WIA WELDMATIC 600 User manual

WELDMATIC 600
MODELNO. CP6
CAT.
7524/6
6/80
FROM SERIAL NO. 6035
THEINFORMATIONCONTAINED IN THE FOLDER IS SET OUT TO ENABLE
YOU TO PROPERLYMAINTAIN YOURNEW EQUIPMENT AND ENSURE THAT
YOU OBTAIN MAXIMUP4 OPERATINGEFFICIENCY.
PLEASE ENSURETHAT THIS FOLDER
IS KEPT IN A SAFE PLACE FOR
READY REFERENCE WHEN REQUIREI?.
WHEN REQUESTINGSPAREPARTS, QUOTE THE MODEIi NO. AND SERIAL
NO. OF THEMACHINE AND THE PARTNO.OFTHEITEMREQUIRED.
FAILURETOSUPPLYTHISINFORMATIONWILLRESULT
IN UNNECESSARY
DELAYS
IN SUPPLYING THECORRECT PARTS.
WELDING INDUSTRIESOFAUSTRALIAPTY.LTD.
Melbourne 4294766 Newcastle 611668 Sydney 5342144
Adelaide 3523022 Brisbane 441391 Perth 3617088
Launceston 317004 Darwin 81 6427 & 843076

OPERATING AND MAINTENANCE INSTRUCTIONS
-
WELDMATIC 600(CP6)
- INTRODUCTION
GENERAL
Thismanualhasbeenpreparedespecially for use in familiar-
izingpersonnelwiththedesign,installation,operation,
maintenance,andtroubleshooting
of this equipment. All inform-
ationpresentedhereinshould
be givencarefulconsideration
to assure optimumperformance of this equipment.
RECEIVING/HANDLING.
Prior toinstallingthisequipment,clean all packing material
from. aroundtheunitandcarefullyinspectforany damage that
may haveoccurredduringshipment. Any
claims for loses or
damage that m.ay haveoccurredintransit must be filedbythe
purchaserwithWeldingIndustries
of AustraliaPty.Ltd. or
authorisedagentimmediately (refer to EQUIPMENT WARRANTY card
enclosedwithOperatingInstructionManual).
When requesting irrbbrmation concerningthisequipment,
it is
essential to supply correct Model identificationandmachine
serial number.
SAFETY.
Before theequipment is putintooperation,the SAFETY PRACTICES
section at the back of this manual MUST BE READ COMPLETELY.
This will kelp avoid possibleinjurydue to misuseorimproper
weldingapplications.
"
CONTENTS PAGE NO.
GeneralDescription l
SettingupforOperation 2-3
WeldingOperationInstructions 4
MaintenanceInstructions 5-6
Welding Data - Table "C" 7
- Parts List CP6-02 Issue 4 8
- AssemblyDrawing CP6-02 Issue 2 9
CircuitDiagrams - CP6-C9 10
Mobile Kit Assem.bly -
Safety Practices
Guarantee Card

STANDARD UNIT
The construction of thestandard package planthas been designed
forinstallation and operating
in a wide variety of applications,
such ashighproductionfactories and generalfabrication shops.
"WELDMATIC" Plantsconsist of threebasic units:-
l, ConstantPotentialRectifier Power Source.
2. Semi-Automatic Wire Feeder.
3, Welding Gun and Cable Assembly.
Separateoperating and maintenance instructionsare provided
forthewirefeeder andgun cables.
1. - POWER SOURCE - FEATURES
The standard C.P. rectifier power source is housed in a drip-
proof enclosure.
Lifting lugs areprovidedforcranetrans-
portation. For
units with wheelmounting foursolidrubber
tyredwheelsareprovided:the two front wheels aresteerable
permittingeasy movement
in restrictedfloorspace. A push bar
is provided on the front of the machine and a gascylinder
carrier
with a supportbracket and chain at therear. A 110
voltplugsocket is located on therear panel for connection
of gaspreheater when welding
with C02 gasshield. Located on
thefrontpanelare a coarsevoltageselectionswitch,fine
voltageselectionswitch, power
ON/OFF switch,controlfuses,
wirefeeder
plug socket and rectifier power outletsockets.
2. CONSTRUCTION
Thepower source is a ConstantPotentialSilicon Diode Rectif-
ier
B.C. Welder, with a threephasetransformer and a three
phase rectifierbridge. Connected
in the outputcircuit is an
inductance
unit providingthe"inductance"ordegree of slope
necessaryforvariousweldingcurrents.Cooling
of thesili-
con diodes,transformerwindings and inductance
unit isby a
singlephaseaxialfan. Thepower source
is protectedagainst
fanfailure and overheating
by thermostats mountedon diode
heatsinks.
3. WELDING PROCESS
Gas metalarcwelding within thecapacity of the power source
can be carried
out with tke followingequipment:-
a) Semi-automatic wirefeeder model
W14.
b) Semi-automatic wirefeeder
with spottimer W14-20.
c) "Hobart"spool gun welding
unit model SP9 with CV2
d) "Mini-mig" push and pull gun and control.
controller.
4. WELDING CAPACITY
Power SourceCapacity is asfollows:-
600 Amps,42 volts, 100% duty cycle.

