WELDING INDUSTRIES Weldmatic 215S User manual

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WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIES LTD
ABN 18 004: 547 Ill
Head Office and International Sales
5 Allan Street, Melrose Park
South Australia, 5039
Telephone [phone] Facsimile [phone]
www.weldingindustries.com.au
[email protected]
OWNERS MANUAL
WELDMATIC
215s
MODEL NO. CPlO9-0, REV. B
l 1 /2000
QUALITY WELDING PRODUCTS, SYSTEMSAND SERVICE
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Page 2 WELDMATIC 21 5s MANUAL
The information contained in this manual is setout to enable you to properly maintain your
new equipment and ensure that you obtain maximum operating efficiency
.
Pleaseensurethatthisinformation is keptin a safe place forreadyreferencewhen
required at anyfuture time
.
When requesting spare parts. please quote the model and serial number of the machine
and part number of the item required
. All relevant numbers are shown in lists contained in this
manual
. Failuretosupplythisinformationmayresult in unnecessary delays in supplyingthe
correct parts
.
SAFETY
Before this equipment is put into operation. the Safe Practices section at the back of the
manualmustbereadcompletely
. Thiswillhelptoavoidpossibleinjury due to misuseor
improper welding applications
.
CONTENTS
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Sec.1 ...................... Introduction ......................................................... P.3
Sec2
...................... Receiving ............................................................. P.3
Sec.3
...................... Specifications ...................................................... P.4
5.1
................... ConnectionTo ElectricalMains Power Supply ..... P.6
Sec.4
...................... Power Source Controls ........................................ P.5
Sec.5
...................... Installation ........................................................... P.6
5.2
................... FittingThe Gas Bottle .......................................... P.7
5.3
................... Fitting The GunCable ......................................... P.7
5.4
................... Fitting The Consumable Wire .............................. P.7
5.5 ................... Feeding TheConsumable Wire ........................... P.7
Sec.6
...................... Normal WeldingSequence .................................. P.9
5.6
................... Output Voltage PolaritySelection ........................ P.8
6.1
................... Weld Start ........................................................... P.9
6.2
................... Weld End ............................................................. P.9
7
.'l ................... Choice Of ShieldingGas ..................................... P.9
?.4 ................... Gun Position ........................................................ P . 10
Sec.8
...................... General Maintenance .......................................... P . 11
Sec.9TroubleShootingP
. 12
Sec
. 10 .................... Service InformationP . 14
Sec
. 12 .................... Parts List - Wire DriveAssembly ......................... P . 18
Sec.13
.................... Parts List - Gun Cable Assembly ........................ P . 19
Sec 14 .................... Safe Practices ..................................................... P.20
Sec.7 ...................... Basic Welding Information ................................... P.9
7.2 ................... ShieldingGas Flow Rate ..................................... P.9
7.3 ................... Establishing A Weld Setting ................................. B.9
...................... .................................................
.............................................
Sec.11 .................... Parts List - Power SourceAssembly .................... P . 16
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FIGURES
FiEp.1 .............. Power Source ControlLocations .................................. P.5
Fig.2 .............. Connection of Supply Cable ......................................... p.6
Fig.4 .............. Negative Wire Connection ............................................ P.8
Fig.5
.............. "Good" Weld ................................................................. p . 10
Fig.6
.............. "Bad" Weld ................................................................... p . 10
Fig.7
.............. Gun Position ................................................................. p . 10
Fig.8
.............. CPlO9-10 Control Board .............................................. P.14
Fig.9
.............. CP'lO9-0 Circuit Diagram .............................................. P . 15
Fig
. 10 ............ Power SourceAssembly ............................................... P . 17
Fig
. 1 1 ............ Wire DriveAssembly .................................................... P . 18
Fig
. 12 ............ Gun Cable Assembly .................................................... p . 19
Fig.3
.............. Positive Wire Connection .............................................. P.8

WELDMATIC 21 5s MANUAL Page 3
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l. INTRODUCTION
Gas Metal Arc Welding (G.M.A.W.) is a welding process where a consumable wire is fed
by motor driven drive rollers to a welding gun, and where welding current is supplied from the
welding power source. The welding arcis struck betweenthe work piece and the end
of the wire,
which melts into the weldpool. The arcand the weld poolare shielded by gas flow from the gun,
or in the case of "selfshielded" wires, by gases generated by the wire core.
By selection of the correct wire composition,diameter and shielding gas, G.M.A.W. can be
usedfor applicationsrangingfromsheetmetal to heavy plate,and metalsrangingfrom carbon
steel to aluminium alloys.
