WIA Weldmatic 205S User manual

WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIESLID
ACN 004 547 ll l
Head Qffice and International Sales
5 Allan Street, Melrose Park
South Australia, 5039
Telephone [phone] Facsimile [phone]
OWNERS MANUAL
WELDMATIC 205s
MODEL MO. CPlO2-6, REV. C
MODEL NO. CPlO2-7, REV. C
220V/240V, 5QHZ VERSION
09/95
QUALITY W€LBING PR05UCTS, SYSTEMS AND SERVICE
4 f

WELDMATIC 205s MANUAL Page 3
SAFEN
Before this equipment is put into operation. the SAFEPRACTICES section at the
back of the manual must be read completely
. This will help to avoid possible injury
due
to misuseor improperwelding applications .
CONTENTS
Sec.1 Introduction ........................................ P.4
Sec.2 .................................... Receiving .......................................... P.4
Sec.3
................................. Specifications ....................................... P.5
Sec.4 ......................... Power SourceControls ............................... P.6
Sec5
................................... Installation ......................................... P.7
Sec.6 ...................... NormalWeldingSequence ............................. P.10
Sec.7 ....................... BasicWelding Information ............................. P.10
..................................
Sec.8 ........................... General Maintenance ................................. P . 13
Sec.9
.............................. Trouble Shooting .................................... P.13
Sec.10
.......................... Service Information .................................. P . 14
Sec . 11 ................................ ..PartsLists .......................................... P . 18
Sec.12
.............................. Safe Practices ....................................... P.23
FIGURES
Fig.1 .......................... Power SourceControls ............................... P.6
Fig.2
................... Remote WirefeederConnection ......................... P.8
Fig.3
......................... PositiveWire Connection .............................. P.9
Fig.6
.................................... ‘Bad’Weld ......................................... P.12
Fig.7
................................... Gun Position ........................................ P.12
Fig.8
................................ Circuit Diagram ...................................... P.15
Fig.9
......................... Dual SCR ControlBoard .............................. P . 16
Fig.l2
.......................... GunCableAssembly ................................. P.20
Fig.13 .......................... Wire DriveAssembly ................................. P.21
Fig.14
........................... Remote Wirefeeder ................................... P.22
Fig.4
........................ Negative WireConnection ............................. P.9
Fig.5 ................................... ‘Good’ Weld ........................................ P.12
Fig.10 ........................ WirefeedControl Board ............................... P.17
Fig . 1 1 ....................... Power Source Assembly ............................... P.19

Page 4. WELDMATIC 2Q5$ MANUAL
The infarmatior1 contained in this manual is set out to enable you to properly
maintainyournewequipment and ensure that you obtain maximum operating
efficiency.
Please ensurethat this information is kept in a safeplaceforreadyreference
when required at any future time.
When requesting spare parts, please quote the model and serialnumber of the
machine
and park number of the item required. All relevant numbers areshown in lists
contained
in this manual. Failure to supply this information may result in unnecessary
delays in supplying the correct parts.
Gas Metal Arc Welding (G.M.A.W.) is a basically simplewelding process, where a
consumablewire is fed by motor driven drive rollers to a welding gun, and where
welding current is supplied from the welding power source. The welding arc is struck
between the workpiece and the end sf the wire, which melts into the wold pool. The
arc and the weld pc101 are both shielded by gas flow from the gun, or in the case of
"self shieldad" wires, by gases generated by the wire core.
The process is very versatile in that by selection of the correct wire composition,
diameter and shielding gas, if: can be used for apptications rartging from sheetmetal
to heavy plate, and metals ranging from carbonsteel to aluminium alloys.
The WELDMATIC 205s has been designed to be used with consumable wires in
the raflge from O.6mm to 1.2rnmdiameter. The smaller wiresizesare used when
welding at lowercurrents, such as sheet-metalapplications.Increasing the wire
diameter permitshigher welding currents
to be selected.
A comfnon application of G.M.A.W. is for welding Mild Steal. Itr this application, a
Mild Steel solid consumable such as WIA E% or ES6 is used with a shielding gas of
Carbon Dioxide,
or Argon mixed with Carbon Dioxide. Alternatively,Flux-cored
consumablesare
available in both gas shielded, and 'gasless' self shieldingtypes.
Stainlesssteel and Aluminium can be welded with G.M.A.W. using the correct
eonsurr-table wire andshielding gas.
Cheek the equipment received againstthe shipping invoice to make surethe
shipment is complete
and undamaged. If any damage has occurred in transit, please
immediately notify your supplier.
The CP102-6 (Internal Wirefeeder) Package contains;
S WELDMATIC 205s Powersource.
B BEQA218AE BERNARD Gun cable, 3 metre, Euroconnector.
U HA481-I85 Regulator and Flowgauge.(Argon)
1 (This)QwnersManual.
The CPlO2-7 (Remote Wirefeeder) Package contains;
W3243 Wirefeeder.
BP AN1224-0/10 Inter-connecting lead kit, IO metre.
a BEQA210AE BERNARD Gun cable, 3 metre, Euro connector.
S HA101-185 RegulatorandFlowgauge. (Argon)
e (This) OwnersManual.
WELDMATIC 2Q5S PQWW Source.

