Wia Weldmatic 180s cp17 User manual

MANUFACTURED

BY

WELDINGINDUSTRIES

OF

AUSTRALIA PTY LTD

HEAD OFFICE AND EXPORT DIVISION

2-20

AustarcAuenue5

ThorrIac.town,

ERUIPMEbIT MANUFACTURING DIU1

SION

1

2

C)~OJS.

Rclad

,

Edwards

t

own

,

SCIIJ

t

h

SALES RRANC:HES

Meltuurne

83

429

4766AA32493

Sydney

Er2

647

2655

AA24155

Newca5.t

1

e

Er49

61

1668

Bric.bane

87

844

1371

WC11

1

ongung

G142

25'

3447

Vice

3874

ph

83

465

Facsimile

G13

465

Mackay

679

51

Adel

aide

88

352

Pert

h

09

361

Launceston

863

44

251

1

AA32493

861

2

3532

3622

AA82856

7088

AA72936

53822

MELDPIAT

I

C

180

S.

PLEASE Et4SURE THAT THIS FOLDER

I

S

KEPT

IN

A

SAFE

PLACE

FOR

REAlD'Y

REFERENCE WHEN REQUIRED.

CONTENT8

SECT1

ON

1

2

3

4

6

7

8

9

c

J

F1GUHE

1

2

3

4

5

7

E

P

18

11

d

PAGE

l

1

2

6

8

9

18

12

15

PAGE

CONTENTS

SFEC

I

F

I

CAT

I

ON$

RECE

IO1

NG

I

NSTALLAT

I

ON

CONTROLS

WELDINGSET-UP

GENERAL MAINTENANCE

TROUBLE SHClOTING

CONTROL PRINTEDCIRCUIT

BOARDS

SFAREPARTS LISTS

. .

,

,..

.

..

A'

WELDMATIC

188s

MANUAL

PAGE

1

L

SPEC1

F1

CAT1

ONS

1.1

TECHNI

CkL

-

WeldingOutput

48

-

1

88

~ITI~

C.

-

Output

us1

tagE.

21

-

38

VDC

-

Duty

Cycle.

1

E;@

ArrIF'E.,

58%

188

Amps,

35X

-

Over

1

clad

Prcttec

t

i

or1 Recti

f

i

er

Therrrlcts.tats (Thermal

j

-

WireSpeedRange

G1

-

16

metrew'mi n

-

I

n5.u

1

at

i

or1

C:~~E.C.

'H''

-

148

C;

rise

at

48

C

amtlient

-

Encl

osure

Dr

i

p-proo-f

-

1.2

STANDARD

PACKAGE

-

AM132-8/'? Nine

Metre

Accec.c.ory

Lead

Kit

-

AM132-0/15

Fifteen

Metre

Accessory

Lead

Ki

t

-

2.

RECEIVING

In genera.1

it

is

a

goodpractice

to

mc~ue

theequipmerlt

to

thesite

ofinstallation

before

unpackinq

Use

care

inorder

to

avoid damage

t

cl

the

i

t

ems

en

c

1

osed.

If

any damage haE. clccurredin transitirrlrrlediatelrnutif).

We1 ding Industries

cl+

Austral

ia

or

theirauthoriE.edagent.

WELDMATIC

180s

MANUAL

PAGE

2

3.

I

NSTALLAT

I

ON

3.1

MACHINELOCATION

Where

poc,c.ittle,

in

chctclsirrg

a

siteforanywelding

pOWer-50UrCe,

considerationshould

be

given

tu

the

fclllowingpoints:-

-

Availahility

of

electricalandc.hielding

gas

c.upp1iec..

-

Accessibilityfor

the

replacement

of

consumables,i.e.welding

wireand

gas

bottles,and

for

any

futurerrlainterlarlcerequirements.

-

The

power-source

must

be

posi

ticsned

so

that

the

free f

1

ow

of

cclcll inqairthrough

the

machineis

not

impeded.

