1.22 MB - Welding Industries of Australia
Contents
1. P 7 ODD us Trouble Shooting ce tton 7 SOC M Service Information P 8 986 10 55st Parts Lists o oov tpe te ener P 10 Sec Safe PIaBell6gs tes ob ote uds P 26 APPENDICES Appendix 1 AM111 Swivel Mount Option P 16 Appendix 2 AM126 Pre and Post Timer Option P 17 Appendix 3 AM127 Soft Start Crater Fill Option P 18 Appendix 4 AM128 Spot Time Cycle Arc Option P 20 Appendix 5 AM130 Vernier Wire Speed Control Option P 21 Appendix 6 AM140 Wire Spool Cover Option P 21 Appendix 7 AM227 0 Push pull Conversion Option P 22 Appendix 8 AM174 amp W17 17 Coil Holder amp Bracket P 24 Appendix 9 W11 14 Suspension Bracket Option P 24 Appendix 10 AM89 0 Balance Boom Option 25 FIGURES PIGS amant Wirefeeder Controls P 4 Fig Connections to Power Source P 5 Wirefeeder Circuit Diagram P 8 Fig As soe W16 20 Motor Speed Control P C B P 9 Fia oen W16 21 Wirefeeder Control P C B P 9 Wirefeeder Assembly Diagram P 11 W2 44 Two Roll Drive Assembly P 12 Fig 8 RR M2. Page 12 WELDMATIC W17 WIREFEEDER MANUAL W2 44 TWO ROLL DRIVE ASSEMBLY ITEM PART DESCRIPTION Dre Mato ets ctn 2 44 1 Die Cast Body Oita esti W2 44 2 rrr Top Roller Housing W2 44 25 Shaft Rue M5 Skt Grub Screw x 10 long WAT idR eU Washer Gites MISE5Z 5 Dia Shakeproof Washer SSKM510U M5 Skt Hd Screw x 10 long W2 44 35 iniciau M8 Shoulder Skt Screw x 20 long PETERET JWATT tiia 8 Dia Belleville Washer TO M ne W2 44 6 eeeessee Tension Arm Tete ote tis W2 44 13 ee Spring a inner 2 44 7 Nut TS nien eiie 2 44 8 Top Roll Shaft qb rere W2 44 031 nesses Bearing Inner 608ZZ W2 44 030 sess Bearing Outer FL608ZZ IS PRE esee tees W2 44 016 sees M6 Hex Dome Nut NASA mt ees Driven Gear Wheel TO RA 305029 8 32 UNC Skt Hd Screw x long 20 Aetas W2 16 Driving Gear Wheel P eda eR ET ATO M3 Pan Hd Screw x 6 long oe es 5 M5 Skt Hd Screw x 15 long 29 ovatis M6 Skt Hd Screw x 12 long CES SSSM612U vee M6 Csk Skt Hd Screw x 12 long r
3. WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ACN 004 547 111 Head Office and International Sales 5 Allan Street Melrose Park South Australia 5039 Telephone 08 8276 6494 Facsimile 08 8276 6327 OWNERS MANUAL WELDMATIC WIREFEEDER MODEL NO W17 02 REV G 04 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE ALL Page 2 WELDMATIC W17 WIREFEEDER MANUAL The information contained in this manual is set out to enable you to properly maintain your new equipment and ensure that you obtain maximum operating efficiency Please ensure that this information is kept in a safe place for ready reference when required at any future 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 Failure to supply this information may result in unnecessary delays in supplying the correct parts SAFETY Before this equipment is put into operation the SAFE PRACTICES section at the back of the manual must be read completely This will help to avoid possible injury due to misuse or improper welding applications CONTENTS SEG uii gore Pre 10 p DERE RR E E ERE P 3 Seo rios aede PREGEIVING ROUTE p P 3 Sec 3 Specifications eeren P 3 Seid cud Wirefeeder Controls ancre P 4 SEG aui tle P MR aAA P 5 OBG D Wirefeeder Operation P 6 SGC ist Maintenance
4. 4 WIRE FEEDER CONTROLS The controls for a STANDARD W17 02 WIRE FEEDER are shown in Figure 1 See Appendix for wirefeeder options 9 recon FIGURE 1 WIRE FEEDER CONTROLS 1 WIRE SPEED CONTROL This control is used to set the speed of the wire drive motor within the specified range of O 126 R P M equivalent to O 16 metres per minute of welding electrode wire Rotate the control clockwise to increase wire feed rate 2 POWER ON INDICATOR This indicator is illuminated when power is connected to wire feeder unit and power switch is in on position 3 POWER ON OFF SWITCH This switch is used to connect or disconnect the wire feeder from 30Vac supply 4 INCH PURGE SWITCH This switch is spring loaded to return to the central off position When switch is raised to upper position the gas valve is energised allowing operator to set gas flow rate and or purge gas lines When switch is depressed to lower position the wire drive motor is energised allowing operator to feed welding wire without energising the power source contactor WELDMATIC W17 WIREFEEDER MANUAL Page 5 5 INSTALLATION The WELDMATIC W17 02 WIRE FEEDER is connected to the power source with a lead kit consisting of WELDING CABLE WORK LEAD E CONTROL CABLE GAS HOSE Connections are shown in Figure 2 Check all connections are firmly made to ensure good electrical contact and to eliminate gas and air leaks The weldi
