A DIVISION OF WELDING INDUSTRIES LTD

Transcription

1 I- WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ABN Head Office and Internationa Saes 5 Aan Street, Merose Park South Austraia, 509 Teephone (08) Facsimie (08) info@wedingindustries.com.au OWNERS MANUAL WELDMATIC FABRICATOR MODEL NO. CP-0, REV. F 11/00 QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE 4 f: 7 i M

2 Page WELDMATIC FABRICATOR MANUAL SAFETY Before this equipment is put into operation, the safety practicesection at the back of the manua must be read competey. This wi hep to avoid possibe injury due to misuse or improper weding appications. INTRODUCTION Gas Meta ArcWeding (G.M.A.)isabasicaysimpewedingprocess,wherea consumabe wire is fed by motor driven drive roers to a weding gun, and where weding current is suppied from the weding power source. The weding arc is struck between the work piece and the end of the wire, which mets into the wed poo. The arc and the wed poo are both shieded by gas fow from the gun, or in the case of sef shieded wires, by gases generated by the wire core. The process is very versatie in that by seection of the correct wire composition, diameter and shieding gas, it can be used for appications ranging from sheetmeta to heavy pate, and metas ranging from carbon stee to auminium aoys. HANDLING Prior to instaing this equipment, cean ai packing materia from around the unit and carefuy inspect for any damage that may have occurred in shipment must be fied by the purchaser with Weding Industries of Austraia, or authorised agent immediatey. (Refer to Equipment Warranty Card encosed with this Operating Manua). When requesting information concerning this equipment, it is essentia to suppy correct Mode Identification and Machine seria number. CONTENTS PAGE Sec.?... Specifications... Sec.... Instaation... 4 Sec... Set up for Weding... 7 Sec.4... Safety Devices... 9 Sec5... Maintenance... 9 Sec.6... Parts List.... IO Sec.7... Safe Practices... 1 i FIGURES PAGE Fig 1... Fitting Mobie Kit... 4 Fig... Good Wed... 7 Fig... Bad Wed... 7 Fig 4... Gun Position... 7 Fig.5... Weding Data Tabe... 8 Fig 6... Power Source Assemby Fig 7... Circuit Diagram... -

3 WELDMATIC FABRICATOR MANUAL Page RECEIVING. The WELDMATIC FABRICATOR package contains: CP-0 Power Source. W17 Wirefeeder. AMI95 Inter-connecting Accessory ead kit, metre. BEQA51OAB BERNARD EZ Gun cabe, metre. Reguator and Fowmeter. (Argon) (This) Owners Manua.. SPECIFICATIONS. MACHINE TYPE... MACHINE CLASS... CP-0 Heavy Duty Weding Power Source, Constant Votage Type. PRIMARY VOLTAGE Vots A.C., Three Phase, 50 Hz. EFFECTIVE PRIMARY CURRENT Amps per phase. MAXIMUM PRIMARY CURRENT... Amps per phase. OPEN CIRCUIT VOLTAGE Vots. WELDING CURRENT RANGE Amps. RATED OUTPUT Amps at 0 Vots, 100% Duty cyce. 0 Amps at Vots, 60% Duty cyce. SUPPLY ALTERNATOR CAPACITY kva minimum. CIRCUIT BREAKER RATING... 5 Amps FITTED SUPPLY CABLE... 50/0.5 Four Core, Heavy Duty PVC. COOLING Fan cooed, air drawn in through rear fan gries. INSULATION... Cass F, ' 15 C Rise. DIMENSIONS... 60mm H, 40mm W, 640mm L. MASS kg Duty cyce is defined in Austraian Standard AS as the ratio of arcing time to 5 minutes in any 5 minute period, expressed as a percentage.