-

Prcltectionfromwindanddriven

rain

-

Breezes

bluwingthrough

an

opendoorwaycanrec.ul

t

in

degradationof

the

weldc.hie1dinq

gas

coverage,which

ca.n

causeweldporosity.

If

such

a

site

is

unauoidat~le,considerationshould

tle

given tcl

the

use

ofportat~le

weldir~gscreensof

a

suitablematerial.

The

nut+low

of

cooling

air

from

the

we1

dingpower-~.c~urcecan

a1

5.0

causesimi

lar

prcatl1

ems.,

and

the

machineshould

tle

pc1s.i

tionedwith

this

in

mind.

-

Airhornedustparticles1~1i1l

always

accumulateinuented

equipment,

particularly

that

withforcedaircoolingandexcessive

tluildupcanoften

tle

the

cause

of

premature

machinefailure.

Ai:

a1

1

timesendeavour

to

position

the

machinetominimise

the

inta.ke

cl+

contaminated

air,

particularly

that

contairrirlq

metal

1

ic

particlessuch

as

from

grindingoperations.

i

see

a1

5.0

MA1NTENANC:E SECT

I

ON

of

t

h

i

c.

Manual

,

plage

}

-

3.2

SUITABLE

MAINS

VOLTAGES

The

WELDtIATIC:

1861s.

isdesigned

for

connectic~ntu

a

s.ingle

phase!

58

hertz

electricalmainc.

power

suppl>’.

‘

L

WELDMATIC

188s

MANUAL

PAGE

3

3.3

CONNECTION

TA

ELECTRICAL

MAINS

POWER

SUPPLY

The

recommendedSupplyFuseRating

is

28

Amps.

When

making

corrnec tion

to

the

t4achineSupplyterminal

s,

ensure

that

localcodes

are

adhered

to,

and

that

the

EARTH

connection

is

seCurE.1

y

made.

The

bins.

PowerSupply Cab1

e

c-.hould

only

be

replaced

W1

th

an

equivalent

size

cattle

as

that

fitted.

Tighten

the

two

s.crews

of

the

internalcableclamp1es.ving

sufficient'5.1ack'in

the

Supply

Flexible

Cat11e

C.UC~

that

the

terminated

wirec.

are

not

intension.

U

L

F1

GURE

1.

CONNECT1

ON

SUPPLY

FLEX1

BLE

CABLE

WELDMATIC:

186s

MANUAL

PAGE

4

””

3.4

CABLE

AND

HOSE

CONNECTIONS

AI

1

weldingcurrent

I

controlandshielding

ac.

connectionc.

are

c.hown

in

figure

3.

The

complete

set

ofnecessarycablez.and

hoses

are

containedin

the

r.tar1dar.d

accec-.sory

kit

AP1132.

-SHIELDING

GAS

HOSES.

The

accessory

ki

t

CctntainC-.two

gas.

hoses.

T

h

E

4-1

or

t

er

1

en

y

t

h

i

E.

used

to

join

the

ouput

of

the

shielding

gas

regulatclr.

-

flowmeter

to

the

gas

nipple

on

the

rear

panel

cl+

the

Power-~.c~urce.

The

c.ec

und

hose

is.

used

to

make

the

gas

connection

from

the

~CIOJ~~

sourcefront

panel

to

the

rear

of

the

L521

wirefeeder.

-CONTROL

CABLE,

Engage

the

’Wirefeeder”contrcll catllepluginto

the

marked

socket

on

the

powersourcefront

panel

The

con

trcll

cab1

e

connectiuns

for

the

wirefeeder

are

c.huwn

the

adjacentdiagram,

-I.IELD

I

NG

CURRENT

CABLES.

G.t.1.k.

we1

ding

is

conductedwith

the

el

ectrclde

polari

ty

pc1c.i

tive,

and

the

workp

i

ece

neqat

i

ve.

