WELDING INDUSTRIES Weldmatic 215S User manual

l
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
l
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
le*&l
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.
l
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
- ~”

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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WELDMATIC 215s MANUAL Page 11
8. GENERAL MAINTENANCE
I I
Beforeremovingthe machine cover, ENSURE that the unitis disconnectedfrom the mains
power supply. Whenthe unit is energised
LETHAL VOLTAGES are present on the electrical
components enclosed.
l I
DUST
Careshouldbetakentopreventexcessivebuild-up of dust and dirt withinthewelding
power source. Itis recommended thatat regular intervals, accordingto the prevailing conditions,
the machine covers and enclosed wirefeeder covers be removed and any accumulated dust be
removed by the useof dry, low pressure compressedair, or
a vacuum cleaner.
WIREFEED
wirefeed must be smoothand constant. It is therefore importantto observe the following points;
In ordertoobtainthemostsatisfactory welding resultsfromthe
G.M.A.W. process,the
' Keep the gun cable liner clear of dust and swarf build-up. When replacementbecomes
necessary, fitonly the correct linerto suit thegun cable model.See page
19. The build-up
of dust in a cable linercan be minimisedby regular purging of the liner with dry
compressed air. This may be conveniently done each time the wire
spool is replaced.
Replace the welding tipas it becomes worn.
Keep the wire drive mechanismclean. Periodically check the drive rollers for wear and for
free rotation.
Check that theconsumable wire spool holder rotates smoothlyand that the braking
action
is not excessive. Thisalso may be conveniently done each time the wireis
replenished.
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Paae 12 WELDMATIC 21 5s MANUAL
v
9. TROUBLE SHOOTING
, ' ' , F,AUL-T;,
, ' REMEDY
I
Power source has no power, ie. Check mains voltage, fuses or circuit breaker
l)power lightis off Turn on mains supply switch
I 2) fansarenotrunning I Check allprimaryconnectionsinpowersourceand inprimaryplug
I
l l l
i
Power source has no output but :
2) fans are running Replace CP109-10 control board 1) power lightis
off
Check allconnections to CP109-10 control board in power source
Power source has no output and Power source overheated. Allow thermostats to cool with fans on
no wirefeed when gun switchis After cooling,if problem still persists, check rectifier thermostat
closed but:
l)power lightison and transformer thermostat for open circuit. Replaceif faulty
Check allconnections to CP109-10 control board in power source
1) power light is on
2) overload lightisoff
3) fans are running
the time when mains poweris
applied and gun switchis
off
variation when coarse and fine
Switches are operated
l I I
painsfusesbloworcircuit I Checkweldingtransformerforaprimaryfaulttoearth.
l
breaker trips instantly when Check fan in power source for short circuit or fault to earth
mains voltage is applied Replace iffaulty
Replace if faulty
Mains fuses blow or circuit
gun switch
is closed Check rectifier for shorted diodes. Replaceiffaulty breaker trips instantly when
Check welding transformer for shorted turns. Replaceiffaulty
Mains fuses blow or circuit Check that the recommended fuse or circuit breaker rating has been
breaker trips when welding used. Consider upgrading
to larger fuse or circuit breaker & wiring.
I 1 I
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WELDMATIC 2A 5s MANUAL Page 13
TROUBLE SHOOTING cont.
UNSATISFACTORY WELDING PERFORMANCE AND RESULTS
-
FAULT
1
Erratic arc characteristics
caused by poor wirefeed Check gun liner for build up of dirt or blockage. Replaceifdirty
Check if wire is slipping
on roller assembly. Replace feed roll if worn
Check ifthere is too much drive roller pressure on wire
Check spool holder
is rotating smoothly
Check that gun liner is not too short andisfitted correctly. Refer to
page
19 for fitting instructions.
I I l
I Constant poor arc
characteristics
Porosity inweld caused by
lack of shielding gas
Check correct polarity has been selected for work and weld cables.