4 ~ ~ Page 4 WELDMATIC FABRICATOR MANUAL. INSTALLATION ASSEMBLY OF PACKAGED PLANT The power source is shipped on its skid base. Where appicabe, the whees, hande, botte carrier and botte crade shoud be assembed as shown beow. %D FIGURE. FITTING MOBILE LIT AM46-0 Lift the power source onto the mobie-kit frame (). Use a crane or fork ift with chains and hooks and insert hooks through the eye nuts on the top cover of the power source. If a crane or fork ift is not avaiabe, the power source may be carefuy sid onto the frame from the back. Line-up hoes in the side beams of the frame with the sots in the sides of the Power Source base. Insert a four /8"W x 1" screws () through the four hoes and sots. Thread on a four 18"W Hex "'Nyoc'~ nuts (4). Tighten a four nuts (you wi need spanners for both the screw and the nut). Remove screws (7), spring washers (6) and fat washers (5) from back pane of the power source. '

5 m WELDMATIC FABRICATOR MANUAL Page - 5 ~ ~~ ~ Fit botte crade () with the chain sots uppermost. Refit screws and washers and then tighten. To fit hande, remove and discard a pane mounting screw from the front-top of each side pane. Fit hande (8) as shown, and repace screws with two 1/4"W x 1" screws (9) and spring washers (IO) as shown. NOTE: DO NOT ATTEMPT TO LIFT POWER SOURCE AND MOBILE KIT ASSEMBLY WITH A GAS BOTTLE IN PLACE. The W17 wirefeeder may be fitted to an AM144 swive socket mounted on the top of power source. Fit swivesocket,cp15-0 to centrestud of power source and tighten securey. Fit the W16-14 pivot pin assemby to the wire feeder and ensure the fibre thrust washer is on the pin before ocating it in the swive mounting. Check that the wire feeder is free to swive in a directions, and if necessary appy a sma amount of graphite grease to the shaft. CONNECTION TO MAINS SUPPLY 1, 8, NOTE. A' e'ectrica work8sha ony'be, underfaken by a,quaified eectrician. Before remdving,soy machin,e covers, ENSURE 'th,at the unit is disconnected 'from the eectrica suppy. men the unit is energised LETHAL VOLTAGES are present on 'the eectrica components encosed The Wedmatic Fabricator power source is suitabe for connection to a Vot 50Hz. Phasesuppy.Therecommendedprimarycabe to use is four core, 50/0.5 (.5mm) Heavy Duty PVC. The minimum capacity of the mains wiring and power outet suppying a weder is seected according to the effecfive primary current of the machine. The effective primary current for a Wedmatic Fabricator is 17 Amps. The minimum recommended circuit breaker rating for a Wedmatic Fabricator is 5 Amps. The current rating of the mains cabe depends on cabe size and method of instaation. Refer to AS/NZS 008.1, Tabe 9. If it becomes necessary to repace the mains fexibe suppy cabe, use ony cabe with correct current rating. Access to the suppy connection terminas in machine may be gained by removing the right hand side pane. Use a fexibe 4 core primary cabe for portabe machines, and camp the cabe to ensure that there isnostrainon cabe connections.theearth connection (green/yeow) must be securey fastened to the Earthing termina which is adjacent to the suppy connection terminas. CONNECTION OF CABLES AND HOSES. Pug respective ends of the wirefeeder contro cabe into the mating sockets on the rear of the wire feeder, and the front pane of the power source. Connect the gas hose from the wire feeder to the gas reguator/fowmeter, ensuring a connections are tightened firmy. Bf 68 shieding gas is to be used, pug the gas heater into the 110 vot socket at the rear of the power source. Connect the gun cabe assemby to the wirefeeder.

6 ~ m - ~~ Page 6 WELDMATIC FABRICATOR MANUAL WELDING CABLES The recommended weding cabe size for the Wedmatic Fabricator is 1 11/0.0 (5mm) Most G.M.A. weding is conducted with eectrode wire at positive eectrica potentia reative to the work piece. This is commony known as D.C. Reverse Poarity (D.C.R.P.). In this connection, the Gun Cabe ead is pugged into the positive (+) output socket of the power source. The Work iead is pugged into the negative (-) output socket of the power source. Thepugs of the wedingcabesmust be fuyinsertedinto the sockets,and rotated cockwise to ock. Some fux-cored wires are intended to be operated with the eectrode at negative eectrica potentia. In this instance, connect the Gun Cabe ead to the negative (-) output termina, and the Work ead to the positive (+) output termina. WIRE FEEDER AND GUN CABLE Fit the required spoo of wire to the wire feeder. Adjust the brake nut within the spoo hoder unti a sight braking effect is fet when turning the wire spoo by hand. This is to prevent over-run when wire feed stops. The wire drive ros, inet wire guide, gun cabe and contact tip a shoud be seected in accordance with the diameter and type of wire being used. Refer to the appropriate manuas for these items. SINGLE FUNCTION CHECK The unit is now ready for operation, but prior to commencing weding, the foowing functions check is recommended. Switch on the power source and check for cooing air fow. Next ensure that a contro cabes and gas hoses are securey connected and if CO is being used, that a gas heater is pugged into socket at the rear of the power source. Open the gas cyinder fuy and check contents gauge for an adequate gas suppy. Press the GasPurge switch on the wirefeederandsetgasfow in accordance with weding requirements. Check for gas fow at the weding nozze. Set the 'Wirespeed' contro to the desired wire speed. Press the 'Wire Inch' switch and check for positive wirefeed. The camping pressure at the drive roers shoud be sufficient to prevent sip on the consumabe wire, without deforming it. Next,cosegun switch momentariy to check for wirefeed,gasfowand weding power. Set the votage seector switches in accordance with required votage (see weding data on page 81, and the unit is now ready for use.