WELDMATIC 205s MANUAL Page 5
3. SPECIFICATIONS
Manufactured to AustralianstandardAS1966.1-1985
PRIMARY VOkTaGE ................................................ 220 Volts A.C., Single Phase, 50 hz.
RATED PRIMARY CURRENT .................................. 16.5 Amps
MAX PRIMARY DEMAND ........................................ 33 Amps, 7.2 kVA
(Minimumrequirementfor
supply
fromenginedriven alternator.
FUSE RATING .......................................................... 20 Amps
FITTED SUPPLY CABbE .......................................... 30/0.25 Three Core,
Heavy DutyPVC
WIRE SIZE RANGE .................................................. 0.6mm - 1.2mm diameter
OPEN CIRCUtT VOLTAGE
...................................... Maximum HI Range 35V.
Maximum LO Range 24V.
WIRE FEED RANGE ................................................. 1 to 15 Metreslmin
COOLING ................................................................. Fan cooted, air drawn in
through rear fan grille.
WELDING CURRENT RANGE ................................. 35 - 205 AMPS
OUTPUT RATING .................................................... RatedOutput: 180 Amps
@ 24 Volts, 35% DutyCycle.
Max, Welding Current:
205 Amps, 25% DutyCycle
(Dutycycle
is defined in Austra!ian StandardAS1966.1 as the ratio of arcing timeto 5
minutes in any 5 minute period,expressed as a percentage.)

Page 6
WELDMATIC 205s MANUAL
____~
4. POWER SOURCE CONTROLS
J
n
U U
FIGURE 1 - POWER SOURCE CONTROLS
1. POWER ON INDICATOR
power isconnected to thewelder.
This is illuminated when the machineis energised, that is when electrical mains
2. HI - LO SWITCH
This switch provides Coarse adjustment ofthe OutputWeldingvoltage.
This control providesFine adjustment of the Output Weldingvoltage. Rotating the
3. VOLTAGE CONTROL
control ina clockwisedirectionwill increase the output voltage.
4. WIRE SPEED CONTROL
clockwise directionincreasesthe wirefeedspeed, increasingthe welding current.
The wirefeed speed of the machine is varied with this control; turning thedial in a
5. SPOT TIME CONTROL
When operating the machine in SpotWeldmode, this control will vary the spot
weld time. Rotating the dial clockwise will increase the spot weld time,
in the range
0.5 - 2.5 seconds.lf the Spot Weld mode is not required this feature can beturned off
by rotating the controlanti-clockwise until it ‘clicks’ intothe minimum position.
6. INTERVAL CONTROL
When operating the machine in CycleArcmode this control sets the period
between welds. The spot time control sets the welding period. Rotating the dial
clockwise will increase the interval time, in the range
0.5 - 2.5 seconds. If the Cycle
Arc mode
is not requiredthis feature can be turned off by rotating both controls fully
anti-clockwise.