-1
-2-
5. SUPPLY AND WELDING CABLES.
Power Sources are suitableforconnection to a 415 volt 50
Hertz
3 phasesupply.
Therecommended fuse
size, primary cable sizeandwelding
cable
size are as follows:-
a) Fuse - 50 amp.
b) Primary Cable - 4 core 77/0.40 T.R.S.
c) Welding Cable - 998/0.30 T.R.S.
6. SHIELDING GASES.
a) Welding Grade C02 for a11 mild andalloy steel weldingin
"
thicknessesranging from lmm upwards.
b) Argon/C02 or Argon/Oxygen mixtures for all applicationson
low currentsrequiring minimum of spatteronsheet steel
and for stainless steel welding.
c) Argon/Oxygenand Argon/C02 mixtures for prime quality weld-
ing of stainless steel.
d) Argon (pure) for all aluminium.welding.
7. §ETTING UP UNIT FOR OPERATION.
a) - General Assembly of Packaqed Plant (Refer Drawing AM1.16)
The Rectifier Welder is shipped with the skids or wheels unbol-
ted. Bolt on the wheel assemblies with the steerable (swivel)
wheelsnearestthefrontpanelandpush bar. If a "Mini-Boom"
wire feedermounting is supplied, locate thevertical boom
post in the special swivel mount at the rear of themachine.
Locate the Wire Feederontheswivelmount,ensuringthatthe
fibre thrustwasher is on the pivot pin. Check that the "Wire
Feeder" is free toswivelin all directions. If necessary
apply
a small am.ount of graphite grease to shaft.
b) Connection to MainsSupply.
Note: This work shouldonly be doneby a qualifiedelectrician.
Thepowersource
is designed for connection to 415 volt, 50
hertz, 3 phase supply and the supplyvoltageshould be ascert-
ained before connectingthemachine. Access to supplyconnec-
tion
terminals in machine may be gainedbydoorinrighthand
side panel. Use a flexible 4 core primary cable for portable
machinesand
clamp cable to ensurethat there is nostrainon
cable connections.The earth (or ground)connection(green/
yellow)must
be securelyfastenedto the 'earth' terminal on
themachineadjacent
to thesupplyconnectionterminals.
CAUTION Before insertingprimary cable pluginmainssupply
socket: ensurethat switch on both plug socket andwelding
machine
is in 'OFF' position.