The WELDMATIC 215s has been designedto be used with consumable wires in the range
from 0.6mm to 1.2mm diameter. Thesmaller wire sizesare used when weldingat lower currents,
such as sheet-metal applications. Increasing the wire diameter permits higher welding currents
to be selected.
Acommonapplicationof G.M.A.W. is for welding MildSteel. Inthis application,aMild
Steel solid consumablesuch
as AUSTMIG ES6 is used with a shielding gas of Argon mixed with
5 - 25% CarbonDioxide.Alternatively,Flux-cored consumables are availableinbothgas
shielded, and 'gasless' self shielding types.
Stainless steeland Aluminium can be welded with G.M.A.W. using the correct consumable
wire and shieldinggas.
2. RECEIVING
Check the equipment received against the shipping invoice to make sure the shipment is
complete and undamaged, Ifany damage has occurred in transit, please immediately notifyyour
supplier.
The CP109-0 packagecontains;
WELDMATIC 215sPower source.
BEXT2-4E21OAE BERNARD Guncable, 3 metre, Euro connector.
R WGAC24 Regulator and Flowgauge. (Argon)
(This)OwnersManual.

Page 4 WELDMATIC 215s MANUAL
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3. SPECIFICATIONS
Manufactured to Australian standard AS1 966.1-1985
Rated toISOAEC 60974-1 (10 minute
duty cycle)
WELDING INDUSTRIES of AUSTRALIA
Weldmatic 2 15s
Made in Australia
1-
M
"-
RATED TO
ISOAEC 60974-1
(21 N803
PF = 0.89 (215A) 0.93 (9OA)
I D W
36 40
I1
17
42
LAN
UdV)
240V
7.9
9.2
2.6 4.1 10-1
S,(kVA)
50Hz CLASS INS H
15
16
11
-
16
I,em(A)
I COOLINGAF I IP21 I I I I
WlNsosR
Under ISO/IEC 60974-1, duty cycle is defined as theratio of arcing time to an operating
time
of 10 minutes, expressed as a percentage.
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WELDMATIC 21 5s MANUAL Page 5
4. POWER SOURCE CONTROLS
I
WIRE SPEED CONTROL
SPOT TIME CONTROL
INTERVAL CONTROL
OVERLOAD INDICATOR
POWER ON INDICATOR
FINE VOLTAGE CONTROL
COARSE VOLTAGE CONTROL
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FIGURE 1. POWER SOURCE CONTROL
1. POWER ON INDICATOR
This is illuminated when electricalmains power is connected to the welding power source.
This switch provides Coarse adjustmentof the Output Welding Voltage over three ranges.
This switch provides Fine adjustment
of the Output Welding Voltage over three ranges.
This controlprovidesadjustment of thewirefeedspeed.Rotatingthedialina clockwise
2. COARSE VOLTAGE CONTROL
3. FINE VOLTAGE CONTROL
4. WIRE SPEED CONTROL
directionwill increase the wirefeed speed, thereby increasing the welding current.
5. SPOT TIME CONTROL
When operating the machinein Spot Weld mode, this control will vary the spot weld time.
Rotating the dial in a clockwise directionwill increase the spot weld time, in the range
0.4 - 3.0
seconds. If theSpot Weldmode is notrequired thisfeature may be turned off by rotating the
control anti-clockwise until it'clicks' into theminimum position.
6. INTERVAL CONTROL
When operatingthemachine in Cycle Arc mode thiscontrol sets theperiodbetween
welds. The spot time control sets the welding period. Rotating the dial in a clockwise direction
will increasetheintervaltime, inthe range
0.4 - 1.8 seconds. IftheCycle Arc mode is not
required this featuremay beturned off by rotating both controlsfully anti-clockwise.
7. OVERLOAD INDICATOR
This is illuminated when the welding load exceeds the operating duty cycle. In this event
the machine will not deliver welding current until the machine has cooled sufficiently. The over-
temperature thermostats will reset automatically
- do not switch the machine off as the cooling
fan will assist the resetting of the thermostats.
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Page 6 WELDMATIC 215s MANUAL
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5. INSTALLATION
5.1 CONNECTIONTO ELECTRICAL MAINS POWER SUPPLY
NOTE. All electrical'workshall only be undertaken by a qualified electrician.
The WELDMATIC 215s is factoryfitted with a 3 metre, 3 core50/0.25 Heavy Duty PVC
mains power supply cable with moulded 3 pin, 15 Amp, Single Phase plug.
