WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ACN l1 l. Head Office and International Sales

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1 ~ ~ ~ ~ ELDNG NDUSTRES OF AUSTRALA A DVSON OF ELDNG NDUSTRES LTD ACN Head Office and nternationa Saes 5 Aan Street, Merose Park South Austraia, 539 Teephone (8) Facsiie (8) info@wedingindustries.co.au ONERS MANUAL ELDMATC 255s MODEL NO. CP17-, REV. A TH 42- REFEEDER 9/2 QUALTY ELDNG PRODUCTS, SYSTEMS AND SERVCE 8 t?!/[ 7

2 ~ Page 2 ELDMATC 255s MANUAL The inforation contained in this anua is set out to enabe you to propery aintain your new equipent and ensure that you obtain axiu operating efficiency. Peaseensure that this inforation is kept in asafepace for ready reference when required at any future tie. hen requesting spare parts. pease quote the ode and seria nuber of the achine and part nuber of the ite required. A reevant nubers are shown in ists contained in this anua. Faiure to suppy this inforation ay resut in unnecessary deays in suppying the correct parts. SAFETY Before this equipent is put into operation, the Safe Practices section at the back of the anuaust be read copetey. This wi hep to avoidpossibeinjuryduetoisuseor iproper weding appications. PLASTC HANDLE Pease note that the hande fitted to the ELDMATC 42- REFEEDER is intended for carrying the achine by hand ony. DO NOT use this hande for suspending or ounting the achine in any other anner. CONTENTS Sec ntroduction... P.3 Sec.2... Recevg..... P.3 Sec.3... Specifications... P.4 Sec.4... Contro Locations. Power Source and irefeeder... P.5 Sec.5... nstaation... P.6 Sec.6... Nora eding Sequence... P.9 Sec.7... Basic eding nforation... Sec.8... Genera Maintenance... P.1 P. 12 Sec.9... Troube Shooting... P.13 Sec Service nforation. Power Source... P. 15 Sec.... Parts List. Power Source... P. 16 Sec Service nforation. irefeeder... P. 19 Sec Parts List. irefeeder... P.2 Sec Safe Practices... P.26 FGURES Fig Contro Locations. Power Source and irefeeder... P.5 Fig2... Connection of Suppy Cabe... Fig.3... Reote irefeeder Connections... P.6 P.7 Fig.4... Positive wire Connection... P.8 Fig.5... Negative ire Connection... P.8 P Fig.6... "Good" ed... P.11 Fig.7 ed... "Bad" Fig.8... Gun Poston..... P. 11 Fig.9... Soid State Reay Contro Board... P. 15 Fig.1... Power Source Asseby... P.17 Fig CP17- Circuit Diagra... P. 18 Fig irefeed Contro Board... P. 19 Fig irefeeder Asseby... P.21 Fig Circuit Diagra (ith Lead Kit)... Fig Gun Cabe Asseby... P.22 P.23 Fig ire Drive Asseby... P24 Fig.7... AM283 nter-connecting Lead Kit... P.25

3 ~ ELDMATC 255s MANUAL Page 3-1. NTRODUCTON Gas Meta Arc eding (G.M.A..) is a weding process where a consuabe wire is fed by otor driven drive roers to a weding gun, and where weding current is suppied fro the weding power source. The weding arc is struck between the work piece and the end of the wire, which ets into the wed poo. The arc and the wed poo are shieded by gas fow fro the gun, or in the case of "sef shieded" wires, by gases generated by the wire core. By seection of the correct wire coposition, diaeter and shieding gas, G.M.A.. can be used for appications ranging fro sheeteta to heavy pate, and etas ranging fro carbon stee to auiniu aoys. The ELDMATC 255s has been designed to be used with consuabe wires in the range fro.6 to 1.2 diaeter. The saer wire sizes are used when weding at ower currents, such as sheet-eta appications. ncreasing the wire diaeter perits higher weding currents to be seected. A coon appication of G.M.A.. is for weding Mid Stee. n this appication, a Mid Stee soid consuabe such as AUSTMG ES6 is used with a shieding gas of Argon ixed with 5-25% Carbon Dioxide. Aternativey, Fux-cored consuabes are avaiabe in both gas shieded, and 'gasess' sef shieding types. Stainess stee and Auiniu can be weded with G.M.A.. using the correct consuabe wire and shieding gas. 2. RECEVNG Check the equipent received against the shipping invoice to ake sure the shipent is copete and undaaged. f any daage has occurred in transit, pease iediatey notify your suppier. The CP17- package contains; ELDMATC 255s Power source. 42- Encosed irefeeder (with Contros). AM283-/8 nter-connecting Lead Kit, 8 etre. BEXT2-4E31AE BERNARD Gun cabe, 3 etre, Euro connector. GAC24 Reguator and Fowgauge. (Argon) (This) Owners Manua.