WELDMATIC 205s MANUAL
CONMECT18M TO ELECTRICAL MAINS POWER SUPPLY
Due to peak current requirements, the Electrical Mains supply to welding
machines is best protected by fuses. Circuit Breakersmay trip frequently
if used in
this application.
The
WELDMATIC 205s is supplied with a 3 metre 3 core Heavy Duly PVC mains
power supply cable. If it becomes necessaryto replace the mains power supply cable,
use only
a cable with an equivalent: or higher current rating. Access to the machine
supply terminals is gained by removing the power-source side panel opposite to the
wire-spoolenclosure.
FITTING THE GUN CABLE
The BERNARD BEQA21BAE gun cableisequipped with a ‘Euro’ wirefeeder
connector which incorporates all required connection points to ‘the gun cable for
welding current, shielding gas and gun switch control.
To attach the gun cable to the wirefeeding mechanism, engage the mating parts
sf the male and femaleEuro connectors, then rotate the lockingring clockwise to
firmly secure the connection.
FITTING THE GAS BOTTLE
The MAXIMUM height of a gas cylinder to be fitted to the standard WELDMATIC
205s is 1 .O metre. The weightand highcentre of gravity of taller cylinderswill result in
the machine becoming unstable. Po enable use of taller cylinders, an optional
accessory AM209 isavailable separately.
Depending
on configuration ofthecylinder to be used, the gas flowmeter
regulator may be fitted directly to the cylinder, or in conjunction with an etbow. D d
NOT apply any greasetothese joints, and tighten the nuts securely.
Fit the end of the gas inlet hose from the back panel ~f the machine to the
connector suppliedwith the flow regulator, and secure with the clamp also supptied.
FITTING THE CONSUMABLE WIRE
Thequality of the consumable wiregreatly affects how reliably a G.M.A.W.
machinewill operate. For bestresultswhen weldingmild steel, we recommendquality
WIA AUSTMIG €34 or ES6. Dirty, rusty or kinked wire will not feed smoothly through
the gun cable and will cause erratic welding. Bspositsfrom the wire will clog the gun
cable linerrequiring it
to be replaced prematurely.
Placethespool sf welding wire onto the spool holder. The locationpin should
mate with a hole provided on thewire spool body.Fitthe spool retaining ’R’clip
supplied.
Check the adjustment sf the spool brake, which should be set to prevent over-run
of the wire spool at theend of 8 weld, without undulyloadingthe wirefeed motor. The
brakingcan be adjusted by the Nyloc nut using
a 15/16” AF or 24mm socket wrench.

Page 8 WELDMATIC 2055 MANUAL
FEEDING THE CONSUMABLE WIRE
Open the two roll drive mechanism by lifting the pressure lever upwards, which
lifts theupper roller away from the drivenroller.The end of the welding wirecan now
be passed through the inlet guide, over the bottom driven roller, and into the
brass
guncable adapter.
Check that the drive roller groove is correct for the wire in use. The a propriate
size is stamped on the visiblesrde of the installed roller. Check also that t r: e correct
size contact tip is fittedat the gunend. Refer to section 11 for gun part numbers.
Returnthe top roller
to the closed position and, with the machine turned on,close
the gun switch to feed wire through the gun cable. Adjust the compressionscrew to
provide sufficient clamping of the drive rotts drive to achieve constant wirefeed. Do
not overtighten.
FIlTlNG REMOTE WIREFEEDER
Where fitted, the W32U remote wirefeeder is connected to the WELDMATIC 205
power source using an AM224 extension lead kit. The connectio'n details are shown
Inthe diagram below.
. GUN CABLE
CONNECTOR - I
POWER CABLE
- BLUE
," WTE
x
GRN/YEL
W32-0 AM224
EXTENSION LEAD KIT
WELDMATIC 205s
WIRE FEEDER POWER SOURCE
DETAIL
OF POWER
CABLE CONNECTION
FIGURE 2. REMOTE WIREFEEDER CONNECTIONS