5. flame to form PHOSGENE a highly toxic gas and lung and eye irritating products The ultra violet radiant energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene Do not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or percholorethylene FIRE AND EXPLOSION PREVENTION Be aware that flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the operator Sparks and slag can travel up to 10 metres from the arc Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are present in the work area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work can not be moved move combustibles at least 10 metres away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields A person acting as Fire Watcher must be standing by with suitable fire extin
6. pressure should only be sufficient to push the wire evenly Excessive pressure can deform electrode wires Dirt in the wire feed liner blow out or replace liner Obstruction in tip ream out Replace tip when oversize Buckles in weld wire cut out Rusty wire replace Check feed roll gear teeth for interfering material dirt or wire bits WELDMATIC W17 WIREFEEDER MANUAL Page 8 9 SERVICE INFORMATION 10d W3dlM 10d NIN 10d q0H1NO3 33 535 JOA 3A1VA 5 HOLON 9n y 3uvds dd 10HLNOj S3033d3UlM auvdS LETsiM E JYYJS L z O33dS XVM LLM y q3uvds E G33dS XVW 8LM E S JAWA SVO bd 13 308 2 9 aNd NONNV3 psy 9 3 SVO L F 8 daads JWA 0 d 71 1 3uvds Sd 0334S WA 0 gt gt 4 54 9 3uvdS H21IMS NNI e s HOL0VINO3 T1 221 6 HOLDVINO2 SNOILdO MN yia OL 101 3vd 4 YOLOW O 9399 81 YIS LL YOLOW cb 8010 TIVNINHAL LS MNISIV3H NISL V3H poy poy HJLIMS NNO D 300H1V3 031 V S O1VIION G31 ISA PA a UOldVOV NOD VIA HILIMS OL pag HOLIMS 340 NO FIGURE 3 WIREFEEDER CIRCUIT DIAGRAM WELDMATIC W17 WIREFEEDER MANUAL Page 9 W16 20 MOTOR SPEED CONTROL BOARD 30VAC SCR TRIGGER W17 MAX SPEED 0v W18 MAX SPE
7. swivel mounting for the wirefeeder and a counter balanced support for the gun and cable thereby reducing operator fatigue when repetitive production welding etc Option kit contains 89 1 Boom Arm 8 9 2 Wirefeeder Pivot 8 3 Boom Swivel Mount 8 10 Boom Pivot 1 Bracket For Wirefeeder 88 15 Wire Guide Assembly 15 Fastener Kit INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Fit Swivel Mount to top cover of power source 3 Fit Wirefeeder Pivot to wirefeeder mount onto boom and mount boom assembly onto power source swivel mount 4 Relocate wire spool and spool holder to new mounting position 5 Fit extension wire guide assembly 6 Refit gun cable to boom mount and feed wire through to gun 7 Test operation of wirefeeder 8 For more information please contact your WIA branch or service agent BRACKET FOR WIREFEEDER 7 BOOM PIVOT WIREFEEDER 7 WIRE SPOOL WIREFEEDER PIVOT BOOM SWIVEL MOUNT FIGURE 12 BALANCE BOOM OPTION Page 26 WELDMATIC W17 WIREFEEDER MANUAL 11 SAFE PRACTICES IN USING 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 p
8. toe boots Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing spark may ignite them Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when welding in overhead positions or in a confined space A hard hat 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 person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing air supplied respirator WELDMATIC W17 WIREFEEDER MANUAL Page 27 Vapours from chlorinated solvents can be decomposed by the heat of the arc or
9. 3 Inch Purge Switch 10 W11 0 16 Knob 11 MC11 32 2 Insulating Bush 4 12 11 13 Mounting Insulator 138 44 Type No Serial No Nameplate 14 11 1171 Hose Barb 15 W17 14H Gas Valve Connector 16 2 2 Nut 17 W17 15 ees Terminal Nameplate 18 WA17 0 24 usus Loom Assembly Includes 18 1 W17 01 indicator Light 18 2 W11 02 15 Potentiometer 10K 18 3 K31 esse Control Socket 19 Spool Holder Assembly Includes 19 1 33 1 1 Spool Holder Moulding 19 2 AM133 1 0 eeees Thrust Washer 19 3 33 3 Retainer R Clip 19 4 AM177 8 Tab Washer 19 5 AM177 4 Shaft 19 6 7 Nut Hex Nyloc 5 8 UNF 19 7 MC11 65 17 Wave Washer 5 8 Dia 19 8 W11 9 1 0 eee Spool Holder Collar 20 38 Spool Dust Cover 214 62513 Gas Hose 5mm CP3 0 23 ooo sss Grommet 2 23 BE4920WIA Adaptor Kit WELDMATIC W17 WIREFEEDER MANUAL Page 11 FIGURE 6 W17 02 WIREFEEDER ASSEMBLY
10. ATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove complete spool holder assembly Undo fixing bolt inside top cover of wirefeeder cover 3 Fit Coil Mounting Bracket to side of wirefeeder case using fasteners supplied Plain washer is required on each bolt between bracket and wirefeeder case to allow clearance for cover to shut 4 Fit Coil Holder to top end of bracket with fasteners supplied Adjust rotation tension of coil holder 6 Fit 30Kg wire coil feed wire through gun cable and check operation of wirefeeder 7 For more information please contact your WIA branch or service agent APPENDIX 9 W11 14 SUSPENSION BRACKET OPTION This option allows the wirefeeder to be suspended from an overhead position giving greater flexibility and access for welding in a production environment etc Option kit contains MATES Suspension Bracket INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove complete spool holder assembly Undo fixing bolt inside top cover of wirefeeder cover 3 Fit Suspension Bracket to side of wirefeeder case using fasteners supplied in two holes and refit spool holder assembly in original position 4 Close cover refit wire spool and test operation of wirefeeder 5 For more information please contact your WIA branch or service agent WELDMATIC W17 WIREFEEDER MANUAL Page 25 APPENDIX 10 AM89 0 BALANCE BOOM OPTION This option provides a
11. ED MOTOR F BACK N C N C ov OPTIONS 0 V INCH GUN SWITCH N C SPEED SIGNAL N C NOTE THIS PCB PLUGS DIRECTLY INTO W16 21 PCB FIGURE 4 W16 20 MOTOR SPEED CONTROL BOARD W16 21 WIREFEEDER CONTROL BOARD 4 5 c Uv 5 3Xvat L Al ff OVAC 12 MOTOR VE 11 MOTOR VE 44 UA TH LT i me 6 GAS VALVE VE EJ 5 GAS VALVE VE SPARE D 3 SPARE 6 j o 10 CONTACTOR 9 5 _ 8 R H CONTACTOR E 9 9 9 L9 8 30VAC LOOPING e 3 5 9 ETS 7 30VAC LOOPING o o 0 o o o o LIT e S mn 1 Ee 8 Ea 2 SPARE LH 1 SPARE LED VE POT MAX BURNBACK CONNECTOR FOR NOTE PURGE POT WIPER ADJUSTMENT W16 20 SPEED BOARD LINK C IS CUT INCH POT MIN FOR W17 APPLICATIONS CONNECTORS FOR GUN SWITCH 30V VE OPTIONS BOARDS FIGURE 5 W16 21 WIREFEEDER CONTROL BOARD Page 10 WELDMATIC W17 WIREFEEDER MANUAL 10 PARTS LISTS WELDMATIC W17 WIREFEEDER ITEM PART DESCRIPTION 1 W16 20 PCB Assembly Motor Speed Control Dis WAIB 21 PCB Assembly Wirefeeder Control 3 W17 11Y wee Wirefeeder Base 4 W17 42Y oe Wirefeeder Case 5 W17 13 8Y oe Front Panel 6 W24 sss Motor and 2 Roll Drive Fe 18 Gas Valve W1 19 On Off Switch 9 7 1
12. LER DOUBLE GROOVE NYLON 047 W2 20 W2 54 W2 44 12 1N 962 W2 20 W2 54 W2 44 12 2N PLAIN ROLLER W2 22 W2 44 12 2N 094 W2 23 W2 23 W2 44 12 3N FLAT ROLLER OPEN U ROLLER 035 W2 49 W2 48 W2 44 12 1N 047 047 W2 44 12 1N W2 49 W2 50 062 W2 44 12 2N FIGURE 9 DRIVE ROLL AND WIRE GUIDE TABLE W2 44 12 1 W2 44 12 2 SOLID AND FLUX CORED WIRES e ALUMINIUM WIRES WELDMATIC W17 WIREFEEDER MANUAL Page 15 AM195 ACCESSORY LEAD KIT ITEM PART DESCRIPTION JEU AMIB ur oe Welding Current Plug Assembly G Type Work Clamp Welding Cable 50mm Cannon Cord Plug 4 pin Male 4 Core Control Cable Cannon Cord Plug 4 pin Female Gas Hose 5mm ID Gas Hose Tail Hose Tail Nut WORK LEAD WIRE FEED ONTROL L FIGURE 10 AM195 LEAD KIT Page 16 WELDMATIC W17 WIREFEEDER MANUAL APPENDIX 1 AM111 SWIVEL MOUNT OPTION This option provides a swivel mounting which allows the wirefeeder to rotate when fitted to the top of the power source Option kit contains INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Unscrew the eye nut from the top of the welding power source and replace it with the AM111 1 socket Tighten using a small bar through the 7mm hole in the socket 3 Invert the wire feeder to fit the W14 swivel pin The pin and bracket are secured to the wire feeder using the four 1 4 B S W and o
