WELDING INDUSTRIES Synchro-Pulse CDT 450 CP38-3 Owner'S Manual Download

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Summary of Contents for Synchro-Pulse CDT 450 CP38-3

Page 1: ...ce and international Sales 5 Allan Street Melrose Park South Australia 5039 Telephone 08 82766494Facsimile 08 82766327 www weldingindustries com au info weldingindustries com au l l i OWNERS MANUAL SYNCHRO PULSE CDT450 MODEL NO CP38 3 REV G 11 oo QUALITY WELDINGPRODUCTS SYSTEMSAND SERVICE 85 I f 2 ...

Page 2: ...MAW 8 4 Cable and Hose Connections GTAW 9 5 Typical Arc Current Waveform 17 6 Functional Block Diagram 18 7 Transistor DriverAssembly CP38 31 22 8 Descriptive and CurrentSignal 29 9 Welding CPU Board CP38 10 30 10 Display CPU Board CP38 11 32 11 Transistor Driver Board CP38 12 33 12 Background Driver Board CP38 13 34 13 Wire Gas Board CP38 16 35 14 Control FuseAssembly CP38 17 36 15 CDT 450Circuit...

Page 3: ...istinct values The lower level is referred to as the Background Current and the higher level as the Pulse Current Under the influence of this pulsed current the transfer of metal within the arc is ideally in the formof a single droplet approximately the diameter of the electrode wire which is transferred during the low energy period following each pulse PULSED GMAW is a full spray transfer process...

Page 4: ...OLTAGE 380 415 440 Volts A C EFFECTIVE PRIMARY CURRENT 25 Amps at 415 Volts MAXUMUM PRIMARY CURRENT 36 Amps at 415 Volts Three Phase 50 Hz OPEN CIRCUIT VOLTAGE 70 Volts WELDING CURRENT RANGE 35 450Amps RATED OUTPUT Note 1 350 Amps 100 Duty cycle CIRCUIT BREAKER RATING 32 Amps FITTED SUPPLY CABLE 56 0 30 Four Core Heavy Duty PVC 450 Amps 60 Duty cycle WIRE SIZE RANGE 0 6mm 2 4mm diameter WIRE SPEED...

Page 5: ... yellow must be securely attached to the marked Earth stud The three supply phases are terminated at the Main Contactor Removethecontactordustcovertogainaccess to the connectionpoints Ensure thatthe internal Brown and Blue loom wires remain connected to the live side of the contactor Tighten the cable clamp leaving sufficient slack in the cable such thatthe terminated wires are not in tension SUPP...

Page 6: ...t the Work Clamp to the welding bench or work piece and attachthe FITTING THE ELECTRODE WIRE Place the spool of electrodewireontothespoolholder Thelocationpinshould mate with a hole in the wire spool body Fit the spool retaining R clip supplied Check the adjustment of the spool brake which shouldbe set to prevent over run of the wire spool at the end of a weld without unduly loading the wirefeed m...

Page 7: ... Lx SOCKET WIRE FEEDER W35 0 E L GUN PLUG WELDING SOCKET GUN 2 TWO 3 RED J S t 3 t THREE 4 7BLACK 4 FOUR i r BLACK 5 t FIVE GREY VOLTAGESENSE 6 SIX 6 7 t SEVEN 7 8 t GREEN YELLOW d 8 SPARE I t ONE B L A C K W F MOTOR 3 PIN 3 CORE PLUG m REMOTE CONTROL PENDANT 2 t BROWN CURRENT 1 t BLUE ARC LENGTH 3 t GREEN COMMON 1 CURRENT ARC LENGTH FIGURE2 CABLE AND HOSE CONNECTIONS GMAW AND PULSED GMAW ...

Page 8: ...lectrode positive A smooth running electrode with a soft arc particularly suited to light sheetmetal and smooth mitrefillet welds Preferred polarity electrode positive A low hydrogen electrode with good arc stability and out of position welding characteristics This electrodeis ideal for medium carbon steels or steels of unknown analysis Operate electrode positive A high tensile 770 MPa high chromi...

Page 9: ... l 2 Thoriated Thistypewill providethebestarcinitiation arcstabilityand tip shaperetentioncharacteristics Thoriated electrodes can be recognised by a red coded end The tungsten electrode is groundto a point with the grinding marks pointing towards the tip For welding currents less than 20 amps the included angle of the point should be 30 for currents greater than 20 amps therecommendedangle is 60 ...