The

posi

tive ou

tpu

t

of

the

power

sc~urce

is.

connectedto

the

welding

gun

via

an

adaptctrmounted

with

the

mire

drive rnechanic,m.

Ensure

that

the

positive

eldin ding

cat11

e

iz,

E.ecure1

y

bo1 ted

ta

thi

5

adaptor.

The

negatiueoutput of

the

power sourceisconnected

to

the

welding

catlleincclrporating

the

work

clamp. Bckth leads.

c.ecured

a.t

the

puwer

source

by

inserting

the

plugintoit5appropriatesocket.

WELDMATIC

188s

MANUAL

PAGE

5

WELDMATIC

180s

l

J

CONTROL

CONNECTIONS

W21-2WlRE

FEEDER

I

"

""

I

CP1

POWER

SOU=

_.

-

BIMK

OR

WHITE

BADWN

bR

RfD

CONTROL

F1

GURE

2.

CABLE

AND

HOSE

CONNECT1

ONS

L

I

WELDMATIC

188s

MANUAL

PAGE

6

QFF

0

ON

dig

E

tN/t

H

0

SPnr

TtME

WELDMATI

C

188s

MANUAL

PAGE

7

-INCH/PURGE

SWITCH:

This

is.

a

dual+unctionswitch.

Movingtheinch/puryeswitch

up

initiateE.thewire

feed

mcltor,

feedingthewireintotheguncable5ystem.

The

wirefeed

speed

duringinch

is

determined

tly

thesettiny

cl+

the’IJire-c,peed”

contra1

.

-L‘OtTACiE

,SW

ITCH

:

Output

v01

tage

wil

1

increasewithincreasingposition

numbers.

-W

I

HE

SPEED

C:CNTHOL

:

-SPOT

TI

ME

CONTROL

:

-I

NTERVAL

CONTROL

:

WELDMATIC

180s

MANUALPAGE

8

-

5.

MELDING

SET-UP

5.1

ELECTRODE W1 RE/SHIELDING

-

Se1

ec

t

the

desiredconsumabl

e

el

ectrode

wireand

f

i

t

to

the

wirefeeder.

Ensure

that

the

wirefeederic.fittedwith

the

cctrrect

drive

rollers

-

5ee

page

23.

-

Conrrect to

the

gac. regulator/flowmeter,

a

supply

of c.hielding

yas

appropriate

to

the

weldingconsumable.

MI

L6,

STEEL

STAINLESSSTEEL

SI

L1

CON

BRONZE

TYFICALSHIELDING

GAS

ARGON

or

ARGON

/'

HEL

I

UP1 P1

I

XTURES

-

Setthegasfloo~rate

to

suit

the

weldingprocedure,

usually

in

the

range

of

18

to

15

1

itres./min.

NOTE:-Excessive

gasflow

is

coc.tlyand

may

adverselyaffect

the

we1

ding

resul

t.

r

WELDING

CURRENT(Arnps)

30440~

50,604

70,85,100,120#140#t60,iB

WIRESPEED

DIAL

SETTING

1-4 2.0

2.8

3.6

4.0

7.0

6mm VOLTS 135558

DIALSETTING

WIRE SPEED

1

1.3

1.6

1.9

2.2

3.3

4.8

6.8

8mm VOLTS l23346810

I

WIRE SPEED

DIALSETTING

.7

.8

11.2

1.8

2.2 3

3.8

6

9mm VOLTS

I

l234457810

WlRESPEED

DIALSETTING 1 1.2

1.5

1.8

2.5

1.2mm VOLTS

I

56789

SETTINGSGIVEN

FOR

C02SHIELDING GAS.-FLOW RATE 8-1OLITRES/MINlJTE.

USETHIS CHART AS A PRELIMINARY SETTING GUIDE. TO'TUNE'EACH WELD

SETTING,

ADJUST

WIRE

SPEED

ONLY

F1

GURE

4.