A 15 Amp plug and socket is recognisable by a wide Earth pin. Power Supply authorities
require that equipment fitted with a
15 Amp plug shall ONLY beconnected to a 240 Volt, 15 Amp
power point.
DO NOT modify the plug.
The minimum capacity of the mains wiringand power outletsupplying a welder is selected
according
to the effective primarycurrent ofthemachine. The effectiveprimarycurrent for a
Weldmatic
21 5s is 16 Amps.
TheminimumrecommendedcircuitbreakerratingforaWeldmatic 215s
is 20Amps.
Note
: The tripping time of a typical20A circuit breakermay limit the duty cycle available fromthe
Weldmatic 215s. A higher rated circuit breaker can be selected, but the mains wiring capacity
must be increased tosuit.
Thecurrentrating
of themainscable depends on cable size andmethodofinstallation.
Refer to AS/NZS
3008.1, Table 9. If it becomes necessary to replace the mains flexible supply
cable, useonly cable with correct current rating.
Access to the machine supply terminals is gained by removing thepower source left hand
side panel. (Power source viewed fromfront).
Passthecablethroughthebushfitted tothemachineback panel. Thecablesare
terminated at the terminal block
as shown in Figure 2.
Tightenthecableclampleavingjustsufficient slack inthecable
so thattheterminated
wires are not
in tension.
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BACKCABLEBLUEBROWNTERMINAL BLOCK
3 CORE
POWER CABLE
BUSHCONNECTIONYELLOWWIRE
FIGURE 2. CONNECTION OF SUPPLY FLEXIBLE CABLE
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WELDMATIC 215s MANUAL Paae 7
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5.2 FITTING THE GAS BOTTLE
Depending on configuration of the cylinder to be used, the gas flowmeter / regulator may
be fitted directly to the cylinder,or in conjunction withan elbow fitting. DO NOT apply any grease
to these joints, and tighten the nutssecurely.
Fit the end of the gas inlet hose from the back of the machine to the connector supplied
with the flow regulator, and secure with theclamp also supplied.
5.3 FITTING THE GUN CABLE
The BERNARD BEXT2-4E21OAEgun cable is equipped with a 'Euro' wirefeeder connector
which incorporates all required connection points to the gun cable for welding current, shielding
gas and gun switch control.
Toattachtheguncabletothewirefeedingmechanism,engagethematingpartsofthe
maleandfemale Euro connectors,thenrotatethelockingringclockwise tofirmlysecurethe
connection.
'
5.4 FITTING THE CONSUMABLE WIRE
The quality of the consumable wiregreatly affects how reliably agas metal arc welderwill
operate. For best results when welding mild steel,
we recommend quality WIA AUSTMIG ES6.
Dirty,rustyorkinkedwire will notfeed smoothly throughthegun cable andwillcauseerratic
welding.Depositsfromthewire will clogthe gun cable linerrequiringit tobereplaced
prematurely.
Place the spool of welding wireonto the spool holder. The location pin should mate with a
holeprovided on thewirespoolbody. Fit the
spool retaining 'R clip supplied.Checkthe
adjustment of the spool brake, which should be set to prevent over-run of the wire spool at the
end of aweld, without unduly loadingthewirefeedmotor. The brakingcan be adjusted by the
Nyloc nut using a15/16''
AF or 24mm socket wrench.
5.5 FEEDINGTHE CONSUMABLE WIRE
With reference to Figure 11, release the pressure screw (6), and rotate the pressure arm
(4) to the open position. The endof the welding wire can now be passed through the inlet guide
(1 l), over the bottom driven roller (91, and into the output wire guide tube. Check that the drive
roller groove is correct for the wire
in use. The appropriate size is stamped on the visible side of
the installedroller. Check also that the correct size contact tipis fitted at the gunend. Drive roller
and tip details are available in Section
11 of thismanual.
Return the pressure arm to the closed position and, adjust the pressure screw to provide
sufficient clamping of the drive rolls drive
to achieve constant wirefeed. Do not over tighten.
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Page 8 WELDMATIC 21 5s MANUAL
5.6 OUTPUT VOLTAGE POLARITY SELECTION.
polarity - positive wire or negative wire.
The design ofthe WELDMATIC
215s allows external selection oftheoutput voltage
5.6.1 POSITIVEWIRE
Most solid wire G.M.A.W. is carried out with the work pieceNegativeandthewelding
consumable wire Positive.