13. W24 Motor amp Two Roll Drive Assembly P 13 Fig 9 REOR Drive Roll amp Wire Guide Table P 14 Oi ees Lead Aib ossis erri depart Ot Set eres lee Soft Start Crater Fill Option P 19 si Is Balance Boom Option P 25 WELDMATIC W17 WIREFEEDER MANUAL Page 3 1 INTRODUCTION The WELDMATIC W17 02 WIREFEEDER has been designed to feed a range of hard soft and flux cored wires for the Gas Metal Arc Welding process A low inertia Printed Circuit type motor with integral gear box is coupled to a two roll drive assembly forming the basic component of the wire feeder The motor is controlled by an electronic speed control which ensures excellent speed regulation over the full torque range of the motor and inherent compensation for supply voltage variations 2 RECEIVING Check the equipment received against the shipping invoice to make sure the shipment is complete and undamaged If any damage has occurred in transit please immediately notify your supplier The W17 02 Standard Package contains E WELDMATIC W17 02 WIRE FEEDER a This Owners Manual 3 SPECIFICATIONS SUPPLY VOLTAGE 30 Volts AC From Welding Power Source FUSE RATING 10 Amps DIMENSIONS L 430mm W 320mm H 320mm MASS 15Kg SPOOL SIZES 5Kg 15Kg 30Kg WIRESPEED RANGE 0 126 RPM 0 16 Metres per min WIRE SIZE RANGE 0 6mm 2 4mm diameter Page 4 WELDMATIC W17 WIREFEEDER MANUAL
14. and Post Gas Timer Option follow installation instructions described in appendix 2 Note PCB must be fitted to P3 in this instance 8 Plug the AM146 PCB and AM131 2 with associated heatsink into the 8 pin Option Board Receptacle P2 and P1 on W16 21 Wirefeeder control PCB Ensure correct alignment of connectors See below for procedure to adjust Minimum and Maximum wirespeed 9 Ensure wires from PCB to 10 pin socket and local remote switch are connected correctly and securely 10 If wirefeeder is to be used for aluminium welding substitute new nylon wire guide and chromed rollers for existing parts 11 For more information please contact your WIA branch or service agent WELDMATIC W17 WIREFEEDER MANUAL Page 23 ADJUSTMENT PROCEDURE The AM146 PCB has two trimpots to adjust maximum and minimum wirespeed These trimpots should be set up so that h The pull motor runs faster than the push motor without wire but with the top rolls closed with correct pressure m The pull motor runs not so fast that it mills the wire away with correct drive roll pressure ADJUSTMENTS Without welding wire in the gun cable a Set both trimpots to minimum ie turn anticlockwise until clicking is heard b Set the wirefeed speed potentiometer to minimum C Set the Min trimpot so that the pull motor runs at 140cm min surface speed or 25 RPM Approximately 400mA see Fine Tuning d Set the wirefeed speed to maximum which should
15. be 16 Metres min 126 RPM e Set the Max trimpot so that the pull motor runs at 17 Metres min or 310 RPM Approximately 300mA see Fine Tuning FINE TUNING Use a multimeter with a DC Amp range of 1 or 2 Amps f With the gun cable laid out straight on the floor and the correct drive roll pressure on both pull and push motors feed wire through gun cable g Remove the fuse from the AM146 assembly Ensure power is off as fuse may come in contact with heatsink h Connect the multimeter to read current passing through the fuse holder Repeat steps a to e noting a current of 300mA to 400mA through the wirefeed range Normally higher at minimum ie 400mA and 300mA at 16Metres min Ensure drive rolls are not milling away the wire with normal drive roll pressure If milling is evident then reduce the current at min or max as required Close cover and check operation of wirefeeder Purge gun cable for several minutes before welding Page 24 WELDMATIC W17 WIREFEEDER MANUAL APPENDIX 8 AM174 amp W17 17 COIL HOLDER AND COIL BRACKET PLATE OPTION This option replaces the existing wire spool holder with a device which enables the wirefeeder to mount 30Kg wire coils Option kit contains AMITA sante Coil Holder Includes 74 Spider 74 2 Clamp 4 e NE UE 1 2 BSW Wing Nut 4 ots Coil Mounting Bracket Includes o Fastening Kit INSTALL