Page 10: ...estimated welding current Actual weld current and voltage during welding Average weld current and voltage during the last weld Advice of any detected fault condition Whenthemachine is firstenergised thescreenbrieflydisplaysthe WIA logo duringwhichtimethemicroprocessorcircuitsareperformingself testroutines When thesecheckshavebeencompleted andprovidedthatnofaultconditionsexist the screenwilldisplay...

Page 11: ...ER 1 2rnrn STRINLESS 318 A5 9 ER318 8 9mrn STAINLESS 312 A5 9 ER312 0 9mrn STAINLESS 316LSiBHP 3CR12 plutle I I Section 14 of this manual lists all of the Pulsed GMAW weld schedules currently available in the CDT library together with their individual schedule numbers In addition tothemethoddescribedabove weldschedules mayalsobeselecteddirectlyby number This feature is available as the last item i...

Page 12: ...llowing facilities INFORMATION Display of Current and Voltage data relating to the last weld performed The figures are averages taken over the last one second of the weld excluding Crater fill and Burn back periods Press any key to exit from this display FAULT To assist with fault finding selection of this option will re display the last fault message Press any key or the gun switch to exit from t...

Page 13: ... conditions CONSTANT CURRENT MODES MMAW AND GTAW CURRENT This control sets the output welding current directly within the range of the selected Constant Current schedule The estimated welding current is displayed when the machine is in the Ready condition ARC LENGTH Arc length controlis not appropriate to MMAW and GTAW which are both Constant Current welding processes When these schedules are sele...

Page 14: ...of the remote Current control During welding the screen displays information similar to that shown below The actual arc voltage and current is displayed both as a digital number and in bar graph form L 8 9 AUSTMIG 316LSi 135 9 ER316LSi 24 V 0 l I 1 S 1 1 1 1 1 1 1 10 20 30 40 50 75 fi B 1 8 8 288 3aa 488 588 I n l 1 1 1 1 1 1 s 1 l I WELD END If a non zero value of Crater fill has been selected th...

Page 15: ...oided it may be necessary toincreasethisrateand ortoprovidescreeningoftheworkarea Holdingdownthe PURGE key willdisplayarecommendedminimumgasflowratefortheselected schedule If weld porosity occurs Remove spatter build up from inside the gun nozzle Check for fraying of the internal nozzle insulator and replace the nozzle if necessary w Check that the gas hoses have not become cracked or frayed and t...

Page 16: ...ing gas and may affect the chemical composition of the weld It is normally a requirementto clean the surface with a suitable solvent or by linishing or grinding ARC BLOW Arc blow occurs when a magneticfield distorts or extinguishes the welding arc The magnetic field is usually the result of welding current passing through the object being welded or through adjacent steel clamp bars This is most of...

Page 17: ...50 suppliestothe l Current pulsesof controlled amplitude time duration and frequency 2 Controlled amplitude background current Typical value ranges for these parameters are welding arc a DC current comprising two distinct elements These are Pulse current peak 200 600 amps w Pulse width 2 5 mS Pulse frequency 30 400 Hz Background current 12 75 amps average WINDOW UPPER 1 1 I WINDOW LOWER I CURRENTP...

Page 18: ...rtransistors mounted on a fan cooled monolithic heatsink The background switch is a bank of three Mosfet transistors The basic D C welding current is the rectified and filtered output of a three phase welding transformer Central to the CDT 450 is a microprocessor based control circuit CP38 10 This circuittakesinputfromthepressbuttonkeypadandremotecontrolpendant plus current and voltage feedback fr...

Page 19: ...en selected This feature may be used to assist detection of intermittentfaults TheScheduleandOptionmenusmay still beaccessedwhena fault exists but the machine will not permit welding Diagrams forall circuits and printed circuit boards referred to maybe found in the next section of this manual Fault No Fault Message Page 1 Display CPU Memory Problem 19 3 Output Terminals Live 20 6 Supply Phase Fail...

Page 20: ...er to Section 12 o f this manual forfitting Replace the complete Welding CPU board CP38 10 Refer to Section 12of Replace the Display CPU Board CP38 11 OUTPUT TERMINALSLIVE IftheCDT 450 detectsvoltageacrosstheoutputterminalsatatimewhenthe machine is not being instructed to weld failure of internal components is presumed and so the machine defaults to a safe condition by de energising the welding tr...