WELDMATIC 205s MANUAL Page 9
OUTPUTVOLTAGE POLARITY.
polarity.
POSITIVE WIRE
Thedesignof the WELDMATIC 205s allows selection ofthe Output Voltage
Most
G.M.A.W. is carried out with the workpiece Negative and the welding
consumable wire Positive.
To set the machine for this condition, bolt the 'WORK' lead onto the (-) output
stud, and the 'GUN
CABLE' leadto the (+) stud, as infigure 3. below.
Some "Self-Shielded"flux cored consumables are intended to be operatedwith
the workpiece Positive and the consumablewireNegative.Refer to the
manufacturersdata for the particularconsumable to be used.
To set the machine for this condition, bolt the 'WORK' lead onto the (+) output
stud, and the 'GUN
CABLE' ontothe (-) stud, as infigure 4. below.
NEGATIVE WIRE
WORK LEAD -
-
FIGURE 3. POSITIVE WIRE
JN CABLE LEAD
GUN CABLE
L
WORK LEAD
FIGURE 4. NEGATIVE WIRE

Page 10 WELDMATIC 2055 MANUAL
6. NORMAL WELDING SEQUENCE
WELD START
Closing thewelding gun switch initiatesthis sequence of events:
The gas valve is energisedandgas flow commences;
The Power Source contactor function is initiated.Weldingvoltage is applied
between the work-pieceand the consumable wire.
The wire drive motor isenergised, wirefeed commences and the arc is
estabiished.
WELD END
Releasing the gun switch initiatesthis sequence of events:
B The wire drive motor is de-energised,and is dynamicallybraked to a stop;
B After a short pre-setperiod, known as the ‘burn-back’time, the Power-source
contactor function isreleased.This periodensuresthat the consumable wire
does not ‘freeze’ in theweld pool. To adjust the ‘burn-back’time, refer to
Section
10.
B The gas valve is de-energisedand the flow of shieldinggas ceases.
7. BASIC WELDING INFORMATtON
CHOlCE OF SHIELDING GAS
The choice of shielding gas is largely determined by the consumable wire to be
The recommendedshielding gases for usewith
the WELDMATIC 205s are :
used. Many proprietaryshielding gas mixturesare available.
B Mild Steel ............................. Argon + 5 to 25% Carbon Dioxide;
Aluminium
............................ Argon;
StainlessSteel ..................... Argon + 1 to 2% Oxygen.
Consult your gas supplier
if more specific information isrequired.

WELDMATIC 205s MANUAL Page 1 1
SHIELDING GAS FLOW RATE
In G.M.A.W., oneof thefunctions of the shielding gas is to protect the molten
weld pool from the effects of oxygen
in the atmosphere. Without this protection the
weld deposit becomes 'honeycombed' inappearance,an effect which isdescribed as
weld porosity.
In draft-free conditions the gas flow rate required to give adequate protection is
typically 10 litres/min. In situations where drafts cannot be avoided, it may be
necessaryto increasethis rate and/or
to provide screeningof the work area.
Weld porosity can also be caused
by air entering the gasstream through 8
damaged hose, ioose gas connection, or from restriction in the nozzle, such as from
excessbuild-upof spatter.
ESTABLISHING A WELD SETTING
the twovariablesthat are adjusted in order toobtain a stablearc are;
Once the consumable wire type, wire size and shielding gas have been chosen,
m Wirefeedspeed,
B Welding arc voltage.
The wirefeed rate determines the welding current; increasing the feed rate
increases the current, and decreasing
it decreases current. The selected wirefeed
rate mustbe matched with sufficient arc voltage; an increaseof wirefeed rate requires
an increase ofarc voltage.
If the voltage is too low the wire will stub and stutter, and there willnotbe a
steady arc.
If the voltage is too high thearc will be long with themetaltransfer within
the arc occurringas a series of largedroplets.
The welding current should be chosen 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.