Refer
to page 8
Check shielding gas is correct for the consumable in use
Check welding circuit
is making good electrical connection
Check all connections in power source and wirefeeder for hot spots
Check gas solenoid. Replace if faulty
Check that the correct gas
flow rate has been set
Check for leaksingas hose. Replace if leaking
Check for leaksingun cable, eg. O-rings. Replaceif leaking
Check nozzleisfirmly attached
to gun and that no air is being
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Page 14 WELDMATIC 21 SS MANUAL
IO. SERVICE INFORMATION.
CP109-10 CONTROL BOARD
The CP109-IO Control board provides the followingfunctions.
Welding transformer ON/OFF control.
w Wirefeed motor ON / OFF control.
Speed control of the wirefeed motor.
w Braking of the wirefeed motor at end of weld.
g Spot-weld timer.
w Interval timer.
Gas solenoid ON / OFF control.
Triac ON / OFF control, phase selected to minimise transformer inrush current.
Triac protection by output short circuit detection.
Connections to the board are detailed in the drawingbelow.
The circuit is factory adjustedto provide a maximum drive roller speed of 160rpm.
MAXIMUM SPEED
CALIBRATION
7
OUTPUT
OUTPUT
THERMOSTAT
THERMOSTAT
TERMINAL+VE
TERMINAL -VE
GUNSWITCH SECONDARYTRANSFORMER
GUNSWITCH ---"I
GASVALVE A 1 1 L."
I SECONDARY TRANSFORMER
WIREFEED MOTOR +VE
GASVALVEWIREFEEDMOTOR-VE
ACTIVE 24OVAC
NEUTRAL 240VAC
FIGURE 8. CPlO9-10 CONTROL BOARD
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WELDMATIC 21 5s MANUAL Page 15
pJlI1
W
‘4
FIGURE 9. CP109-0 CIRCUIT DIAGRAM
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Page 16 WELDMATIC 21 5s MANUAL
11. PARTS LIST
WELDMATIC 215s POWER SOURCE
ITEM # ............... PART #............................DESCRIPTION
1 .............................. CP109-lON ............................
PCBAssy Wirefeed
2 .............................. CP109-5L ...............................
Weld Transformer Assy inc. Overload & Wire Loom
2.1 ........................... CP104-1612 ............................
Thermal Overload
Includes
3 .............................. CP109-6 ................................. InductanceAssembly
5.1 ........................... CP106-0/1 ..............................
Rectifierwith Thermal overload
5.3 ........................... CP109-32 ...............................
Heatsink (NotShown)
5 .............................. CPI09-8 ................................. RectifierAssembly
Includes
5.1.l ........................ CP3-918 ..................................
Thermal Overload (Not Shown)
5.2 ........................... CP102-5112 ............................
SCR Module (NotShown)
6 .............................. CP43-23 ................................. BaseAssembly
Includes
6.1 ........................... CP42-2416 .............................. CastorWheel (2)
7 .............................. CP109-20Y ............................
Front Panel
8 .............................. CP109-24Y ............................
Back Panel
9 .............................. CP109-21Y ............................
Centre PanelAssembly
l0 ............................ CP109-23 ...............................
Baffle Panel
11 ............................ CP42-27Y ..............................
Side Cover-FixedLower (Not Shown)
12 ............................ CP109-28Y ............................ Door Hinged (Not Shown)
13 ............................ CP42-29Y ..............................
Top Cover
14 ............................ W29-1/20 ...............................
Slam Action LatchOn Door(Not Shown)
15 ............................ CP43-24Y ..............................
Side Cover (Not Shown)
16 ............................ CP42-0/3 ................................
RubberTyre Wheel (2)
17 ............................ MC11-53/6 .............................
RatchetCap (2)
18 ............................ CP109-50 ...............................
LoomAssembly, LowVoltage (Not Shown)
19 ............................ CP109-54 ...............................
~ernalPolarity Change Lead
20 ............................ CP109-55 ...............................
Loom Assembly,Transformer (Not Shown)
21 ............................ CP109-56 ...............................