Page 21: ...RIVER POWER This fault message results from failure of any of the three onboard power supplies of the Transistor Driver Board CP38 12 and is signalled on the status line ERR TS These are 1OVDC high current and 1QV DC control supplied from the three phase welding transformer auxiliary windings and 1OV DC supplied from a control transformer winding via the Control Fuse Assembly CP38 17 Check to esta...

Page 22: ...ee phase rectifier This voltage is supplied from auxiliary windings of the welding transformer and should be available whenever the machine is energised Test both external diode bridges d FROM MAIN WELDIF TRANSFORMER AUXILLIARY dG FIGURE 7 TRANSISTOR DRIVER ASSEMBLY CP38 31 ...

Page 23: ...1SUPPLY LOW ThesefaultmessagesresultfromtheCP38 12boarddetectingtheelectrical supply voltage outside of an acceptable range High voltage is signalled on status line ERR VH and low voltageon ERR VL The acceptable rangeis IO of the setting of the welding transformer primary voltage selector fitted inspect theloomwiring to these points Check the selected welding transformer primary voltage For Austra...

Page 24: ...unt connected the machine has no ability to regulate arc current Has the machine been used in excess of its ratings If so modify the pattern of use Is a non standard schedule i e from the Download menu in use Ifso the weld Ensure correct termination of the red and black twisted pair of shunt wires Did the welding current and arc length become uncontrolled at the time of failure If yes itis possibl...

Page 25: ...Constant Current mode is selected as arc voftage detection is not required switch relay whichis part of theWireiGas Board CP38 16 also will not operate Check that the wirefeeder control cable is correctly inserted into the CDT Check that the positive welding lead is correctly inserted into the positive GMAW Inspect the wirefeeder to ensure that the grey arc voltage sensing wire is not Inspect the ...

Page 26: ...he Display is completely blue showing no white characters a problem with the display screen biasing is indicated This may be due to incorrect setting of the Display Contrast adjustment or to failure of the 15V DC power supply of the Display CPU Board CP38 11 Note the present setting of the Display Contrast potentiometer Adjust the potentiometer however if this does not correct the fault return it ...

Page 27: ...elding work piece This wire will act as a temporary load resistor for the CDT 450 Set the Current control to 0 0 then select OPTION SERVICE BACKGROUND Close the gun switch Approximately 15 Amps should now be flowing in the welding circuit andbe indicated on the display screen Increasing the setting of the Current control should increase the output current up to a maximum of 30 Amps If the above oc...

Page 28: ...F7 on CP38 17 LED 4 is referred to as the Beacon ItflashestoindicatethattheCP38 IO microprocessor circuitis functioning correctly If LED 4 is either onor off continuously or flashing erratically a fault involving the microprocessor is indicated LED 5 is lit to indicate continuity of the remote pendant Current circuit LED 6 is lit to indicate continuity of the remote pendant Arc Length circuit TEST...

Page 29: ...sure thatall of the device pins are engagedin the socket Lift up the orange coloured tags on both ends of the socket then remove the w Press down both orange tags which will click into position locking the Eprom into the socket SHUNT AMPLIFIER NULL ADJUSTMENT This procedure must be carried out any time the CP38 10 board is replaced The Shunt Amplifier circuit of the CP38 IO board incorporates a nu...

Page 30: ...Page 30 SYNCHRO PULSE CDT 450MANUAL 8V I N IN SPEED S I G 0 12 15V DC ALL 12mA OK EXTERNAL FAULT INPUT BYPASSED 12V AC VIA THERMOSTATS TO SOLID STATE RELAY FIGURE 9 WELDING CPU BOARD CP38 IO ...

Page 31: ... contrast should not require routine adjustment as variation of contrast due to temperature change is electronically compensated for EPROM Theoperatingcodeforthemicroprocessorandthelibraryofweldschedules is stored in a memory device called an Eprom Erasable Programmable Read Only Memory The Epromfor the CP38 l lboard is fitted toa socket which allows the device to be changed This may be required t...

Page 32: ... m n z m CIQ A 0 wm 2 OQ U x A z 0 g CL W v r c k c n a n 6 AI Q0 I 7 E l 1 5 z U 0 F 2 c l n l v a U lCVo Z Y B 4 s C V 5r 5 m 5 3 W O a L U 7 0 U Ho0 g x rg o o a o o 0 0 I_ o m I S Q v n a L O t l Y FIGURE IO DISPLAY CPU BOARDCP38 11 ...