To set themachineforthiscondition,insertthe‘WORK’leadplug into the (-) output
socket
on thefront of thepowersource.Insertinter-connecting ‘WELD’ leadplugintothe (+)
output socket on the front of the powersource. See Figure 3 below.
5.6.2 NEGATIVE WIRE
Some ‘self-shielded’fluxcoredconsumables are intendedto be operated with the work
piece Positive and the consumablewire Negative. Refer to themanufacturersdataforthe
particular consumable to beused.
To set themachineforthiscondition,insertthe‘WORK’leadplug into the (+) output
socket onthefront of thepowersource.Insert inter-connecting ‘WELD’leadplugintothe
(-)
output socket on the frontof the powersource. See Figure 4 below.
B
v 00 0-
d
I)
W!& 215s
l
&“&l
e
WORK LEAD
e
J
5eG
FIGURE 3. POSITIVEWIRE
WORK LEAD
FIGURE 4. NEGATIVE WIRE
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WELDMATIC 215s MANUAL Page 9
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6. NORMAL WELDING SEQUENCE
6.1 WELD START
Closing the welding gun switch initiates thissequence of events:
The gas valveis energised, gas flow commences;
The power source triac functionis initiated.Welding voltage is applied between the work
piece and theconsumable wire;
The wire drive motoris energised. Wirefeed commences and the arc is established.
6.2 WELD END
Releasingthe gun switch initiates thissequence of events:
The wire drive motor is de-energised,and is dynamically braked to a stop;
The power source triac functionisde-energised;
The gas valveis de-energisedand the flow of shieldinggas ceases.
7. BASIC WELDING INFORMATION
7.1 CHOICE OF SHIELDING GAS
proprietary shieldinggas mixtures are available.
The choice of shieldinggas is largely determined
by the consumable wireto be used. Many
The recommended shieldinggases for use with the WELDMATIC
21 5s are :
Mild Steel .................................... Argon + 5 to 25% Carbon Dioxide;
Aluminium ................................... Argon;
Stainless Steel ............................ Argon + 1 to 2% Oxygen.
Consult yourgas supplier if more specific informationis required.
7.2 SHIELDINGGAS FLOW RATE
In G.M.A. welding, one of the functions of the shielding gas is to protect the molten weld
pool fromtheeffects of oxygeninthe atmosphere. Withoutthisprotection the welddeposit
becomes ‘honeycombed’ inappearance, an effect which
is described as weld porosity.
In draft-free conditions thegas flow rate requiredto give adequate protection is typically
10
litredmin. Insituations where draftscannot be avoided, it may be necessary to increase this rate
and/or to provide screening of thework area.
Weld porosity canalso be causedby air entering the gas stream through a damaged hose,
loose gas connection,or from restriction in thenozzle, such as from excess build-upof spatter.
7.3 ESTABLISHINGA WELD SETTING
variables whichare adjusted in order toobtain a stablearc are;
Oncethe consumable wire type, wire size and shieldinggas havebeenchosen, the
two
Wirefeed speed,
Welding arc voltage.
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Page 10 WELDMATIC 21 5s MANUAL
The wirefeed rate determines the welding current; increasing the feed rate increases the
current, and decreasing it decreases current. The selected wirefeed rate must be matched with
sufficient arc voltage; an increaseof wirefeed raterequires an increase of arc voltage.
If the voltage is too low the wirewill stub and stutter, and there will not be a steady arc. If
the voltage is too high the arc will be long with the metal transfer within the arc occurring as a
series of large droplets.
IMPORTANT:
Do not operate the Voltage Control switches during welding.
The welding current should be chosento suit the thickness of the metal to be welded. It
is
importantto check that the deposited weld providessufficient strength to suit the application.
A "good" weldwill have the characteristics illustrated in Figure
5. The weld has penetrated
into the parent metal, fusing theroot of the joint where the
two plates meet, and the weld blends
smoothly into the sidewalls.
A "bad" weld is shownin Figure
6. The weld hasnot penetrated thejoint root, andthere is
poor side wall fusion.This lack of fusionwouldnormallybecorrectedbyincreasingthearc
voltage, or by increasing both wirefeed rate and arc voltage to achievea higher current weld
setting.
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FIGURE 5. "GOOD" WELD FIGURE 6. "BAD" WELD
7.4
GUN POSITION
with the nozzleend pointing in thedirection of travel.
For "down hand" fillet welding, the gun
is normally positioned as shown in Figure 7 below
lli!!??
FIGURE 7. GUN POSITION
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