16. en arc spotting and cycle arc timer for use during welding for applications such as in sheet metal work Option kit contains 28 0 PCB Assembly Includes CP29 0 39 Potentiometer 50K A curve 2 AM128 3 Switch W11 28 llli Current Relay Coil Assembly W5 10 19 oe Potentiometer Knob 2 W17 13 8Y oe Front Panel INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove existing front panel from wirefeeder 3 Fit new front panel W17 13 8Y to wirefeeder 4 Transfer Speed Contro potentiometer Power On LED On Off switch etc from original panel to new front panel 5 Fit new potentiometers 2 to holes in front panel designated SPOT TIME and CYCLE ARC TIME 6 Plug the AM128 PCB into either of the vacant 8 pin Option Board Receptacles P2 or P3 on W16 21 Wirefeeder control PCB Ensure correct alignment of connector 7 Ensure wires from potentiometers to PCB are connected securely Close covers and check operation of wirefeeder 9 For more information please contact your WIA branch or service agent eo OPERATION Spot Time potentiometer controls the time period during which arc spot welding Occurs Cycle Arc Time potentiometer controls the duration of the time interval between welds WELDMATIC W17 WIREFEEDER MANUAL Page 21 APPENDIX 5 AM130 VERNIER WIRE SPEED CONTROL OPTION This option provides a 10 turn vernier calibrated pote
17. ertaining 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 have additional requirements WTIA Technical Note TN7 98 also provides a comprehensive guide to safe 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 shade filter lens Amps TIG MMAW MIG Pulsed MIG 0 100 10 9 10 12 13 100 150 FT 10 10 12 13 150 200 12 10 11 11 12 12 13 200 300 13 TT 12 13 12 13 300 400 14 12 13 14 400 500 HU 14 500 EIS 14 14 BURN PROTECTION The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight 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 Wear protective clothing leather or heat resistant gloves hat and safety
18. eters to PCB are connected securely 8 Fit the Current Relay brass block to the rear wirefeeder motor mounting bolt connecting the welding cables as shown in diagram 9 Connect the two wires with spade lugs from the AM127 PCB into the W16 21 Wirefeeder Contro PCB terminals 2 and 3 along with the two wires from the current relay The wires are not polarity sensitive 10 Remove link E on W16 21 Wirefeeder Control PCB See page 9 Note If AM127 PCB is removed link E must be replaced to resume normal operation 11 Close covers and check operation of wirefeeder 12 For more information please contact your WIA branch or service agent A ND OPERATION Soft Start Speed potentiometer controls the initial speed of the welding wire Soft Start Time potentiometer controls the duration of the soft start speed after welding current commences Crater Fill Speed potentiometer controls the speed of the welding wire during crater fill period WELDMATIC W17 WIREFEEDER MANUAL Page 19 Crater Fill Time potentiometer controls the duration of the crater fill period after the gun switch is released SHORT WELDING LEAD CURRENT RELAY WELDING LEAD FROM SUPPLIED WITH KIT BRASS BLOCK POWER SOURCE FIGURE 11 SOFT START CRATER FILL OPTION Page 20 WELDMATIC W17 WIREFEEDER MANUAL APPENDIX 4 AM128 SPOT TIME CYCLE ARC TIMER OPTION This option provides the dual functions of a spot timer for accurate time control wh
19. fit wire spool adjust tension and feed wire through to gun Fit cover to spool cover base and check operation of wirefeeder 7 For more information please contact your WIA branch or service agent Page 22 WELDMATIC W17 WIREFEEDER MANUAL APPENDIX 7 AM227 0 PUSH PULL CONVERSION OPTION WITHOUT GUN This option provides all the necessary items to convert a standard wirefeeder to a push pull unit Option kit contains 46 9 PCB Assembly Includes 46 1 PCB Assembly AM131 2 PCB Assembly Includes KS cna Socket 10 Pin W1 20 oe Local Remote Switch AM131 2 3 Heatsink 26 5 PCB Assembly Includes CP29 0 39 Potentiometer 50K A curve 2 cubic Nt Euro Adaptor Kit W5 10 19 Potentiometer Knob 4 NA TESTS Front Panel W2 44 12N Nylon Wire Guide 0 8 1 2mm W2 49 Chromed Grooved Roller 2 49 Chromed Flat Roller INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove existing front panel from wirefeeder 3 Fit new front panel W17 13 5Y to wirefeeder 4 Transfer Speed Control potentiometer Power On LED On Off switch etc from original panel to new front panel 5 Fit Euro Connector and associated panel to wirefeeder base and wire drive unit 6 Fit 10 pin socket and local remote switch to front panel 7 Fit Pre