Page 12 WELDMATIC 205s MANUAL
A "good" weld will havethe 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 theside walls.
A "bad"weld is shown in figure 6. The weld has not penetratedthe joint root, and
there is poor side wallfusion. This lack of fusion would normally be corrected by
increasing the arc voltage, or by increasing both wirefeed rate and arc voltage to
achieve a highercurrent weld setting.
FIGURE 5. "GOOD" WELD FIGURE 6. "BAD"WELD
GUN POSITION
below with the nozzleend pointing in the direction of travel.
For "down hand" fillet welding, the gun is normally positioned as in the figures
FIGURE 7. GUN POSITION

WELDMATIC 205s MANUAL Page 13
8. GENERAL MAINTENANCE
DUST
Care should be taken to prevent excessive build-up of dust and dirtwithin the
welding power source. It is recommended that at regular intervals, according to the
prevaiiingconditions, the machine covers be removed and any accumulateddust be
removed bythe use of dry, low pressurecompressed air, or a vacuum cleaner.
WIREFEED
In order to obtain the mast satisfactory welding results fromthe G.M.A.W.
process, the wirefeed must be smooth and constant. It is therefore important to
observethe followingpoints;
m Keep the gun cable liner clear of dust and swarf build-up. When replacement
becomes necessary, fit only the correctliner tosuit the gun cable model.See
Section 11, The build-up of dust ina cable liner can be minimizedby regular
purgingof the linerwith dry compressed air.This may be convenientlydone
each time thewire spool is replaced.
a Replacethe welding tip as it becomesworn.
m Keep thewire drive mechanism clean.Periodicallycheck the drive POIlerS for
wear and for free rotation.
E Check that the consumable wire spool holder rotatessmoothly and that the
braking action is notexcessive.This also may be conveniently done each
timethe wire is replenished.
9. TROUBLE SHOOTING
UNSATISFACTORY RESULTS
WIREFEED
Erratic wirefeed is the MOST LIKELY causeof failure in all Gas MetalArc
Welding.
It should therefore bethe first point checked whenproblemsoccur.
Refer tothe section above.
m Check for correct gas flow rateat thewelding torch nozzleand ensurethere
are no gas leaks. The gunnozzlemust be free fromspatter and firmly
attachedtothe welding gun toensurethat air is not drawn into the shielded
area.
P Check that the shielding gas selectedis correctfor the consumablewire in
use.
WELDING CIRCUIT
Ensurethat the work clamp is securely tightened onto the work-piece so that
good electrical contact isachieved.Check also that theoutput polarity
selectedis appropriatefor the consumable
in use.
Surfacecontaminationof thework-piece by water, oil, grease, galvanizing,
paint,or oxide layerscan severely disturbthe welding arc resulting in
a poor
weld. Should this conditionoccur, surfacecleaningof thework piecewill be
beneficial.