7 ~ WELDMATIC FABRICATOR MANUAL Page 7 SETUP FOR WELDING In GMA weding, the wirefeed rate determines the weding current. Increasing the feed rate increases the current, and decreasing it decreases current. The seected wirefeed rate must be matched with sufficient arc votage. An increase of wirefeed rate requires an increase of arc votage. If the votage is too ow the wire wi stub and stutter, and there wi not be a steady arc. If the votage is too high the arc wi be ong with the meta transfer within the arc occurring as a series of arge dropets. The weding output votage of the FABRICATOR is set by the use of Coarse and Fine seector switches. A tota of 0 output votage settings are avaiabe. The weding current shoud be chosen to suit the thickness of the meta to be weded. It is important to check that the deposited wed provides sufficient strength to suit the appication. A "good" wed wi have the characteristics iustrated in figure. The wed has penetrated into the parent meta, fusing the root of the joint where the two pates meet, and the wed bends smoothy into the side was. A "bad" wed is shown in figure. The wed has not penetrated the joint root, and there is poor side wai fusion. This ack of fusion woud normay be corrected by increasing the arc votage, or by increasing both wirefeed rate and arc votage to achieve a higher current wed setting. b L FIGURE - "GOOD" WELD FIGURE. "BAD" WELD GUN POSITION For "down hand" fiet weding, the gun is normay positioned as in the figure beow with the nozze end pointing in the direction of trave. FIGURE 4. GUN POSITION & F 6 0 I I

8 ~ Page 8 WELDMATIC FABRICATOR MANUAL The setting detais given beow are for weding grade CO shieding gas, used with a gas preheater. The recommended gas fow rate for CO is 8-10 itres/min. If mixed gases are to be used, the chart wi sti provide a usefu setting guide, however for optimum resuts, votage adjustment may be necessary. In genera the votage setting wi need to be reduced. For mixed gases use a gas fow rate of itres/minute. WIRE SIZE WIRESPEED VOLTS AMPS and TYPE DIAL SETTING COARSE FINE 0.8rnm Mid Stee rnm Mid Stee mm Mid Stee mm Fuxofi 1 ni The recommended wire stick-out is 6-9mm for up to 00 amps weding current, and 1-19mm for over 00 amps. FIGURE 5. WELDING DATA TABLE. ~ ~ - -

9 ~ ~ ~-~ WELDMATIC FABRICATOR MANUAL Page 9 4. SAFETY DEVICES In the event of the power source becoming overheated, thermostats on the diode heat sinks wi operate preventing further weding. The thermostats automaticay reset, and with the cooing fan operating this wi take approximatey 10 minutes. A check shoud be made to ascertain the reason for the overheating such as the fan not operating or restriction of the cooing air fow. Fuses are provided for a circuits are as indicated on the front pane:-. HEATER GAS SUPPLYVOLTAGEFUSES E & E INTERNALLY MOUNTED WIREFEEDER 10A. E4 5. MAINTENANCE POWER SOURCE Apart from the fan the rectifier has no rotary components. To achieve compete dissipation of heat from the active components the rectifier shoud be thoroughy bown off with dry compressed air after 6 months operation. Ceaning shoud be carried out at shorter intervas if dust accumuation is considerabe. The wirefeed motor/gearbox is pre-packed with grease and needs no other ubrication. Change the grease after approximatey 14,000 service hours. (See Wirefeeder instruction manua). The drive roers and the inner wire guides shoud be kept cean. If necessary, bow out the inside of the wire feeder with compressed air. GUN AND CABLE Frequenty remove any spatter which might adhere to the nozze bore so that the shieding gas fow is not impeded. The condition of the contact tip shoud be reguary checked. Damaged or burnt tips are an impediment to troube-free weding operation and shoud be repaced immediatey. Troube-free operation depends to a arge extent on the good condition and ceaniness of the gun cabe iner. The iner shoud be repaced when dust and other deposits buid-up in the bore. -