Page 33: ...ischarge of the main transistors via the driver transistors w 8V AC via fuse F1 of the Control Fuse Assembly CP38 17 This is rectified on The board includes means for detecting four separate fault conditions Failure of an on board power supply w Mains Supply phase failure Mains Supply high Mains Supplylow If a fault is detected on board hardware prevents further operation of the transistors andsig...

Page 34: ...hibits further operation of the background transistors and signals the fault to the Welding CPU Board CP38 IO The fault status line labelled ERR BG in circuits is a failsafe current loop ie current flow OK Transistors H I and H2 are directly connected to the Background Transistors and are likely tobe damaged should these fail If this occurs replace the entire Background Switch assembly CP38 32 1 0...

Page 35: ...he wirefeed motor speed becorrectlycalibrated Thismustbecarriedoutanytimethe CP38 16 board or the wirefeed motoris replaced To check and adjust the wirefeed motor speed Disengage the wirefeed drive mechanism At the keypad select OPTION SERVICE WIREFEED MAX Using an accurate tachometer monitor the speed of the wirefeed drive rolls Adjust RV1 as required to obtain126 rpm Press any key or the gun swi...

Page 36: ...VERSING RELAY FROM CONTROL TRANSFORMER I 8V AC I NAC I NAC I NAC 12V AC 15V AC 8V AC DRIVER CP38 13 8V AC TO TRANSISTOR DRIVER CP38 12 I I sua 1 CPU N 7 CPU I N 6 CPU 15V 5 SHUNT AMP W 4 GUN CIRCUIT 3 BACKGROUND CIRCUIT 2 TRANSISTOR CIRCUIT I FIGURE 14 CONTROL FUSE ASSEMBLY CP38 17 l I ...

Page 37: ...CP38 64 1 Busbar Horizontal 30 2 CP38 64 2 Busbar Vertical 31 CP38 81 BusbarTa Inductance 32 CP38 82 Busbar Ind uctance 33 CP38 83 Busbar Shunt 34 CP38 65 ResistorAssembly 35 CP38 0 5 Control Transformer 36 CP38 016 Contactor Transformer 37 CP38 67 Spacer 38 CP38 68 Llfting Rod 39 M08029F Eyenut 1 2 44 AM16 5 Output Socket Assembly 45 AMl6 0 Output Socket Assembly Including 46 CP34 0 28 Gas Valve ...

Page 38: ... 40 SYNCHRO PULSE CDT 450 MANUAL AIR U LEFT VIEW BACKGROUND ASSEMBLY n USE DOW CORNING HEATSINK COMPOUND No 340 BETWEEN ALL SURFACES WHERE THERMAL CONTACT IS REQUIRED FiGURE 17 MAIN SWiTCH ASSEMBLY CP38 21 ...

Page 39: ...m cover 6 CP38 21 9 Busbar Emitter 7 CP38 21 10 Busbar Bo 8 CP38 21 11 Busbar B 9 CP38 21 12 Connecting Link 10 CP38 21 4 Side Insulation 11 CP38 21 16 Transistor 12 CP38 21 l 4 Fast Diode 12 1 CP38 21 15 Diode Clamp 13 CP3 918 Thermostat 95 C 14 CP38 31 Transistor Driver Assembly 15 CP38 32 Background Assembly 16 CP38 21 13 Insulating Spacer Top 17 CP38 21 17 Insulating Spacer Bottom 18 CP38 21 1...

Page 40: ...metal Panel 2 CP38 50 1 Printed Membrane 3 CP38 50 Clear Window 4 CP38 50 7 LCD Display Assembly 5 CP38 18 Press Button PCBAssembly 6 CP38 11 Display CPU Assembly 7 CP38 50 4 Spacer 11mm 8 CP38 50 5 Spacer 6 4rnm 9 CP38 50 6 Nut 8mm 10 CP38 50 8 Rocker Switch U t I FIGURE 18 KEYPAD ASSEMBLYCP38 50 ...

Page 41: ...Capacitor 7 CP38 53 Fan Mounting Bracket 8 CP38 5115 Fan Motor 9 CP38 51 6 Fan Blade 10 CP38 5113 Terminal stud 11 MC11 322 Nylon InsulatingBush 12 W11 13 Insulator 13 CP38 51 4 Support Spacer NOTE 1 USE DOW CORNING HEATSINK COMPOUND N0 340 BETWEEN ALL SURFACES WHERE THERMAL CONTACT IS REQUIRED 2 TORQUE DIODE NUTS TO 30Nm 3 WHEN FITTING FAN BLADE ENSURE BLADES ARE WELL CLEAR OF DIODES FIT WHER FIG...