LoomAssembly, High Voltage (Not Shown)
22 ............................ SA140-0/2 ..............................
Socket Dinsel25mm (2)
23 ............................ MK6/2 .....................................
Terminal Block,2 position
24 ............................ CP27-0/15 ..............................
Cooling Fan (2)
25 ............................ CPl01-0/18 ............................
GasValve24V DC
26 ............................ W11-11/1 ...............................
GasValve Hose Tail (2)
27 ............................ OCLl3 ....................................
“0“ Clip W (2)
28 ............................ CP106-0/3 ..............................
20A Flex & 15A Plug
29 ............................ CP109-15 ...............................
Rod Hinge (Not Shown)
30 ............................ W5-10/19 ...............................
PotentiometerKnob,Small (2)
31 ............................ W11-0/16 ...............................
Potentiometer Knob, Large
32 ............................ 62513 .....................................
Black Oxy Single Hose
36 ............................ SCG030M ..............................
Steel Chain650mm
37 ............................ CP3-0/23 ................................
Rubber Grommet
50 ............................ CP42-39 .................................
HandleAssy
51 ............................ WFOOI-6 ................................
PlasticCover
72 ............................ W39-0/1 .................................
Switch (2)
80 ............................ H907 .......................................
Cable Clamp
84 ............................ BBA210-1 ...............................
Busbar Inductance
85 ............................ BBA320-1 ...............................
Busbar, Inductanceto Output-ve
86 BBA315-2 Busbar, Rectifier-ve
to Inductance
87 ............................ BBA500-1 ...............................
Busbar, Rectifier+veto Output+ve
................................ MC14-0/10 .............................
Male InsulatingBush For FlexCord (Not Shown)
................................ MC14-0/11 .............................
Female InsulatingBush For FlexCord(Not Shown)
................................ CP109-40 CP109-0 Owner
S Manual (Not Shown)
............................ ...............................
...............................
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WELDMATIC 215s MANUAL Page 17
N N
\
1 m L
FIGURE IO. WELDMATIC 215s POWER SOURCE ASSEMBLY
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Page 18 WELDMATIC 21 5s MANUAL
12. PARTS LIST
CP109-7 MOTOR, TWO ROLL DRIVE & EURO ADAPTOR ASSEMBLY
ITEM # ............... PART #............................DESCRIPTION
1 .............................. WFOOI-l ................................ Motor & Gearbox
3 .............................. WFOOI-3 ................................ 2 Roll Feed Plate
5 .............................. WF001-4/1 ............................. Pressure Roll 30mm Diameter
6 .............................. WFOO 1-5 ................................
Pressure Screw Complete
7 .............................. WFOOI-6................................ InsulationBoard
8 .............................. WFOOI-7 ................................
InsulationWasher
9 .............................. W26-1/8 .................................
Feed Roll 30mm - 0.8 f 1.Omm, Solid Wire
10 ............................ W27-0/9 .................................
PositioningScrew Main Gear
11 ............................ W26-0/13 ...............................
InletGuide
12 ............................ WFOOI-21 ..............................
InletGuideTube
(9) ........................... W26-0/8 ................................. Feed
Roll 0.6 + 0.8mm, Solid Wire
(9) ........................... W26-518 .................................
Feed Roll 0.9 + 1.2mm, Solid Wire
(9) ........................... W26-218 .................................
Feed Roll 1 .O + 1.2rnm,Solid Wire
(9) ........................... W26-418 .................................
Feed Roll 1 .2 + 1.6mm, Solid Wire
(9) ........................... W26-3/8 .................................
Feed Roll 1 .O f 1.2mm,Aluminium Wire
(9) ........................... W26-7/8 .................................
Feed Roll 1 .O f 1.2mm, FluxCored Wire
(9) ........................... W26-6/8 .................................
Feed Roll 1 .2 + 1.6mm, FluxCored Wire
2 .............................. WFOOI-2 ................................
Euro Gun Adaptor inc. Guide & Gas Connector
4 .............................. WFOOI-4 ................................
