WIA Weldmatic 256 Operator'S Manual Download Page 1

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Weldmatic 256 (480 V) MIG welder
With Four Roll Drive
Enclosed Wirefeeder
Model No. CP124-3, Iss B
05/09

CP124-41 Rev C

Weldmatic 256

[external wirefeeder]

Operators Manual

Summary of Contents for Weldmatic 256

Page 1: ...Weldmatic 256 480 V MIG welder With Four Roll Drive Enclosed Wirefeeder Model No CP124 3 Iss B 05 09 CP124 41 Rev C Weldmatic 256 external wirefeeder Operators Manual ...

Page 2: ...Quality Reliability Performance Welding Industries of Australia An ITW Company ABN 18 004 547 111 Telephone 1300 300 884 Facsimile 1300 301 884 Email Info welding com au www welding com au ...

Page 3: ...1 Power Source 7 4 2 Wirefeeder 8 5 Installation 10 6 Normal Welding Sequence 12 7 Basic Welding Information 13 8 General Maintenance 14 9 Trouble Shooting 15 10 Service Information 17 11 Assembly and Parts Lists 11 1 Power Source 20 11 2 Wirefeeder 22 11 3 Wirefeed Assembly 24 11 4 Gun and Cable Assembly 25 11 5 Interconnecting Lead Kit 27 12 Warranty information 28 ...

Page 4: ...ered Recommended Shade Filter Lens Amps TIG MMAW MIG Pulsed MIG 0 100 10 9 10 12 13 100 150 11 10 10 12 13 150 200 12 10 11 11 12 12 13 200 300 13 11 12 13 12 13 300 400 14 12 13 14 400 500 13 14 14 500 14 14 Read first 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...

Page 5: ...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 Vapours from chlorinated solvents can be decomposed by the heat of the arc o...

Page 6: ...olvent 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 2 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 d...

Page 7: ...tion of G M A W is for welding Mild Steel In this application a Mild Steel solid consumable wire such as AUSTMIG ES6 is used with a shielding gas of Carbon Dioxide or Argon mixed with Carbon Dioxide Alternatively Flux cored consumable wires are available in both gas shielded and gasless self shielding types Stainless steel and Aluminium can be welded with G M A W using the correct consumable wire ...

Page 8: ...3 Specifications Power Source Manufactured to Australian Standard AS60974 1 Primary Voltage 480 Vac 50Hz Rated Primary Current 12 Amps Maximum Primary Current 25 Amps Recommended Generator kVA 12 kVA Rated Output 40o C Duty cycle based on 10min cycle time 255 Amp 27 V 25 duty 100 Amp 19 V 100 duty Welding Current 30 255 Amps Open Circuit Voltage 20 42 V Shipping weight 104 kg inc wirefeeder and le...

Page 9: ...l Socket Connector for control cable from remote wirefeeder 3 Coarse Voltage On Off Control This switch provides mains power ON OFF and Coarse adjustment of the output welding voltage over three ranges 4 1 Power Source Controls 3 4 Gas Outlet Connector for shielding gas hose from remote wirefeeder 5 Negative Welding Output Terminal 6 Positive Welding Output Terminal 1 2 6 5 4 ...

Page 10: ...er starts suitable for applications such as rapid tack welding Rotating the knob towards SOFT will slow wire acceleration providing a softer start suitable for larger diameter and aluminium wires 4 Wire Speed Control This control sets the speed of the wire drive motor within the range of 0 172 RPM equivalent to 0 20 metres per minute of welding electrode wire Rotate the control clockwise to increa...

Page 11: ...hes smoothly This is followed by rapid acceleration so that the arc does not flare up and damage the tip Even if an arc is not established within one second of the gun switch being operated the wire feed accelerates to selected welding speed Wirefeeder Controls on Inside Panel Pre Gas Control Sets the time period of gas flow before welding commences and can be set for 0 2 seconds Post Gas Control ...

Page 12: ...ormal variations of sensitivity the tripping time of some 15A circuit breakers may limit the duty cycle available from the Weldmatic 256 A higher rated circuit breaker can be selected but the mains wiring capacity must be increased to suit The current rating of the mains cable depends on cable size and method of installation Refer to AS NZS 3008 1 Table 9 If it becomes necessary to replace the mai...

Page 13: ... ensure good electrical contact and to prevent gas leaks The Weldmatic 256 wirefeeder is supplied fitted with WF027 bottom rollers which are suitable for both 0 9mm and 1 2mm diameter steel wire Fitting The Gun and Cable Assembly The supplied BERNARD gun cable assembly is equipped with a Euro wirefeeder connector which incorporates all required connection points for welding current shielding gas a...

Page 14: ...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 Compression screw Top roller arms Feeding the Consumable Wire At the wirefeeder release the compression screw and rotate the top roller arms to the open position The end of the welding wire can now be passed through the inlet guide ove...

Page 15: ...piece preparation in order to avoid weld porosity Establishing a Weld Setting Once the consumable wire type wire size and shielding gas have been chosen the two variables that are adjusted in order to obtain a the desired weld setting are Wirefeed speed Welding arc voltage The wirefeed speed determines the welding current increasing the speed increases the current and decreasing it decreases curre...

Page 16: ...removed and any accumulated dust be removed by the use of dry low pressure compressed air or a vacuum cleaner Wirefeed In order to obtain the most satisfactory welding results from the G M A W process the wirefeed must be smooth and constant Most causes of erratic wirefeed can be cured by basic maintenance Check that the 1 Feed rolls are the correct size and type for the wire in use Check also tha...

Page 17: ... following checks do not identify the fault condition the equipment should be returned to a WIA Service agent Phone 1300 300 884 for details of your nearest service agent Power source has no output and no wirefeed when gun switch is closed Power light on wirefeeder is off 1 Check equipment is connected to a functional mains power outlet Test outlet using a known working appliance 2 Check the equip...