Page 14 WELDMATIC 205s MANUAL
WIREFEED / ARC VOLTAGE RELATIONSHIP
If the consumablewire is stubbing intothe workpiece,and a steady arccannot be
obtained, it is likely that the arc voltage is set too low to suit the wirespeed. To
correctthis situation either increasearc voltage, or decreasethe wire speed.
If the arc length is too long, the arc voltage is too high tosuit the wire speed. To
correctthis, increasewire speed or decreasearc voltage.
NO WELDING CURRENT
Check that Mains Supplyis availableat the WELDMATIC 205s Power Source, i.e.
that the fan isrunning and the indicator light isilluminated.
Check continuity of the welding current circuit, i.e.,worklead,workclamp and
gun cable connections.
TheWELDMATIC
205s wetding ower source incorporates an inbuilt over
temperaturethermostat which will trip i
P the welding load exceeds the operating duty
cycle.
In this event the machine will not deliver welding current untilthe machinehas
cooled sufficiently. The thermostat will reset automatically
- do not switch the
machineoff as the cooling fan will assist the resetting of the thermostat.
If the forgoingchecks have been madeand have not revealedthe fault condition,
a QUALIFIED SERVICE personshould be consulted.
10. SERVICE INFORMATION.
The main electrical components of the WELDMATIC 205s are listed below, with
referenceto
the following circuitdiagram.
Welding RectifierAssembly, Item t. This comprisestwo high-current rectifier
diodes mounted
on an aluminium heatsink, electrolytic filter capacitors,
transient protection network and discharge resistors.
Welding Transformer, Item 2. The Primarywinding is tapped to provide High /
Lowrange adjustment, andthe secondary is centre tap ed.Maximumopen
circuit secondary voltage
= 24 - 0 - 24 Volts ACwtt I: HI range and the
maximumvoltage selected.
Wirefeed control Board, Item
4. See following description.
Dual SCR Control Board (including Dual SCR), Item 5. See following
description.
Control Transformer, Item 19.The secondary winding is centre-tapped,
providingan output voltage
= 30 - 0 - 30 Volts AC.
Welding Inductance,item
3.
HI / LO Range Switch, Item 57.
LimitingInductance,Item 47.
Gas valve, Item21.

WELDMATIC 205s MANUAL Page 15
220v
50Ht
TRANSFORMER
I
L
L
L
L
I 4'1b000uf INDUCTOR
LIMITING
I+" I +-
WIRE FEED
MOTOR
I WELDING GUN I
FIGURE 8. WELDMATIC 205s CIRCUIT DIAGRAM
,F INDUCTOR

Page 16 WELDMATIC 205s MANUAL
DUAL SCR CONTROL BOARD CP102-51
TheDual SCR Controlboard and associated Dual SCR together provide two
M Welding transformer ON / OFF control in response to an output of the
wirefeed control board, (the contactor function).
E Output voltage control by meansof phase-shiftingof the Welding transformer
primary voltage,as adjusted by the front panel 'VOLTAGECONTROL'
potentiometer.
With
HI rangeselected, the 'VOLTAGE CONTROL' provides adjustment of the
welding transformer secondary voltage over the range
11 - 24 Volts A.C.,measured
from the centre tap toone end of the winding.
circuit functions;
Connections to the boardare detailed in the diagram below.
POTENTIOMETER
IOK'A'CURVE
FIGURE 9. DUAL SCR CONTROL BOARD

WELDMATIC 205s MANUAL Page 17
WIREFEED CONTROL BOARD CP101-10
The Wirefeedcontrol boardprovides the following circuitfunctions:
u Wirefeed motor ON / OFF control inresponseto the gun-switch.
Speed control of the wirefeed motor.
Braking of the wirefeed motor at end of weld.
H Spot-weldtimer.
m Intervaltimer.
Control of the gas solenoid valve.
Connectionsto the board, and Servicepoints aredetailed in thedrawing below.
The circuit
is factory adjusted to provide a maximum drive roller speed of 126
'Burn-back' control.
rpm.
FUSES 5A. -<
AC 30"
SUPPLY O -
30 -
CONTACTOR
FUNCTIONOUTPUl
-TO TRIAC
CONTROL
BOARD
TOGAS +-
VALVE <--
"ZDl
D18 @
DIP OR25
OR26
"
P2
I
MOTOR
/ SPEED
POT.
1
SPOT
TIME
POT.
:: " - }ivl!kR
, MOTOR
RUN/BRAKE
RELAY
LJ GUN SW.
L BURNBACK L INTERVALTlME
ADJUSTMENTPOT.
FIGURE 10. WIREFEED CONTROL BOARD