Page 42: ...ic Dust Flap 5 W24 2 Wirefeed Motor andDrive Assembly Including 5 1 W17 01 6 Wirefeed Motor 5 2 W2 44 Two Roll DriveAssembly 5 3 W2 20 Fiat Drive Roller 5 4 W2 22 Grooved DriveRoller 5 5 W2 44 12 1 Input Wire Guide 6 K34 Cannon Socket 9 TC262 Gas Inlet 10 TC262N Nut 19 W24 0 6 EZ Quick Connect Assembly 20 W2 44 20 Small I D Guide Tube 21 W2 44 19 Adaptor Il FIGURE 20 WIREFEEDER ASSEMBLY W35 0 ...

Page 43: ...ven Gear Wheel 19 SO305029 8 32 UNC Skt Hd Screwx long 20 W2 l6 I Driving Gear Wheel 21 SSNM36Z M3 Pan Hd Screwx 6 long 22 SSKM515U M5 Skt Hd Screwx 15 long 23 SSKM612U M6 Skt Hd Screwx 12 long 24 SSSM612U M6 Csk Skt Hd Screwx 12 long 28 W2 44 22 M24 x 1P Brass Locknut 31 SSKM815U M8 Skt Hd Screw x l 5 long 33 W2 4415 Insulating Ring 34 W2 44 21 Flat Washer 6 WSE5 Z 5 Dia ShakeproofWasher 9 JW418 ...

Page 44: ...51 w2 51 W2 44 12 1 1 6 w2 24 w2 24 1 W2 44112 2 2 0 2 4 w2 25 w2 25 W2 26 W2 44 12 3 3 2 W2 26 w2 27 _____I w2 27 W2 28 W2 44 12 4 4 0 5 0 W2 28 60 V ROLLER POUBLE GROOVE I NYLON FLAT ROLLER l 2 w2 20 w2 54 I W2 44 12 1N 1 6 w2 20 w2 54 I W2 44 12 2N PLAIN V ROLLER W2 22 PLAIN V ROLLER 1 6 W2 22 W2 44 12 3N w2 23 W2 44 12 2N 2 4 w2 23 FLAT ROLLER OPEN U ROLLER 0 9 w2 48 W2 49 w2 49 W2 44 12 1N 1 ...

Page 45: ...nect body H BE4911 Snap ring Large I BE4916 Wave Spring ITEM PART DESCRIPTION J BE4912 Snap Ring Small K1 BE4907 0 Ring K2 BE4906 Gas Pin Liners BE441 15 0 9 1 2mm BE44215 1 2 1 6mm BE44315 2 0mm BE431 15X 0 9 1 2mm Nylon BE44215X 1 2 1 6mm Nylon Nozzles BE4491 Brass 19mm BE4492 Tapered 13mm BE4591 Copper 19mm Contact Tips BE7497 0 6mm BE7488 0 8mm BE7489 0 9mm BE7496 1 Omm BE7490 1 2mm BE7498 1 3...

Page 46: ...31 Crimp Lug 5 AM145 3 1 Cannon Cord Plug 8 pin Male 6 CAB8C32 8 Core Control Cable 7 AM145 3 2 Cannon CordPlug 8 pin Female 8 HOSSR Gas Hose 5mm ID 9 TC362 Gas Hose Tail l 0 TC362N Hose Tail Nut 12 OCL13 0 Clip 11 OR1 0 6 Rubber 0 Ring l 1 I 0 Y WORK LEA r 2 L g q p WELDING LE D j WIRE FEEDER CONTROL 7 F y i c GASHOSE g z u GAS HOSE FROM CYLINDER FIGURE 24 AM223 ACCESSORY LEADKIT ...

Page 47: ...w AlloySteel Argon 5 C02 CG05 AR40 AR L l44 1 2mm Linde 95 Argon 5 C02 CG05 AR40 AR L l45 l 6mm Linde 95 Argon 5 C02 CG05 AR40 AR L 320 0 9mm Linde 120 Argon 5 C02 CG05 AR40 AR L 321 1 2mm Linde 120 Argon 5 C02 CG05 AR40 AR L 270 0 9mm Linde 120 Argon 2 0 2 AR60 S1 271 1 2mm Linde 120 Argon 2 0 2 AR60 S1 l43 1 6mm Linde 140 Argon 5 0 2 CG05 AR40 AR L I STAINLESS STEELS SCHED DIAM MATERIAL GAS COMP...