Page 18: ...s Replace the feed roll if it is the incorrect size or is worn 3 Check that gun cable liner is not too short and is fitted correctly Refer to page 28 for fitting instructions Constant poor arc characteristics Check that the 1 Correct polarity has been selected for work and weld cables refer page 10 2 Shielding gas is correct for the consumable wire in use refer page 13 3 Welding circuit is making ...

Page 19: ...control board provides the following functions Welding transformer ON OFF control in response to an output from the wirefeed control board the contactor function Output voltage control by means of Phase shifting of the welding transformer primary voltage as adjusted by the wirefeeder front panel Fine voltage selection knob Connections to the board are detailed in the drawing below Fig 10 CP107 10 ...

Page 20: ...18 Operators Manual Quality Reliability Performance Quality Reliability Performance Fig 11 Power Source Circuit Diagram 10 2 Circuit Diagram Power Source ...

Page 21: ...Weldmatic 256 Model No CP124 3 Iss B 05 09 19 10 3 Circuit Diagram Wirefeeder Fig 12 Wirefeeder Circuit Diagram ...

Page 22: ...iability Performance Quality Reliability Performance 11 1 Assembly and Parts List Weldmatic 256 Power Source Fig 13 Weldmatic 256 Power Source Assembly 8 7 9 12 16 6 5 3 4 2 1 15 17 10 19 20 22 23 24 25 26 27 28 13 14 29 10 11 18 21 ...

Page 23: ...1 15 CX58 Socket Dinse 2 16 E0024 Circuit Breaker 5 Amp 1 17 MZ230304 Plastic Front 1 18 PWA007N Fan on Demand PCB 1 19 CP107 10N SSR Control PCB 1 20 D0030 Solid State Relay 1 21 R0025 Resistor 330 R 50 W 22 CP106 0 1 Rectifier 1 Not Shown CP3 9 8 Thermostat included in Rectifier 1 23 L0014N Control Transformer 1 24 C0028 Capacitor 10 000mfd 80 V 5 25 IND001 Inductance Assembly 1 26 TFM011 Weldin...

Page 24: ...Manual Quality Reliability Performance Quality Reliability Performance 11 2 Assembly and Parts List W60 0 Wirefeeder Fig 14 Weldmatic W60 0 Wirefeeder Assembly 6 13 14 15 8 16 17 19 18 21 20 2 1 3 4 5 9 8 10 12 11 7 ...

Page 25: ...Set Complete 1 11 WF001 06 Euro Surround Plastic 1 12 PAN085 Front Panel 1 13 PAN090 PCB Cover 1 14 PWA008N Wirefeed Control Printed Circuit Assembly 1 Includes Potentiometer Voltage Control 1K 1 Potentiometer Wirespeed Control 1K 1 Potentiometer Creep Arc Start 10K 1 15 WF024 Four Roll Drive and Euro Adaptor Assembly see page 26 1 16 HF200 1 15 Plastic Foot 4 17 E0041 Gas Valve 24 vdc 1 18 PAN086...

Page 26: ...ve Box Nylon 1 8 W26 0 4 Woodruff Key 2 9 W27 0 9 Roller Retaining Screw 2 10 WF027 Feed rolls 0 9 1 2 mm Solid Wire fitted 2 WF026 0 6 0 8 mm Solid Wire 2 WF028 1 2 1 6 mm Solid Wire 2 WF029 1 0 1 2 mm Aluminium 2 WF030 1 0 1 2 mm Flux Cored Wire 2 WF031 1 2 1 6 mm Flux Cored Wire 2 11 WF001 21 Outlet Guide Tube oversize cut to 41mm long 1 12 WF038 Positioning Shaft Brass 1 13 WF007 Euro Adaptor ...

Page 27: ... 11 BE2520033 Strain Relief 12 BE1199E Euro Direct Plug Kit Includes12a BE4816 Euro Adaptor Nut 12b BE9165 Small O ring on gas nipple 12c BE4421 Large O ring at base of gas nipple 13 BE43115 BE43115X BE44215 Steel Liner 0 9 1 2mm Nylon Liner 0 9 1 2mm Steel Liner 1 6mm 14 BE2520069 Rigid Strain Relief 15 BE1983 Rear Cone Nut Repair Kit includes jacket clamp conduit clamp cone nut end fitting nippl...

Page 28: ...liner Disconnect gun cable assembly at the Euro adaptor Remove nozzle 1 and head 3 Withdraw old liner from the wirefeeder end Insert new liner and refit gun cable assembly to the wirefeeder At the gun end compress the liner within the gun cable then cut it one contact tip length past the end of the body tube 5 Refit head tip and nozzle Fig 17 Replacing the gun cable liner Cut Here Compress Liner ...

Page 29: ...Clamp 1 2 8m Composite Cable Interconnecting Lead 1 Includes 2 1 CABW25COMP Composite Cable with 25mm2 Weld Flex 1 2 2 WGEC4 Plug 1 2 3 WG62513 Gas Hose 5mm 1 2 4 AM283 1 Control Plug 1 2 5 WGAC23 5 8 UNF Gas Nut and Tail 1 Fig 18 Interconnecting Lead Kit 1 1 1 1 3 2 1 2 3 2 11 5 Assembly and Parts List Composite Cable Interconnecting Lead Kit 1 2 2 2 2 4 2 5 ...

Page 30: ... the equipment WIA PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at WIA s option 1 repair or WIA Gold Shield 3 Year Warranty Effective 1st March 2005 At WIA we are serious about product quality Ever...

Page 31: ... costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL WIA BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTEE OR REPRESENTATI...

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