PressureArm (Complete)
ALTERNATIVE PARTS
FIGURE 11. CPlO9-7 TWO ROLL DRIVEASSEMBLY

WELDMATIC 215s MANUAL Page 19
13 . PARTS LIST
BEXT2-4E21OAE GUN ASSEMBLY
ITEM # DESCRIPTION .......... PART # ITEM # DESCRIPTION .......... PART #
1
2
3
4
5
6
7
8
9
10
14
Nozzle
........................
BE4392
Contact tip 0.6mm
...... BE7497
Contact tip 0.8mm
...... BE7488
Contact tip 0.9mm
...... BE7489
Contact tip 1.2mm
......
BE7490
Head
..........................
BE4335
Cap
............................ BE4323R
Nut Insulator
............... BE4780
Insulator
..................... BE1370117
Handle Kit
................... BE1780006
Trigger
........................ BE5662
Screw Kit
.................... BE1880004
Cable 3m
....................
BE8681TE
Body Tube
.................. BE1370116
45
16
17
18
19
20
21
22
23
24
25
26
27
End Fitting
..................
BE4E2135
Cone Nut
.................... BE4305
Terminal
..................... BE2660001
Clamp
.........................
BE1520008
Strain Relief
...............
BE252001 7
Bushing
......................
BE1470007
Strain Relief, rigid
....... BE1880135
Screw
.........................
BE2280002
Insulated Link
............. H2072
Nut
.............................
BE4816
Euro Block
..................
BE5060
'0' Ring ......................
BE44211
Liner
0.9 - 1.2mm .......
BE431 10
To replace liner: Disconnectgun cable assembly fromtheEuroadaptor on themachine
case. remove nozzle
(l) and head (3) . Withdraw old liner from the wire feeder end . Insert new
linerandrefitguncable assembly to Euro adaptor
on themachinecase . At thegunend.
compress the liner within the gun cable. then
cut it one contacttip length past the end of the
body tube (7) . Refit head. tipand nozzle .
FIGURE12 . BEXT2-4E21OAE (200 AMP) GUN CABLE ASSEMBLY

Page 20 WELDMATIC 215s MANUAL
I 14. SAFE PRACTICESWHENUSINGWELDINGEQUIPMENT
These notes are provided in the interests of improving operator safety. They should be considered
only as a basic guide to Safe Working Habits. Afull listof Standards pertaining to industry is available from
theStandardsAssociationofAustralia,alsovariousStateElectricityAuthorities,DepartmentsofLabour
andIndustryorMinesDepartmentandotherLocalHealthorSafetyInspectionAuthoritiesmayhave
additionalrequirements.WTlATechnicalNoteTN7-98alsoprovidesacomprehensiveguidetosafe
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 shadefilter lens.
Amps TIG MMAW MIGPulsed MIG
l 0-100 ............. 10 .................. 9 10 .................. 12-13
100-150 ......... 11 .................. 10 .................. IO ..................
12-13
150-200 ......... 12 .................. 10-11 ............. 11-12 .............
12-1 3
200-300 ......... 13 .................. 11 ..................
12-13 .............
12-13
300-400 ......... 14 .................. 12 ..................
13 .................. 14
400-500
............................. " 13 .................. 14 .................. 14
500 + ........
............................ --...... .............. 14 .................. 14
....................
BURN PROTECTION.
Theweldingarc isintense andvisiblybright. Itsradiationcandamageeyes,penetratelightweight
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.
Wearprotectiveclothing
- leather or heatresistantgloves,hat,andsafety-toeboots.Buttonshirt
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.
Earplugsshouldbewornwhenweldinginoverheadpositionsorinaconfinedspace.Ahardhat
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
personin the area as well as the operator mustwear an air-supplied respirator. For beryllium, both must be
used. Metalscoatedwithorcontainingmaterialsthatemitfumesshouldnotbeheatedunlesscoating is
removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.
Workinaconfinedspaceonlywhileit
is beingventilatedand, ifnecessary,whilewearingair-
supplied respirator.
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