20. guishing equipment during and for some time after welding or cutting if E Combustibles including building construction are within 10 metres E Combustibles are further than 10 metres but can be ignited by sparks E Openings concealed or visible in floors or walls within 10 metres may expose combustibles to sparks E Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat After work is done check that area is free of sparks glowing embers and flames A tank or drum which has contained combustibles can produce flammable vapours when heated Such a container must never be welded on or cut uniess it has first been cleaned as described in AS 1674 1974 the S A A Cutting and Welding Safety Code This includes a thorough steam or caustic cleaning or a solvent or water washing depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment as recommended in AS 1674 1974 Water filling just below working level may substitute for inerting Hollow castings or containers must be vented before welding 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 other bare metal in the welding circuit or ungrounded electrically alive equipment can fatally shock a person whose body becomes a conductor Ensure that the
21. i that W2 44 26 ooo sss Adaptor Bush DB W2 44 22 ooo see M24 x 1P Brass Locknut CARE 25 M8 Skt Hd Screw x 25 long WSSBZ etie 8 Dia Spring Washer Sd a SSKM815U oe M8 Skt Hd Screw x 15 long 8 Dia Plain Washer dose Td aaa W2 44 5 esse Insulating Ring Kr 2 4 2 Flat Washer TTI OO D D FIGURE 7 W2 44 TWO ROLL DRIVE ASSEMBLY WELDMATIC W17 WIREFEEDER MANUAL Page 13 W24 MOTOR amp TWO ROLL DRIVE ASSEMBLY ITEM PART DESCRIPTION sere W17 01 6 in Wirefeed Motor 2 W2 44 oon 2 Roll Drive Assembly Be W2 20 nec Drive Roll 4 2 22 Drive Roll 5 W2 4421 oes Input Wire Guide 6 24 0 Quick Connect Assembly W2 44M9 oon Adaptor 2 44420 Guide Tube 9 sasteeeeseeserttesteseessseceeennns M4x4 Socket Grub Screw FIGURE 8 W24 MOTOR amp TWO ROLL DRIVE ASSEMBLY Page 14 WELDMATIC W17 WIREFEEDER MANUAL WIRE DIA INCHES MATERIAL FLAT ROLLER PLAIN V ROLLER 030 W2 20 W2 21 035 W2 20 W2 22 047 W2 22 W2 22 KNURLED ROLLER KNURLED V ROLLER QUU W2 54 W2 54 W2 44112 1 W2 24 W2 24 W2 44 12 2 078 W2 44 12 3 125 W2 26 W2 26 W2 27 W2 27 ES oe ru W2 28 W2 28 amp 0 V ROLLER FLAT ROL
22. liably a gas metal arc welder will operate For best results when welding mild steel we recommend quality WIA AUSTMIG ES6 Dirty rusty or kinked wire will not feed smoothly through the gun cable and will cause erratic welding Deposits from the wire will clog the gun cable liner requiring it to be replaced prematurely Place the spool of welding wire onto the spoo holder The location pin should mate with a hole provided on the wire spool body Fit the spool retaining R clip supplied Check the adjustment of the spool brake which should be set to prevent over run of the wire spool at the end of a weld without unduly loading the wirefeed motor The braking can be adjusted by the Nyloc nut using a 15 16 AF or 24mm socket wrench FEEDING THE CONSUMABLE WIRE WIRE INCH To feed wire through the gun cable liner first carefully straighten the free end of the electrode wire then cut it in the centre of the straightened section Release the top feed roll gate assembly and rotate the pressure arm to the open position The end of the welding wire can now be passed through the inlet guide over the bottom driven roller and into the output wire guide tube Check that the drive roller grooves are correct for the wire in use The appropriate size is stamped on the visible side of the installed roller Check also that the correct size contact tip is fitted at the gun end Drive roller and tip details are available in Section 10 of this manual Return the
