

Themachineshould

checkedonlyby

fully

skilled

electr-

ician.

the

unitstopsworking,

first

determinewhetherstoppages

are

initiatedby

the

mains

(for

instance,burntfuse)

the

supply

cable

(looseconnection,

cable

break)

orby

the

unitproper.

thethreeterminals

L1,

and

the

primaryterminal

board

are

correctlyconnectedto

the mains (voltmeter reading)

thecauseofthestoppagemust

soughtintheunit

itself.

The wiringdiagramonthenextpages

will

facilitatethe

location

the

defect.

-7-

WELDING

DATA

TYPICAL

VALUES

Shielding Gas

welding

Grade

C02

used

with

Gas

Preheater.

ContactTip1.5minside

Gas Nozzle.

Wire

"Stick

Out"

9m.m

200

amps.

19mm

over

200

amps.TheseTables

are a guideonlyforinitialmachinesettingandfiner

adjustments may benecessary

achieve optimumwelding

characteristicsfor

the

application. Recommended machine

setting method

set

Voltage

Switches,

Inductanceand Gas

Flow asperTablethenadjust

wire

speed toobtain recommended

current.

:ect-

fier

JP6

Wire

Size Gas

0.9m

(Solid

Wire)

1.2m.

(Solid

Wire)

Lit./Min

(for

vertical Down)

Lit./Min

1.6mm

15/17

(Fluxo-

Lit./Min.

fil)

2.0m.

(Fluxofil)

4mrn

(Fluxofil)

Wire

Speed

Metres

Per

Min.

3.9

6.3

2.2

3.2

4.4

5.7

5.8

7.6

9.0

10.0

5.1

6.4

5.5

6.6

Coarse

190

2 200

250

330

360

380

450

500

550

Volt

23.5

NOTE:

Wire

speed

shown

metres/minuteandarenotdial

calibrationsettings.

TEP

NO.

2.1

2.2

2.3

3.1

4.1

4.2

26.1

37.1

37.2

DRAWING

NO.

CP6-02

SPAREPARTS LISTISSUE

PART

NO.

CP6-5

CP6-5/2

CP6-5/3

CP3-9/8

CP6-8

CP6-19

CP6-2

CP6-7/1

CP6-7/2

CP25-0/7

CP3-0/4

14235-0/6

CP15-0/7

CP5-25

CP5-0/19

AM1

CP15-0/14

TC262

TC262N

CP3-0/47

CP6-0/35

w1-22

CP6-0/47

CP5-0/13

CP5-0/14

CP5-0/15

W1-23

CP22-3/13

CP6-20

CP6-21

K10

K11

DESCRIPTION

RECTIFIER ASSEMBLY

DIODE

DIODE (R)

THE

R?.!lOS

TAT

TRANSFORMER ASSEMBLY

PRIMARY/SECONDARY COIL

INDUCTANCEASSEMBLY

LEFT

HAND

INDUCTANCE COIL

RIGHT

HAND

INDUCTANCE COIL

CONTROL TRANSFORMER

FAN

BLADE

FAN

MOTOR

GAS

HEATERPLUGSOCKET

RECTIFIERPROTECTION ASSEMBLY

WELDING CONTACTOR

OUTPUT TERMINALS

CONTROL PLUG

GAS

NIPPLE

GAS

NIPPLE NUT

VOLTMETER 0-60V.

AMPETER 0-800A.

INDICATORLIGHT

APNTER SHUNT 0-800A

POWER

ONYOFF

SWITCH

COARSE VOLTAGE SWITCH

FINE VOLTAGE SWITCH

FUSE HOLDER

STAND

OFF

INSULATOR

RESISTOR

SERIESRESISTOR

3AG.

DELAY FUSE

3AG.

DELAY FUSE

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