WELD SETTING CHART

WELDMATIC

18Bs

MANUAL

PAGE

10

”

7.1

POOR

WELDING

RESULT

-

Check

for gclud wirefeedconditions,

i

.e.

spr~ol

holder

brake

not

ouer-tightened,drive

rollers

notclcqged

with

dustbuild-up,driue

rcll

lers

are

the

correct

size

and

type

to

suit

the

weldingwire5and

the

driueroll

pressure

is

adequateforconsistent.feeding.

Chec

k

&l

5.0

that

the

guncab1

e

1

iner

i

5.

ofccfrrec

t

r.ire

andnotblclckedand

that

the

welding

tip

is

in

goodconditionandnutexcessively

worn.

A1

1

of

the

ahue

cancauseerratic

el

ding

cclrrdi

t

ionsand

IT

IS

THE

AREA

WHICH

HAS

THE

HIGHEST

PROBABILITY

OF

FAILURE

IN

ALL

GAS

METAL

ARC

WELDING

and,therefclrr,~.hc~uld

be

thefir5.tpclintchecked

whef-1

probl

emE.

occur.

-

Check

that

the

shieldinq

gas.

ic. cc~rrectfor

the

electrodewire

in

use

and

for

correct

gas

flow

rate

at

theweldingtorchnozzle.

Ensure

there

are

no

gas

1

eakc.,

as.

this

wi

1

l

resul

t

in

we1

d

pclrosi

t;~,.

The

gas

nuzzle

must

be

free

from

spatter

andfirmlyattached

to

the

welding

nozzle

to

ensure

that

atmctsphericgas.

is

nc~tdra,wnintct

the

shielding

gas.

-

Estatll

ish

that

the

arc

{JOI

tage

is

correct

1

y

5.et

An

arc

I,JCI~

tage

which i

5

too

1

ow wi

1 1

causeexcec.c,i

{le

crack1

e

I

shorting

and

spat

ter

,

wh

i

1

e

an

arc

uul

tagetoohigh

may

resul

t

i

rl

el

d undercutand/or

lossofarc“direction’.

Arc

lengthisproportional

to

arc

I,JOI

tage.

-

l.pJctr

k

-p

i ece

5.u

r

f

ac e

c

on

tam

i

na

t

i

on

by

wa

t

er

cti

1

,

grease,

galuanising,paint,

or

oxide

layers

can

severely

disturb1the

we1

dirig arc

rec.ul

t

in9in

a

poor.

we1

d

deposi

t

.

Shou

1

d

t

h

i

S

conditionoccur,surfacecleaning

c?f

the

work

piece

wi1

1

be

n

ec

esc,ar

Y

.

,

WELDMATIC

180s

MANUAL

PAGE

i

l

“

7.2

NO

WELDING

CURRENT

-

Check

that

Mains Supply

is.

auailatlle

at

the

WELDMATIC

188s

Power

Source, i.e.,

that

thefan

is

runningand theindicator light

is

on.

-

Check continuity

of

the

weldingcurrentcircuit,i.e.y

work

lead,

work

clamp

and gun cableconnections.

-

Inspect,

andreplace ifnecessaryfuses on

the

WELDMATIC

i86zs

Power

Sourcefront

panel,

Replacefusesonly

with

the

correct

type

(3AGi)

and

correctcurrent rating.

-

Checkoperation

of

theweldingguncwitch,i.e.

,

wir~?-t”eed

motor

runs,

and

gas

val

ue

CIFIerates

when-

gun

sui

tch

c

1

osed.

I

f

not

replace

the

gun cable

assembly,

and

re-test.

-

If

the

forgoing checks

haue

tleerl

made

.md

notrevealed

the

Saul

t

condition

it

is possible

that

a.

failure

has

occurredin

the

electroniccontrol circuitsofthe

WELDMATIC

1538s

.

In

thisinstance,

QUALIFIED

SERVICE

PERSONNEL

should

refer

ts

the

in-formationcontainedinthefc111c11~~inqSection.