Page 48: ...Argon 2 0 2 AR60 51 239 0 9mm Stainless 347 Argon 1 5 0 2 AR60 S I 282 0 9mm Stainless 347 Argon 30 He 5 C02 AR61 54 283 1 2mm Stainless 347 Argon 30 He 5 C02 AR61 54 l24 1 2mm Cronifer 1925hMo Argon high purity Ar HP 240 1 2mm Stainless 1707 Argon l 5 0 2 AR60 51 SANDVIK 22 8 3L Argon 30 He 5 C02 AR61 54 SANDVIK 22 8 3L Argon 30 He 5 C02 AR61 54 SANDVIK 22 8 3L Argon 30 He 5 C02 AR61 54 SANDVIK 2...

Page 49: ...ATERIAL GAS COMPOSITION GAS NAMES 212 0 9mm De ox Copper Argon 75 He AR81T MS TCA 261 1 2mm De ox Copper Argon 75 He AR81T MS TCA 307 1 2mm De ox Copper Extended Argon 75 He AR81T MS TCA 213 1 2mm De ox Copper Argon 27 He AR80T MS TCB 302 1 6mm HulfteggerSG CuSn Argon 75 He AR81T MS TCA 306 1 6mm HulfteggerSG CuSn Helium 100 HEL l01 1 6mm Aluminium Bronze AI Argon Ar l02 1 2mm AluminiumlBronzeA2 A...

Page 50: ...02 MI CG18 AR51 l39 1 6mm Fluxodur 1855 Argon l 5 0 2 AR60 S I 228 1 2mm Metalcor XP Argon l8 C02 MI CG18 AR51 280 1 2mm Outershield 71M Lincoln Argon 16 C02 2 5 0 2 AR51 CG2 281 1 6mm Outershield 71M Lincoln Argon l6 C02 2 5 0 2 AR51 CG2 246 1 2mm O Shield MC 710 Lincoln Argon 18 C02 MI CG18 AR51 269 1 6mm O Shield MC 710 Lincoln Argon 16 C02 2 5 0 2 AR51 CG2 296 1 6mm O Shield MC 710 Lincoln Arg...

Page 51: ...82 Argon 27 He AR80T MS TCB on MONEL 600 Argon 27 He AR80T MS TCB on MONEL 600 Argon 30 He 5 C02 AR61 S4 l64 l 2mm Nirod44 Argon 7 0 2 M4 CG07 l65 1 6mm Nirod44 Argon 7 0 2 M4 CG07 l68 1 2mm Sanicro 72 Argon high purity Ar HP CONSTANT CURRENTMODE 205 CC Mode 10 30A 204 CC Mode 25 300A 203 CC Mode 250 450A G M A W MODE 208 0 9mm CARBON STEEL GMAW DIP 209 1 2mm CARBON STEEL GMAW DIP l76 1 2mm Sanicr...

Page 52: ...m itisnecessary to ensure that the wirefeed rate of thepull motor slightly leads that of the push motor In this way the consumable wire within the cable assembly is heldin tension so reducing drag on the wire Two speedadjustmentpotentiometers marked in and Max arepartofthe CP38 16 board and protrude through the AM217 1 transistor heatsink assembly These are adjusted by the following method to obta...

Page 53: ...IRE 4 EURO GUN q SWITCH SOCKET 8 CORE 8 PIN PLUG w35 4 10 PIN PLUG HT24 1 FLEX SOCKET WIRE FEEDER SOCKET PULL GUN GREEN BLACK RED RED G S h h F RED BLACK 5 BLACK 0 PUSHMOTOR WHlTE y GREY VOLTAGESENSE BLUE y WHITE BROWN T ORANGE g zQ BLUE WHITE SPARE CURRENT GREEN YELLOW BLACK 3 CORE 3 PIN PLUG FLEX soc ET r c LHS BROWN CURRENT p ARC BLUE ARC LENGTH 43 RH9 GREEN COMMON 8 LENGTH FIGURE 25 CABLE AND ...