10 Page 10 WELDMATIC FABRICATOR MANUAL 6- CP-0 PARTS LST DESCRIPTION ftem PART, 1... CP-0... BASE FRAME ASSEMBLY... CP-1... TRANSFORMER ASSEMBLY.... CP INDISGTANCE ASSEMBLY 4... CP FAN BLADE 50mm DIAMETER 5... CP9-0/7... FAN MOTOR 6... CP-6... RECTIFIER ASSEMBLY CP15-1/... DIODE SEMIKRON SKR40/04) CP15-1/... DIODE I SEMIKRON SKN40/04) CP-9/8... THERMOSTAT 7... CP15Q/7... tteater RUG SOCKET 8...CP8-0/10...W DNG CONTACTOR 9... CP-0/0..,.... AMMETER SHUNT CP-0/10... AMMETER 1... CP-0/11... VOLTMETER 1... W1-... INDICATOR LIGHT 1... W1-... FUSE HOLDER CP9-/0... ON/OFF SWITCH CP5-0/18... FtNE SELECTOR SWITCH CP5-04/16... COARSE SELECTOR SWITCH CP15-0/14... CONTROL, PLUG CP FRONT PANEL CP BACK PANEL 0... CP TOP COVER 1... CP SIDE PANELS... WIN#... TYPE NO./SERIAL NO. PLATE 4... AM16... OUTPUT TERMINALS F... 1/"W. EYE NUT 6...CP-0/9... LOOM ASSEMBLY 7... CP-... AIR FLOW FINS 8... WIN1... TERWNAL CONNECTION NAMEPLATE 9... CP PIVOT MOUNTING FOR W CP-0/1... FUSE HOLDER (MOUNTED INTERNALLY) 1... CP65-0/44... FUSE LINK 6A (MOUNTED INTERNALLY)

11 1 ~ ~ ~..~"~ "" _ ~ _ ~ ~~ ~ ~ ~. ~ ~. ~ ~ ~ WELDMATIC FABRICATOR MANUAL Page 11 FIGURE 6. CP-0 POWER SOURCE ASSEMBLY

12 ~ Page I WELDMATIC FABRICATOR MANUAL if\ or * -1! "8" c $ 99 PP a gs & 5 e!! jg, B, g 4Q; c r--1 r a prrnc In Irn Y e NI= $ g p E EE i%, fa f gp "& &$&g4 p E 5 FF Zw"ggE:; rwwg qq$:gg&er@%d+ g8 ;r,,i,!a ~ ~ ~ ~ ~ ~ ~ U g 5 E55 e ~ B a x ~ 5 s ~ a = ~ c & 4 % 5 s I c H I ~~~~~~~ FIGURE 7. CP-0 CIRCUIT DIAGRAM -