WELDMATIC

180s

MANUAL

PAGE

12

-

8,

CONTROL

PRINTED

CIRCUIT

BOARDS

-

8.2

WIRE-FEED

CONTROL

BOARD

W1A-21

The

PCBW16-ZI

in

conjunction

with

PCB

Wid-28

perfctrmc,

the

fol

lclwinq

f

uric

t

i

onc.

:

-

Closed-lc~ap

speed

cclntrol

fur

the

wire

feed

motclr.

-

Run,

and

braking

control

of

the

wire

feed

mator.

-

Driver

for

the

gas

c.ct1enc~idvalve.

-

"Burn-back"

of

the

electrode

wire

at

end

af

weld.

It

a1

5.0

pravides

the

el

ec

trieal E.cIcket5.

to

a1

1

c~w

pctst-f

i

t

of

vdricIu5

W14

wire-feeder

'Options'

such

a5

:

3OY.

ACSUPPLY

UTILUX

HIPP6

U.

. .

.

F1

GURE

7.

W1

RE-FEEDER

MOTHER

BOARD

pcS

OUERLAY

W1

6-21

-

c

WELDMATIC

18Gis

MANUAL

PAGE

13

0

;I

3

c5

00

cb

U

Y

FIGURE

3

WIRE-FEEDER

SPEED

BOARD

PCB

OIJERLAY

W1

6-20

WELDMATIC

i805

MANUAL

PAGE

14

This

tmard

detects

welding

current

initiation

and

times

the

Spat

Welding

and

Cycle

Arc

operation.

>l-1-1-1-

k

WELDMATIC

180s

MANUAL

PAGE

15

eSPAREEm3LL.i

”

9.1

POWER

SOURCE ASSEMBLY

ITEM

3

PART

3

1

2

3

4

5

L

7

8

8.1

9

16

11

12

13

14

15

16

17

15‘

17

28

21

22

Lb

24

25

26

27

’

28

2

P

38

,l

31

.1

31.2

31.3

31.10

32

33

34

35

36

37

38

37

48

41

cc

CP17-29

CP17-25

CP17-28

CP17-11

Wid-21

W1

6-20

W1

1-28

CP1

7-8/Y

CPi7-6/16

CPl7-6/11

W

1

-23

CP15-61/4

CP17-B/14

CP1

5-6/14

W1

1

-8/‘i

6

k15-16/19

CP28-

1

4/‘

1

8

W

1

-33/

1

W1

1-1

1

W1

7-1

4

TC262

TC262N

C:P17-1

1

CPL 7-36

CP17-14

CP17-16

CP17-17

CP17-6/38

w1-19

CPf

7-8/31

Id1

7-8/‘1

1

IJ

1

7-6,’

1

3

W1

1-82/15

Ard

128-50

Ar113-14

W

I

rd

4

Am

m-3

AA35

(MC14-6/18

<MC

1

4-8~9

1

CP17-8/36

GP

l

7-8/37

CP1

7-8/38

W1

1-8/13

AM97

CP17-@1/4i

DESCRIPTION

BASEASSEMBLY

TRANSFORMER ASSEMBLY

LIMITING

BC

WELDINGINDUCTANCEASSEMBLY

RECTI F1ER ASSEMBLY

WIRE-FEEDER MOTHER

BOARD

PCB

W1

RE-FEEDERSPEED

BOARD

PCE

SPOT TIMER/’CYOLE ARC

BOARD

PCB

CURRENT RELAY

CO1

L

REED RELAY

CONTROL TRANSFORMER 248-31VF226UA

CONTACTOR

VOLTAGESWITCH

FUSE HOLDER

FAN

BLADE

FAN

MOTOR

240056Hz

CONTROL PLUG

TYPEbIO./SERIAL

NO.