4 Paae 4 Y ELDMATC 255s MANUAL 3. SPECFCATONS Manufactured to Austraian standard AS Rated to SOAEC (O inute duty cyce) ELDNG NDUSTRES of AUSTRALA edatic 255s Made in Austraia 1- - RATED TO SOAEC N83 7N3R Under SO/EC , duty cyce is defined as the ratio of arcing tie to an operating tie of 1 inutes, expressed as a percentage. Note.Theachinehasbeenshippedwith a 15 Appug fittedto aow initia coissioning ony. To obtain rated output current fro the ELDMATC 255S, the 25 Ap fexibe suppy cabe ust be fitted with a 3 pin pug that is rated for at east 25 Ap, and connected to a correcty instaed power outet of at east 25 Ap.

5 ELDMATC 255s MANUAL Page 5 4. CONTROL LOCATONS. POER SOURCE AND REFEEDER B POER SOURCE REFEEDER ~:., FGURE 1. CONTROL LOCATONS. POER SOURCE AND REFEEDER 1. POER ON NDCATOR This is iuinated when the wirefeeder is energised, that is when eectrica ains power is connected to the weding power source. 2. COARSE VOLTAGE CONTROL This switch provides Coarse adjustent of the Output eding Votage over three ranges, Low, Mediu and High. 3. FNE VOLTAGE CONTROL This contro provides Fine adjustent of the Output eding votage. Rotating the contro in a cockwise direction wi increase the output votage. 4. RE SPEED CONTROL This contro provides adjustent of the wirefeed speed. Rotating the dia in a cockwise direction wi increase the wirefeed speed, thereby increasing the weding current. 5. SPOT TME CONTROL hen operating the achine in Spot ed ode, this contro wi vary the spot wed tie. Rotating the dia in a cockwise direction wi increase the spot wed tie, in the range seconds. f the Spot ed ode is not required this feature ay be turned off by rotating the contro anti-cockwise unti it 'cicks' into the iniu position. 6. NTERVAL CONTROL henoperating the achine in CyceArcode this controsets the period between weds. The spot tie contro sets the weding period. Rotating the dia in a cockwise direction wi increase the interva tie, in the range seconds. f the Cyce Arc ode is not required this feature ay be turned off by rotating both contros fuy anti-cockwise. 7. REFEEDER FUSE This 5 Ap standard action fuse protects the 3Vac irefeeder suppy circuit.

6 Page - 6 ELDMATC 255s MANUAL 5. NSTALLATON CONNECTON TO ELECTRCAL MANS POER SUPPLY NOTE. A eectrica work sha ony be undertaken by a quaified eectrician. D The ELDMATC 2558 is factory fitted with a 3 etre, 3 core, 25 Aps ains power suppy cabe with a ouded 3 pin, 15 Aps, Singe Phase pug. Note : The 15 Ap pug is fitted to aow initia coissioning ony. The iniu capacity of the ains wiring and power outet suppying a weder i seected according to the effective priary current of the achine. The effective priary current for a edatic 255s is 25 Aps. To obtain rated output current fro the ELDMATC 255S, the 25 Ap fexibe suppy cabe ust be fitted with a 3 pin pug that is rated for at east 25 Ap, and connected to a correcty instaed power outet of at east 25 Ap. Note : 25 Aps pugs and sockets are not coerciay avaiabe. A 32 Aps, 3 pin pug is avaiabe fro your A distributor. A Part Nuber for this pug is CL156P332. Theiniurecoendedcircuitbreakerratingforaedatic 255s is 25 Aps. Note : The tripping tie of a typica 25A circuit breaker can iit the duty cyce avaiabe the fro edatic 255s. A higher rated circuit breaker can be seected, but the ains wiring capacity ust be increased to suit. The current rating of the ains cabe depends on cabe size and ethod of instaation. Refer to AS/NZS 38.1, Tabe 9. f it becoes necessary to repace the ains fexibe suppy cabe, use ony cabe with correct current rating. Access to the achine suppy terinas is gained by reoving the power source eft hand side pane. (Power source viewed fro front). Pass the cabe through the bush fitted to the achine back pane. The cabes are terinated at the terina bock as shown in Figure 2. Tighten the cabe cap eaving just sufficient sack in the cabe so that the terinated wires are not in tension. EARTH CONNECTON.LO RE TR \ / 1 k PLASTC BUSH -L BACK PANEL BRO RE 1 L3 CORE POER CABLE TERMNAL BLOCK BLUEEJ i FGURE 2. CONNECTON OF SUPPLY FLEXBLE CABLE FTTNG THE GAS BOTTLE Depending on configuration of the cyinder to be used, the gas foweter! reguator ay be fitted directy to the cyinder, or in conjunction with an ebow fitting. DO NOT appy any grease to these joints, and tighten the nuts securey. Fit the end Q% the gas inet Rose fro the inter-connecting ead kit to the connector suppied with the fow reguator, and secure with the cap aso suppied.