- 3-
c) " CONNECTION OF CABLES/HOSES, ETC.
Withunitswitched 'OFF' connectcontrol cable (6 pinplug)
from power sourceto wire feeder. Connect gas hosefrom wire
feeder to gas regulator/flowmeter,ensuring all connections are
tightenedfirmly. If C02 Gas Shield is beingused,plug heater
into 110 volt socket at rear of unit. Next insert gun cable
into socket of wire feeder outputguideandretaininplace
with
set screw provided. Set screw shouldnot be tightened so
as to preventgun cable fromswivelling.Connect "Gas Hose"
and "Gun Switch"
leads to respectivesockets.
d) WELDING CABLES.
All G.M.A. welding is done with electrode wire connectedto
"positive"
pole comrn.only known as D.C. reversepolarity
(D.C.R.P.) therefore,connecttheshortjumper lead from 'I+''
socketon machine toterminallugongun cable. Thework lead
("negative")should
be pluggedinto the 'I-'' socketon the
machine.Theplugsofthewelding cables must be fullyinserted
inthe
sockets, to preventaccidentaldisconnection. To avoid
error, weldingshouldnot be attempted untilallconnections
have
been secured.The wire feeder may be installed remote from
the
power source,in which case, extension lead sets comprising
power cable, gas hose andcontrol cable (four core) arerequired
inaccordance
with the desired length.Standardlength avail-
able from stock is 9 m.etres.
3) WIRE FEEDER AND GUN CABLE.
Fit a spool of wire to the wire feeder (see notesin "Wire
FeederInstructionManual").Tightenthe "brake" screw until
a slightbraking effect is felt when turningthe wire spool by
hand
to prevent"over-run" when wire feed stops. The wire drive
rolls
and inlet wire guideshould be selected inaccordance with
the diameter andtype of wire beingused. Refer to current wire
feedermanual for correct selection of wire feed rolls andinput
guides.
0.8mm. =
0.030"
1.6m =
1/16"
0.9mm =
0.035" 2.4m =
3/32"
1.2mm = 0.045"
3.2m =
1/8"
The
gun
cable andgun are normally delivered with thecontact
tip
and liner spring for wire size nominated,but
check that
both are correct sizefor wire beingused.

8.
-4-
WELDING OPERATION INSTRUCTIONS
SINGLE FUNCTION CHECK
Unit is now ready for operation,but prior t
o commen
ina, thefollowins"functionscheck'' is recommended,cing
weld-
switchon
poGersourceandcheck
air flow. See that all weldinglead
plugs
are inserted in the correct polarity sockets - electrode
"positive" , work "negative". Check all weldingconnections
andplugsfortightnessparticularly"work"
clamp.
Next ensurethat all control cables and gas hoses are securely
connectedandthat
Gas Heater (for C02 only) is pluggedinto
socket
at rear of power source.Switchon wire feeder, indic-
ator lightshould now show "Power On".Open Gas cylinderfully
andcheckcontentsgauge
for adequategassupply.
Press "Gas Purge"switchand set gasflowinaccordancewith
weldingrequirements,
at the same time checkthat gas flow is
adequate from gunnozzle, Set "wire speed"control to desired
wire speed. Press "wire inch"switchandcheck wire feed for
correct pressureondrive rolls. Pressureshould be sufficient
to preventany''slip" when feedingthroughgunandcable.
Next,
close gunswitchmomentarily for wire feed, gas flow and
welding
power check. Set thevoltage selector switchesin
accordance
with required voltage (see welding table), unit is
now ready for welding.
The weldingcurrent is determinedautomaticallyby "Wire Speed".
Theelectrode
wire is fed at thepre-selected speed bythe
driverollsthroughthegun
cable to the arc at a constant speed,
unchanged except when reset bythe "Wire Speed" control. The
higherthe
wire speed, thehighertheweldingcurrent, as will
be indicatedby the ammeter. The outputvoltage of the power
source,indicatedbythevoltmeter when
the gunswitch is closed,
is dividedinto a number of steps by Coarse Selector andFine
Selector switches.
The CP6
has Coarse Voltage and FineVoltageSwitches,eachwith
six steps, giving 36 voltage settingsforthemachine.The
inductanceterminal
sockets are numbered ''1 - 4". No.1 socket
should not be usedforweldingcurrents over 300 amps. Depend-
ingonthetype
of weldingconditions,variousinductancevalues
are required.Thetypical weld settingchartindicatesthe
recommended socketsforvariousweldingconditions.
As a general
rule,lowweldingcurrentsrequireinductance
No. 1 or 2. For
aluminiumandtubularfluxcored wires, inductancesocket No. 2
is usedexclusively.