Page 18 WELDMATIC 205s MANUAL
11. PARTS LISTS
WELDMATIC 205s POWER SOURCE
ITEM #
PART# DESCRIPTION
1 .................
CP102-12 ..................
Recifier assembly
Includes CP34-14/19
.............. Diode SKI? 130/04 (2)
CP102-12/8
.............. Capacitor IO,OOOyF, 63V.(4)
CP101-12]7
.............. Dischargeresistor(2)
CP3-9/8
....................
Thermostat
2
................. CP102-35 ..................
Weldingtransformer(22Qv)
3 ................. CP102-14 ..................
Welding inductanceassembly
4
................. CP101-10 ..................
Wirefeedcontrol board
5 ................. CP102-51 ..................
Dual SCR control PCB(inc.Dua1 SCR)
8 ................. CP102-43 ..................
Side panel(fixed)
Includes W1
1 -7/16 .................. Relay, 24v (2)
6 ................. CP102-40 ..................
Front panel
7
................. CP102-22 ..................
Back panel
9 ................. CP102-44 ..................
Side panel(opening)
l0 ............... CP102-26 ..................
Centre panel
1 1 .............. .CP102-42.. ................
Top tray
12
............... CP102-20/2 .............. Base
13
............... AM1 19-3 ................... Wheel
14
................................................
Rear axle
15 ............... MC11-53/6 ............... Ratchet caps
16 ............... CP102-0 20 .............. Castor wheel
l8
............... CP27-0/15 ................ Fan
l9 ............... CP102-6/1 ................
Control transformer220/240 Vac
21
............... CP010-0/18 .............. Gas valve
22
............... W1 1-11 /l ..................
Hose barb
25
............... MC66-0/8 ................. Primary flex andplug
17
............... MC14-1 / 14 ............... Terminalblock
20
............... CP101-0/17 ..............
Fan finger guard
23 ............... OCL13 ...................... 1 /2” hose clip
24 ............... H532-12 ....................
Miniaturehose clamp
26 ............... W27-1 ....................... Motor and two rolldrive assembly
27 ............... W17-2/12 ..................
Lens
28
............... W5-10/19 ..................
Small knob (2)
29
............... W11-0/16 .................. Largeknob
30 ............... HOS5R ......................
Gas hose, black rubber
38 ................................................
Bottlechain
43
............... CP3-0/23 ..................
Rubber grommet
44 ............... MC14-0/10 ...............
Conduit bush, male
45 ............... MC14-0/11 ...............
Conduit bush,female
47
............... CPlQ2-17 .................. Limiting inductanceassembly
4%.
............. .CP102-l5 .................. Work leadassembly
49
............... AM177 ...................... Spool holder assembly (not shown)
57
............... CP102-0/17 ..............
HI / Lo switch
58 ............... W6-9/10 ................... Conduit bush, male
59 ............... W6-9/11 ................... Conduit bush, female
76
............... TC396-1 .................... Euroconnector and stem
7’7 .............. .CP102-28 ..................
Diodeprotectionassembly
78 ............... CP102-34 .................. Motor and gun switch loom
NOTE
For the Remote Wirefeeder package, Items 26 & 49 are deleted,and item76 becomes
Rubber grommet CP102-27.

WELDMATIC 205s MANUAL Page 19
I
@
WIRE FEED MOTOR &
2 ROLL DRIVE
@ SPOOL HOLDER
THESE ITEMS
NOT SHOWN
3
FIGURE l1 - WELDMATIC 205s POWER SOURCE ASSEMBLY