13 - WELDMATIC FABRICATOR MANUAL Page 7. SAFE PRACTICES IN USING WELDING EQUIPMENT These notes are provided in the interests of improving operator safety. They shoud be considered ony as a basic guide to Safe Working Habits. A fu ist of Standards pertaining to industry is avaiabe from the Standards Association of Austraia, aso various State Eectricity Authorities, Departments of Labour and Industry or Mines Department and other Loca Heath or Safety Inspection Authorities may have additiona requirements. KIA Technica Note TN7-98 aso provides a comprehensiveguide to safe practices in weding. EYE PROTECTION NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a hemet with safety gogges or gasses with side shieds underneath, with appropriate fiter enses protected by cear cover ens. This is a MUST for weding, cutting, and chipping to protect the eyes from radiant energy and fying meta. Repace the cover ens when broken, pitted, or spattered. Recommended shade fiter ens. AmPS TIG MMAW MIG Pused MIG BURN PROTECTION. The weding arc is intense and visiby bright. Its radiation can damage eyes, penetrate ightweight cothing, refect from ight-cooured surfaces, and bum the skin and eyes. Bums resuting from gas-shieded arcs resembe acute sunburn, but can be more severe and painfu. Wear protective cothing - eather or heat resistant goves, hat, and safety-toe boots. Button shirt coar and pocket faps, and wear cuffess trousers to avoid entry of sparks and sag. Avoid oiy or greasy cothing. A spark may ignite them. Hot meta such as eectrode stubs and work pieces shoud never be handed without goves. Ear pugs shoud be worn when weding in overhead positions or in a confined space. A hard hat shoud be wom when others are working overhead. Fammabe hair preparations shoud not used be by persons intending to wed or cut. TOXIC FUMES. Adequate ventiation with air is essentia. Severe discomfort, iness or death can resut from fumes, vapours, heat, or oxygen depetion that weding or cutting may produce. NEVER ventiate with oxygen. Lead, cadmium, zinc, mercury, and beryium bearing and simiar materias when weded or cut may produce harmfu concentrations of toxic fumes. Adequate oca exhaust ventiation must be used, or each person in the area as we as the operator must wear an air-suppied respirator. For beryium, both must be used. Metas coated with or containing materias that emit fumes shoud not be heated uness coating is removed from the work surface, the area is we ventiated, or the operator wears an air-suppied respirator. Work in a confined space ony whie it is being ventiated and, if necessary, whie wearing air-suppied respirator.

14 Page 14 WELDMATIC FABRICATOR MANUAL Vapours from chorinated sovents can be decomposed by the heat of the arc (or fame) to form PHOSGENE, a highy toxic gas, and ung and eye irritating products. The utra-vioet (radiant) energy of the arc can aso decompose trichorethyene and perchorethyene vapours to form phosgene. Do not wed or cut where sovent vapours can be drawn into the weding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichorethyene or perchoorethyene. FIRE AND EXPLOSION PREVENTION. Be aware that fying sparks OF faing sag can pass through cracks, aong pipes, through windows or doors, and through wa or foor openings, out of sight of the operator. Sparks and sag can trave up to 10 metres from the arc. Keep equipment cean and operabe, free of oi, grease, and (in eectrica parts) of metaic partices that can cause short circuits. If combustibes are present in the work area, do NOT wed or cut. Move the work if practicabe, to an area free of combustibes. Avoid paint spray rooms, dip tanks, storage areas, ventiators. If the work can not be moved, move combustibes at east 10 metres away out of reach of sparks and heat; or protect against ignition with suitabe and snug-fitting fire-resistant covers or shieds. Was touching combustibes on opposite sides shoud not be weded on or cut. Was, ceiings, and foor near work shoud be protected by heat-resistant covers or shieds. Apersonactingas Fire Watcher must be standing by with suitabe fire extinguishing equipment during and for some time after weding or cutting if; Combustibes (incuding buiding construction) are within 10 metres. Combustibes are further than 10 metres but can be ignited by sparks. Openings (conceaed or visibe) in foors or was within 10 metres may expose combustibes to sparks. Combustibes adjacent to was, ceiings, roofs, or meta partitions can be ignited by radiant or conducted heat. After work is done, check that area is free of sparks, gowing embers, and fames. A tank or drum which has contained combustibes can produce fammabe vapours when heated. Such a container must never be weded on or cut, uness it has first been ceaned as described in AS , the S.A.A. Cutting and Weding Safety Code. This incudes a thorough steam or caustic ceaning (or a sovent or water washing, depending on the combustibe's soubiity), foowed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AS Water-fiing just beow working eve may substitute for inerting. Hoow castings or containers must be vented before weding or cutting. They can expode. Never wed or cut where the air may contain fammabe dust, gas, or iquid vapours. SHOCK PREVENTION. Exposed conductors or other bare meta in the weding circuit, or ungrounded eectricay aive equipmentcan fatay shockapersonwhosebodybecomesaconductor.ensure that themachine is correcty connected and earthed. If unsure have machine instaed by a quaified eectrician. On mobie or portabe equipment, reguary inspect condition of traiing powereadsandconnectingpugs.repairor repace damaged eads. Fuy insuated eectrode hoders shoud be used. Do not use hoders with protruding screws. Fuy insuated ock-type connectors shoud be used to join weding cabe engths. Terminas and Other exposed parts of eectrica units shoud have insuated knobs or covers secured before operation. I "