-5-
The followingsequence of weld setting is recommended:-
a) Consulttypical weld settingchart.
b) Selectweldingcurrent most suited to theapplication by
followingthesettings of wire speed and voltage shownon the
settingchart.
To "tune"each weld setting,adjustwire
speed only.
c)Ifvoltage
is too low fortheapplication,wire"stubbing"
will occur,particularlyatstart of weld and weld contour
will be very convex. If thevoltage is toohigh,metal
transfer
will be erratic with excessspatter.
d) With weldingcurrent and voltage matched theresult will
beanoptimum tunedweldingcondition with a smooth spatter-
freearc.
10. SAFETY DEVICES
In theevent of the power source becoming overheatedthether-
mostats on thediodeheatsinks
will operatepreventingfurther
welding. The thermostats
will automaticallyreset and with
thecoolingfanoperating this will takeapproximately 10 min-
utes. A check should be made toascertainthereasonforthe
over-heating such
as fannotoperatingorairflowrestricted.
Fusesprovidedfor allcircuitsareasfollows and are
indicated on thefrontpanel:-
Fuse
El
- 3
amps (Delayed action)
Fuse
E2
- 3
amps
( 'l
'I 1
Fuse E3 - 5
amps
( 'I
'I 1
Fuse
E4
- 5
amps
( 'I
'I 1
11 . ENT ENANCE
a) Power Source
Apart from thefantherectifier has no rotary components.
To achievecompletedissipation of heat from theactive com-
ponents,therectifier should be thoroughly blown off
with
dry compressed airafter 6 months' operation.Cleaningshould
be carriedoutatshorterintervalsif
dust accumulation is
considerable.
Prior
to cleaning, remove the unit cover by detachment of lugs
and thefixing screws. Thus a11 the components of the power
source
will bs accessible.
b) The wirefeedmotor/gearbox is pre-packed with grease and
needs no otherlubrication. Change thegreaseafter approx-
im.ately
14,000 servicehours.(see Wire Feeder Instruction
Manual
.
The driverollers and theinner wire guides should be kept
clean.
If necessary, blow off theinside of the wirefeeder
with compressed air.

-6-
c) Gun and Cag
Remove any spatter which might adhere to the nozzle bore so
that the shieldinggasoutflow is not impeded. The condition
of the contacttubesshould be regularlychecked. Damaged
and/orburnt tubes are animpediment to trouble-freewelding
operationandshould
be replacedimmediately.
Trouble-freeoperation
depends to a largeextenton the good
conditionandcleanliness of theinner wire liner (See Instr-
uctionson Gun
Cables).
12. WELDING OPERATION
Neverobserve the arc with unprotectedeyes. It is ofimpor-
tancethatthe
welder wear protectiveclothingproviding
sufficientsafety.
13. STOPPAGES AND THEIR ELIMINATION
Themachineshould be checkedonlyby a fully skilled electr-
ician.
If the unitstopsworking, first determinewhetherstoppages
are initiatedby the mains (for instance,burntfuse) or by
the supply cable (looseconnection, cable break) orby the
unitproper.
If thethreeterminals L1, L2 and L3 on the primaryterminal
board
are correctlyconnectedto the mains (voltmeter reading)
thecauseofthestoppagemust be soughtintheunit itself.
The wiringdiagramonthenextpages will facilitatethe
location
of the defect.