Page 28 WELDMATIC 205s MANUAL
BEQA2IBAE GUN ASSEMBLY
-
l ... 4392 ........ Nozzle 12 .5662 ........ Trigger assembly
3A. 7’126 ........ ‘0’ Wing
15.2520012 .. Cable Support
3B. 7360 ........ Retainingring
16 .l8863074 .. Connection Case
4 ... 4323R ......
Cap
19 .1199E ...... Eurodirect plug
6 ... QT2-45 ....
Body tube Includes
7 ... 43138 ......
Endfitting
A .... 4822 .... Bushing
8 ... 4305 ........ Cone nut
B .... 608 ...... Screw
Includes
B ... 5060 .... Euroblock
5630 ........ Handle half, right
5631 ........ Handlehalf, left 20 .A920082 .. Liner
10 .4238 ........ Hang-up hook
1 1 .188O004 .. Screwkif: Contact tips
Includes 0.6mm ........... 7497
4207
........ Postfastener0.8mm ........... 7488
4209 ........ ScrewQ.9mm ........... 7489
1 .Omm ........... 7496
1.2mm ........... 7490
3 ... 4335 ........ Head 14.4261TE .... Cable assembly
9 ... *I 980006 .. Handle kit C ... 4816 .... Adaptor nut
PS replaceliner:remove Euro connector from power source, removenozzle (1)
and head (3) from gun hand piece.Withdraw old liner from Euroconnector end. Feed
new linerin
alss from the Euro connector end. Refit the Euro connection to th epower
source. At the gun end compress the liner within thegun cable, then cut it one
contact tip length past theend
of the body tube (6). Refit head, Pip and nozzle.
r---------
””””-”
FIGURE 12. BEQA216AE (260 AMP) GUN CAOLE ASSEMBLY

WELDMATtC 205s MANUAL Page 21
W27-1 MOTOR & TWO ROLL DRIVE ASSEMBLY
ITEM # ...... PART# ...................... DESCRIPTION
1 ..................... W27-0/1 ........................... Motor & Gearbox
2
..................... W26-0/3 ...........................
Screw M6 x 12
4 ..................... W27-1/1 ...........................
FeedPlate
6 ..................... W27-0/9 ...........................
PositioningScrew
7 ..................... W27-1/2 ........................... Axle
Comprising
8.1
................ W27-1/5 ........................... Axle
8.2
................ W27-1/6 ........................... Pressure Arm
8.3
................ W27-1/7 ........................... Spacer (narrow)
8.4
................ W27-1/8 ........................... PressureRoll
8.5
................ W27-1/9 ........................... Spacer (large)
8.6
................ W27-1/10 ......................... Axle Clip
9 ..................... W26-0/13 ......................... InletGuide
l0
................... W27-1 /l 1 ......................... Pressure Screwcomdete
3 ..................... W27-0/4 ........................... Key
5 ..................... W26-5/8 ...........................
Feed Roll 0.9 - 1.2mrn
8 ..................... W27-1/4 ...........................
Pressure Armcomplete
Comprising
10.1
.............. W27-1 /l 2 ......................... Thumbscrew
10.2 .............. W27-1/20 ......................... Spring
10.3
.............. W27-1714 ......................... Base-
10.4
.............. W27-1/15 .........................
PressureLink
l l ................... W27-1/16 .........................
Pressure ScrewAxle
12 ................... W27-1 /l 7 .........................
Spring
13
................... W27-1/18 .........................
Pin
15 ................... W27-1/19 ......................... External Circlip 5mm ID
14 ................... W27-1/3 ........................... ExternalCirclip4mm ID
ALTERNATIVE PARTS
(5 .................. W26-1/8 ........................... Feed Roll 0.8 t 1.Omm
5 W26-2/8 Feed Roll 1 .O t 1.2mm
5 W26-3/8
5 W26-4/8 FeedRoll 1.2 t 1.6mm
9 .................. W27-1/13 ......................... Inlet Guide 3mm
(9) .................. W27-2/13 ......................... Inlet Guide 2mm
.................. ...........................
/l
.................. ...........................
.................. ...........................
Feed Roll 1 .O t 1.2mm Al.
FIGURE 13. W27-0 TWO ROLL DRIVE ASSEMBLY