Page 54: ...ess Connector 11 HT100 102 Press NippleLow Pressure 12 HT300 730 Armoured Hose Connector 13 HT400 0101 Protective Sleeve 14 HT1 00 735 Hose Clip 16 HT300 834 Power Cable Assembly 8 metre 17 HT300 837 Armoured Hose Assembly 8 metre ACCESSORY LEADKIT AM223 9 ITEM PART DESCRIPTION 1 AM230 0 1 Cannon Cord Socket 3 pin Female 2 TC490 1 Cannon Cord Plug 3 pin Male 3 CAB3C24SP 3 Core FlexibleCable Note T...

Page 55: ...SYNCHRO PULSECDT450 MANUAL Page57 I r 27 1 24 7 26 3 36 b FIGURE 27 HULKEGGER GUN EXPLODED VIEW ...

Page 56: ...ip 14 HT300 757 Pin Screw M3x14 15 HT300 750 Pin Screw M4x18 16 HT300 769 Pressure Spring 17 HT300 053 Screw for Pressure Adjuster 18 HT300 461 3 Motor and Gearbox 19 HT300 064 Drive Key 20 HT300 059 Knurled Drive Roller 21 HT300 060 Drive Shaft Nut 22 HT300 758 Cylindrical Screw M4x6 23 HT24 1 l Potentiometer 1k6 24 HT300 717 Plastic Body Upper 25 HT300 719 Protective Sleeve 26 HT300 711 Potentio...

Page 57: ...p 5 BE4635 1 16 Head Assembly 6 BE4492 Nozzle assembly 7 BE1590 Contact Tip 1 2mm 8 HT310 077 Wire Guide m g h HT24 l2 CURVED TORCH NECK ITEM PART DESCRIPTION 1 11 1 Neck Adaptor 2 BE4780 Insulator 3 HT24 12 1 Curved Body 4 BE4423 Insulatingcap 5 BE4635 116 Head Assembly 6 BE4492 Nozzle assembly 7 BE1590 Contact Tip 1 2mm 8 HT300 806 Wire Guide v FIGURE 28 TORCH NECK ASSEMBLIES ...

Page 58: ...7 01 6 Wirefeed Motor 5 2 W2 44 Two Roll Drive Assembly 5 3 W2 49 Flat Drive Roller Chromed 5 4 W2 48 Grooved Drive Roller Chromed 5 5 W2 44 12 1N InputWire Guide Nylon 6 K34 Cannon Socket 8 Pin 9 TC262 Gas Inlet 10 TC262N Nut 19 K57 Cannon Socket 10 Pin MS 20 AM217 1 Transistor Heatsink Assembly 21 W35 4 1 Cannon socket 3 Pin Male 22 TC396 5 Euro Gun Adaptor Fittedto CP38 16 Wirefeed board TRANSI...

Page 59: ...aces and bumtheskin and eyes Bums resulting from gas shielded arcs resemble acutesunbum but can bemore severe and painful Wear protective clothing leather or heat resistant gloves hat and safety toe boots Button shirt collar and pocket flaps and wear cufflesstrousersto avoidentry of sparks and slag Avoid oilyor greasy clothing A spark mayignite them Hot metal such as electrode stubs and work piece...

Page 60: ...g building construction arewithin 10 metres w Combustiblesare further than 10metres but can be ignited by sparks Openings concealedor visible in floorsor walls within 10metres may exposecombustiblesto sparks Combustiblesadjacent to walls ceilings roofs or metal partitionscan be ignited by radiantor After work is done checkthat area is freeof sparks glowing embers and flames conducted heat A tank o...

Page 61: ... I bo1 1 ora r _ 1 I I I i i 1 OXTACTOR 2 i _I Q3maccna I _ vi0 I 1j I FRCNTPAML DISPLAYASSEMBLY l I I 1 1 1 1 1 1 1 1 I I I I 1 I I 1 1 I I 1 1 I I l I L l I l I I l l l 1 I l I I L _ 0L TRANSFORMER S E R N v0 WUMNG CPU BOARD m 7 ora cc 1 _ ___ l PJ SCJMIGhWDE L WSITIVE NEGATIVE FIGURE 15 CDT 450 CIRCUIT DIAGRAM ...

Page 62: ... Page 38 q 3 p p LEFT VIEW I I I I I I v I l F T ACK VIEW 0 I L I L U j 3 J B I I 3 v FIGURE 16 CDT 450 POWERSOURCEASSEMBLY CP38 3 ...

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