-7-
WELDING DATA - TYPICAL VALUES
Shielding Gas is welding Grade C02 used with a Gas Preheater.
ContactTip1.5minside
of Gas Nozzle. Wire "Stick Out" 6 -
9m.m up to 200 amps. 12 - 19mm over 200 amps.TheseTables
are a guideonlyforinitialmachinesettingandfiner
adjustments may benecessary
to achieve optimumwelding
characteristicsfor
the application. Recommended machine
setting method
is to set Voltage Switches, Inductanceand Gas
Flow asperTablethenadjust
wire speed toobtain recommended
current.
:ect-
fier
JP6
Wire
Size Gas
0.9m
(Solid
Wire)
1.2m.
(Solid
Wire)
10
Lit./Min
(for vertical Down)
15 Lit./Min
1.6mm
15/17
(Fluxo-
Lit./Min.
fil)
2.0m.
(Fluxofil)
2 . 4mrn
(Fluxofil)
Wire
Speed
Metres
Per
Min.
3.9
6.3
2.2
3.2
4.4
5.7
5.8
7.6
9.0
10.0
5.1
6.4
5.5
6.6
Coarse
-
2
2
2
3
3
3
3
4
5
5
5
5
5
6
4 1 190
4 2 200
2
3
250
2 2
330
3 2 360
4 2
380
5 2
450
6 2 500
1 2
550
Volt
18
21
20
21
22
23.5
26
27
31
32
33
34
34
35
NOTE:
Wire speed is shown in metres/minuteandarenotdial
calibrationsettings.

-
I TEP
NO.
-
2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
5
S
9
18
21
22
24
25
26
26.1
27
28
29
30
32
33
34
37
38
39
40
37.1
37.2
8
DRAWING NO. CP6-02 - SPAREPARTS LISTISSUE 5.
PART NO.
CP6-5
CP6-5/2
CP6-5/3
CP3-9/8
CP6-8
,
CP6-19
CP6-2
CP6-7/1
CP6-7/2
CP25-0/7
CP3-0/4
14235-0/6
CP15-0/7
CP5-25
CP5-0/19
AM1 6
CP15-0/14
TC262
TC262N
CP3-0/47
CP6-0/35
w1-22
CP6-0/47
CP5-0/13
CP5-0/14
CP5-0/15
W1-23
CP22-3/13
CP6-20
CP6-21
K10
K11
DESCRIPTION
RECTIFIER ASSEMBLY
DIODE
DIODE (R)
THE
R?.!lOS TAT
TRANSFORMER ASSEMBLY
PRIMARY/SECONDARY COIL
INDUCTANCEASSEMBLY
LEFT
HAND INDUCTANCE COIL
RIGHT
HAND INDUCTANCE COIL
CONTROL TRANSFORMER
FAN BLADE
FAN MOTOR
GAS HEATERPLUGSOCKET
RECTIFIERPROTECTION ASSEMBLY
WELDING CONTACTOR
OUTPUT TERMINALS
CONTROL PLUG
GAS NIPPLE
GAS NIPPLE NUT
VOLTMETER 0-60V.
AMPETER 0-800A.
INDICATORLIGHT
APNTER SHUNT 0-800A
POWER
ONYOFF SWITCH
COARSE VOLTAGE SWITCH
FINE VOLTAGE SWITCH
FUSE HOLDER
STAND
OFF INSULATOR
RESISTOR
SERIESRESISTOR
3AG. 3A DELAY FUSE
3AG. 5A DELAY FUSE

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1

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3 ?-
7
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SAFE PRACTICES IN UStNG WELDING EQUIPMENT
These notes are provided in the interests of improving operator safety.They should be considered
only as a basic guide
to Safe Working Habits. A full list of Standards pertaining to industry is available
from the Standards Association of Australia, also various State Electricity Authorities, Departments of
Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may
haveadditional requirements.
EYE PROTECTION
NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or glasses
withsideshields underneath, withappropriate filter lenses protected by clear cover glass. This is a
MUST forwelding,cutting,andchipping to protectthe eyes fromradiant energy andflyingmetal.
Replace the cover glasswhen broken, pitted,or spattered.
WELDING CURRENT SHADE NUMBER
Below
30 Amps ....................................... 6
30 - 75 Amps ......................................... 8
75 - 200 Amps ....................................... 10
200 - 400 Amps ...................................... 12
Above 400 Amps ..................................... 14
BURN PROTECTION.
The welding arc is intense and visibly bright. Its radiation candamage eyes, penetrate lightweight
clothing,reflectfromlight-coloured surfaces, andburntheskinand eyes. Burns resultingfrom gas-
shielded arcs resemble acute sunburn, butcan be moresevereand painful.
Wear protective clothing - leather or heat resistant gloves, hat, and safety-toe boots. Button shirt
collar and pocketflaps, andwear cuffless trousers
to avoid entryof sparks and stag.
Avoid oily or greasy clothing.A spark may ignitethem.Hotmetal such as electrode stubs and
workpieces shouldnever behandled withoutgloves.
Ear plugs should beworn when welding
in overhead positions or in a confined space. A hard hat
should be wornwhen others are workingoverhead.
Flammable hair preparations should not be used bypersons intendingtoweld or cut.
TOXIC FUME PREVENTION.
Adequateventilationwith air is essential. Severe discomfort, illness ordeath can resultfrom
fumes, vapors, heat,
of oxygen depletion that welding or cutting may produce. NEVER ventilate with
oxygen.
Lead, cadmium, zinc, mercury,andberylliumbearingandsimilarmaterials when welded or cut
may produce harmful concentrationsof toxic fumes. Adequate local exhaust ventilation must be used,
or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium,
bothmust be used.
Metals coated withor containing materialsthat emit fumes should not be heated unless coating is
removedfromtheworksurface,the area
is wellventilated, or the operator wears an air-supplied
respirator.
Work inaconfined space only while
it is beingventilatedand, if necessary, whilewearing air-
supplied respirator.

Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form
PHOSGENE, a highly toxicgas, andlungand eyeirritating products.The ultra-violet (radiant) energy of
the arc can also decompose trichlorethylene and perchlorethylene vapors to form phosgene. Do not
weld or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the
radiant energy can penetrate
to atmospherescontaining even minuteamounts of trichlorethylene or
percholorethylene.
FIRE AND EXPLOSION PREVENTION.
Beaware thatflying sparks or falling slagcan pass through cracks, along pipes, through windows
or doors, and through wall
or floor openings,out ofsight of the operator. Sparks andslag can travel up
to 10 metresfromthe arc.
Keepequipmentcleanandoperable,freeof oil, grease,and (inelectricalparts)ofmetallic
particles that can cause short circuits.
If combustibles are present in the workarea, do NOT weld or cut. Move the work if practicable, to
anarea free of combustibles, Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work
cannotbemoved,movecombustibles at least
10 metresaway out of reachofsparksandheat; or
protect against ignition with suitableand snug-fltting fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on
or cut. Walls, ceilings,
and floornear work should be protected by heat-resistant covers or shields.
A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment
duringand for sometime after weldingor cutting
if;
R Combustibles (includingbuildingconstruction)arewithin 10 metres.
m Combustibles are further than 10 metresbutcan be ignited bysparks.
R Openings(concealedor visible) Infloors or walls within 10 metres may exposecombustibles
m Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or
After workis done, check that areaisfree of sparks, glowing embers, and flames.
to sparks.
conducted heat.
An tank or drum which has contained combustibles can produce flammable vapors when heated.
Such acontainermust never beweldedon orcut,unless
It has first beencleanedasdescribed in
AS. 1674-1974, the S.A.A. Cutting and Welding Safety Code.This includes a thorough steam or caustic
cleaning(orasolventorwaterwashing,depending on thecombustible’ssolubility),followedby
purgingand inerting with nitrogenor carbon dioxide,and using protective equipmentas recommended
in
AS.1674-1974. Water-fillingjust below workinglevel may substitute for inerting.
Hollow castings or containers must
be vented beforewelding or cutting. They can explode. Never
weld or cut where the air may contain flammable dust, gas,or liquid vapours.
SHOCK PREVENTION.
Exposed conductors or otherbaremetal intheweldingcircuit, or ungroundedelectrically alive
equipment can fatally shock a person whose body becomes a conductor. Ensurethat the machine is
correctly connected and earthed.
If unsurehave machine installed by a qualified electrician.On mobile
orportableequipment,regularlyinspectcondition
of trailingpower leads and connectingplugs.
Repairor replace damaged leads.
Fullyinsulatedelectrodeholdersshouldbe used.
Do not use holderswithprotruding screws.
Fully insulated lock-type connectors should be used
to join welding cable lengths.
Terminalsandotherexposedparts of electricalunitsshould have insulatedknobs or covers
secured before operation.

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