23. machine is correctly connected and earthed if unsure have machine installed by a qualified electrician On mobile or portable equipment regularly inspect condition of trailing power leads and connecting plugs Repair or replace damaged leads Fully insulated electrode holders should be used Do not use holders with protruding screws Fully insulated lock type connectors should be used to join welding cable lengths Terminals and other exposed parts of electrical units should have insulated knobs or covers secured before operation
24. ne 3 8 B S W set screws supplied inserted through the pre punched holes in the wire feeder sheet metal Note that the pin is offset on the mounting bracket and will only fit correctly in one position Secure all fastenings firmly 4 Fit the fibre thrust washer onto the swivel pin then lower the assembly onto the AM111 socket 5 For more information please contact your WIA branch or service agent WELDMATIC W17 WIREFEEDER MANUAL Page 17 APPENDIX 2 AM126 PRE AND POST GAS TIMER OPTION This option provides adjustment for time period of shielding gas flow before and after welding Option kit contains 26 5 PCB Assembly Includes CP29 0 39 Potentiometer 50K A curve 2 W5 10 9 Potentiometer Knob 2 Front Panel INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove existing front panel from wirefeeder 3 Fit new front panel W17 13 1Y to wirefeeder 4 Transfer Speed Control potentiometer Power On LED On Off switch etc from original panel to new front panel 5 Fit new potentiometers 2 to holes in front panel designated PRE GAS and POST GAS 6 Plug the AM126 PCB into either of the vacant 8 pin Option Board Receptacles P2 or P3 on W16 21 Wirefeeder control PCB Ensure correct alignment of connector 7 Ensure wires from potentiometers to PCB are connected securely Close covers and check operati
25. ng cable is attached to the side of the two roll drive unit using the M8 socket screw provided Check that the wire guide and drive rollers fitted are appropriate to the electrode wire to be used For the recommended combinations see Figure 12 Standard wire feeders are factory fitted with a W2 22 bottom roller and W2 20 top roller which is suitable for both 0 9mm and 1 2mm diameter steel wire WORK LEAD FROM G CLAMP TO NEGATIVE TERMINAL ON POWER SOURCE WORK CLAMP GAS HOSE FROM HOSE FITTING TO GAS BOTTLE CONTROL CABLE FROM PLUG TO CONTROL SOCKET ON POWER SOURCE WELDING CABLE FROM EZ TO POSITIVE TERMINAL ON POWER SOURCE GUN CABLE ADAPTOR GREY VOLTAGE SENSE WIRE WIREFEEDER j CONTACTOR POWER SOURCE 1 zs 4 2 30 VAC D 3 CONTACTOR Em 30 VAC 2 3 CONTROL CABLE FIGURE 2 CONNECTIONS TO POWER SOURCE Page 6 WELDMATIC W17 WIREFEEDER MANUAL 6 WIRE FEEDER OPERATION FITTING THE GUN CABLE The W17 02 WIREFEEDER equipped with a BERNARD EZ Gun Cable 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 wirefeeder mechanism engage the mating parts of the male and female EZ connectors then rotate the locking ring clockwise to firmly secure the connection FITTING THE CONSUMABLE WIRE The quality of the consumable wire greatly affects how re
26. ntiometer for fine control of wire speed Option kit contains CP28 0 20 Vernier Dial 28 0 2 Potentiometer 10K 10 Turn x 3W 2 INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove existing Speed Control potentiometer and knob from front panel of wirefeeder 3 Fit new 10 turn Speed Control potentiometer to front panel of wirefeeder 4 Fit new vernier dial and dial cover to potentiometer shaft Extra hole may be required for key on dial cover 5 Remove wires from existing potentiometer and fit to new 10 turn potentiometer 6 Close cover and check operation of wirefeeder 7 For more information please contact your WIA branch or service agent OPERATION Vernier Wire speed control allows fine adjustment of wirespeed and accurate resetting of previously noted wire speeds APPENDIX 6 AM140 WIRE SPOOL COVER OPTION This option provides a plastic cover and removable lid to cover the wire spool and protect it from dust and moisture during operation Option kit contains Spool Cover and Lid INSTALLATION INSTRUCTIONS 1 Ensure Power Source is switched off 2 Remove wire spool from wirefeeder 3 Remove spool holder from spool holder axle ensure washers spool holder and nut etc are kept in correct order 4 Fit spool cover base over axle then refit spool holder keep components in correct order 5 Re