NAMEPLATE

KNOB

-

bJ1

RE

SPEED

KNOB

-

SP@T/’CYCLE

PCB

PlOUNT

I

NGS

GAS

VALVE

HOSE

GARB

GAS

VALVE CONNECT1

ON

GAS

HOSE NIPPLE

NUT

FRONT PANEL

BACK

PANEL

BAFFLE

BC

COWONENT

MOUNT

I

NG

PANEL

TOP COUER

SIDE PANEL

LOOM ASSEMBLY

-

POWER SOURCE

OFF/ON

SWITCH

LOOM

AssErIBw

-

WI

RE

FEEDER

I

rm

I

CATOR

L

I

GHT

INCH/PURGESWITCH

W1

RE

SPEED

POTENTI

OtIETER

SPOT/CYCLE

SELECTION SI*!ITCH

GAS

HOSE

OUTPUT TERtlINAL ASSEMBLY

CABLE ENTRYBUSH

CABLE

ENTRY

BUSH

CASTOR WHEELS

FIXED WHEELS

HOSE PLUG

SUPPLYFLEX

CAPAC

I

TOR

BOTTLE CRADLE

ASSEMBLY

HANDLE

.

WELDMATIC

188s

MANUAL

PAGE

16

9.3

WELDMATI

C

118s

MANUAL PAGE

l7

TWO-ROLL-DRIVE ASSEMBLY

ITEM# PART

3

i

2

3

4

5

6

7

8

9

18

11

12

13

14

1';

16

17

18

15'

26

21

22

23

24

25

26

27

28

29

36

31

32

33

34

35

36

37

W2-44/1

w2-44/2

b52-44/25

W2-17

W2-44/&.

W2-44/'13

w2-44/7

W2-44/8

w2-15

w2-44/9

03r356ZP

W

2

-

1

6

WZ-,

.

W2-44/12.

.

W2-44/2X

W2-44.>'22

LJ2-44/5

w2-44/21

4928

W2-44/.1

9

W2-44./26

DESCRIPTION

2

ROLL

DRIVE

BODY

2

ROLLDRIUETOPROLLERHOUSING

SHAFT

SOCKET SET SCREW

1.15

x

18

WASHER

M5

STAR LOCK WASKER

SOCKET HEAD SHOULDER SCREW

M8

x

26

BELLE01LLE WASHER JW417

SPRING

NUT

TOP

ROLL

SHAFT

1.18

x

48

S.H. SHOULDER SCREW

BEAR

I

NG

60

82

2

BEARING FL6C-rEZZ

M6

HEXAGONAL DOME

NUT

DRIUEN GEAR WHEEL

TOPROLLERBUSH

aL.REW

NO.

8-32

X

1

/2"

LING:

S0C.K

,

CAP

HEAD

CAP

HEAD

SOCKET

SCREW

rm

X

10

TENS1

ON

ARM

'

0-

DRIwrdG

GEAR

WHEEL

SLOTTED

PAN

HEAD

SCREW

rl3

x

e;

CAP

HEADSOCKET

SCREM

M5

>:

15

CAP

HEAD

SOCKET

SCREW

1.16

x

12

C/SUNK

HEAD

SOCKET

SCREW

r.16

X

12

DRIVEROLLERS

-

SEE TABLE

WIREINPUTGUIDE

-

SEE

TABLE

ADAPTER

BUSH

LOCKNUT

P124

x

1

CAP

HEAD

SOCKET

SCREW

1.18

X

2s

SPRING WASHER 5'1

6"

CAP

HEAD

SUCKET

SCREW

rw

>:

1s

FLAT WASHER

5/

1

6"

I

NSLILAT

I

biG

R

I

NG

FLAT MASHER 24mm

I

.D.

x

34mrr1

O

.D.

BERNARD

QUI

Cl<

CONNECT

BERNARD CABLEADAPTER

GLlI DE TUBE

i

FIGURE

i

l.

TWO

ROLL

DRIVE

ASSEMBLY

WIA Weldmatic 180s CP17 User manual

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