27. on of wirefeeder 9 For more information please contact your WIA branch or service agent eo OPERATION Pre gas potentiometer controls time period during which shielding gas flows before welding current begins Post gas potentiometer controls time period during which shielding gas flows after welding current ceases Page 18 WELDMATIC W17 WIREFEEDER MANUAL APPENDIX 3 AM127 SOFT START CRATER FILL OPTION This option provides adjustment for time period and wirefeed rate at commencement and completion of weld Option kit contains 27 0 PCB Assembly Includes W11 02 15 Potentiometer 10K x 3W 2 29 39 Potentiometer 50K A curve 2 W11 28 ooo Current Relay Coil Assembly W5 10 19 oe Potentiometer Knob 4 18 Front Panel INSTALLATION INSTRUCTIONS Ensure Power Source is switched off Remove existing front panel from wirefeeder Fit new front panel W17 13 1Y to wirefeeder Transfer Speed Control potentiometer Power On LED On Off switch etc from original panel to new front panel 5 Fit new potentiometers 4 to holes in front panel designated SOFT START SPEED SOFT START TIME CRATER FILL SPEED and CRATER FILL TIME 6 Plug the AM127 PCB into either of the vacant 8 pin Option Board Receptacles P2 or P3 on W16 21 Wirefeeder contro PCB Ensure correct alignment of connector 7 Ensure wires from potentiom
28. preferably after each spool or coil of wire Contact tips should be kept clear of spatter and hole size should be checked regularly Regularly check gas lines and connections for tightness to prevent gas or air leaks which may lead to porosity occurring in welds 8 Keep gun cable free from sharp bends loop in a C curve in preference to an S curve If wire feeder can be suspended from overhead this will greatly improve consistency of wire feed rate 8 For CO2 gases use gas pre heater at all times to eliminate gas flow irregularities caused by gas freezing in the regulator 8 TROUBLE SHOOTING E DRIVE MOTOR WILL NOT TURN WHEN GUN SWITCH IS OPERATED AND SPEED CONTROL IS SET TO DESIRED SPEED E Check that 30 Volts A C power is turned on and all fuses are intact a Operate Inch switch If motor turns fault may be either in gun switch or the Switch wires in the gun cable If motor does not turn visually check both printed circuit boards and ensure that all components wiring and electrical connections are secure Check motor relay on printed circuit board and ensure that it is operating correctly a FUSES FAIL REPEATEDLY WHILE WELDING a Check to ensure that a 10 Amp fuse has been installed in the wire feeder fuse holder in the power source 8 Motor may be overloaded check E Spool Holder or Wire Reel brake Reel or Spool should only have sufficient pressure applied to prevent over run when motor stops E Feed roll
29. top feed roll gate to the closed position and adjust the compression screw to provide sufficient clamping of the drive rolls to achieve constant wirefeed Do not over tighten Excessive pressure between the drive rollers will result in deformation of the electrode wire and will result in erratic wire feeding Using the Wire Inch switch advance the wire down the gun cable and out of the welding tip Cut the wire approximately 10mm from the welding tip For information regarding weld settings gas flow rates etc consult the welding power source manual NOTE When the welding power source contactor is energised the two roll drive and the spool of wire are at welding potential with respect to the work lead WELDMATIC W17 WIREFEEDER MANUAL Page 7 7 MAINTENANCE The wire feeder should require little maintenance other than regular blowing out of any accumulated dust in order to ensure the efficient cooling of the electronic components The wire drive motor gearbox is lubricated with a long life grease and should not normally require any maintenance procedure To gain access to the electronic components of the wire feeder remove the two 3 16 mushroom head screws from the top front of the wire feeder enclosure and hinge the lid upwards To ensure consistent wire feeding the following points with regard to the gun cable assembly should be noted E Blow out gun cable and liner with dry compressed air at regular intervals and
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