7 ELDMATC 175s MANUAL Paae 7 U 5.3 FTTNG THE GAS BOTTLE Fit the gas reguator to the gas cyinder. DO NOT appy oi or grease to these connections. Fit the gas connector suppied with the reguator to the gas hose of the weder, and secure it with the '' cip suppied. Aways ensure the gas reguator adjusting knob is fuy reeased before opening the gas cyinder vave. Faiure to observe this practice can resut in daage to the reguator. 5.4 FTTNG THE GUN CABLE The gun cabe is attached to the power source via a 'Euro' adaptor which incorporates a required connection points for weding current, shieding gas and gun switch contro. To fithe gun cabe, engage the ating parts of the ae and feae Euro connectors, then rotate the ocking ring cockwise to firy secure the connection. 5.5 FTTNG THE CONSUMABLE RE The quaity of the consuabe wire greaty affects how reiaby a gas eta arc weder wi operate. For best resuts when weding id stee, we recoend quaity A AUSTMG ES6. Dirty, rusty or kinked wire wi not feed soothy through the gun cabe and wi cause erratic weding. Deposits fro the wire wi cog the gun cabe iner requiring it to be repaced preaturey. Pace the spoo of weding wire onto the spoo hoder. The ocation pin shoud ate with a hoe provided on the wire spoo body. Fit the spoo retaining 'R' cip suppied. Check the adjustent of the spoo brake, which shoud be set to prevent over-run of the wire spoo at the end of a wed, without unduy oading the wirefeed otor. The braking can be adjusted by the Nyoc nut using a 15/16" AF or 24 socket wrench. 5.6 FEEDNG THE CONSUMABLE RE Open the two ro drive echanis by drawing the pressure spring outwards, aowing the upper roer asseby to be rotated away fro the driven roer. The end of the weding wire can now be passed through the inet guide, over the botto driven roer, and into the gun cabe asseby. Check that the drive roer groove is correct for the wire in use. The appropriate size is staped on the visibe side of the instaed roer. Part nubers for aternate size drive roers are shown in Section - 1. Check aso that the correct size contact tip is fitted to the gun. Gun part nubers are shown in Section 12. Return the top roer to the cosed position and, with the achine energised, cose the gun switch to feed wire through the gun cabe. Adjust the copression screw to provide just sufficient caping of the drive ros drive to achieve constant wirefeed. Do not over tighten the copression screw, as the consuabe wire can be crushed eading to erratic wirefeed.

8 Page 8 ELDMATC 255s MANUAL OUTPUT VOLTAGE POLARTY. Thedesignof the ELDMATC 255s aowsexternaseection of the output votage poarity. POSTVE RE Most soid wire G.M.A.. is carried out with the work piece Negative and the weding consuabe wire Positive. To set the achine for this condition, insert the ORK ead pug into the (-) output socket on the front of the power source. nsert inter-connecting ELD ead pug into the (+) output socket on the front of the power source. See Figure 4 beow. NEGATVE RE Soe sef-shieded fux cored consuabes are intended to be operated with the work piece Positive and the consurnabe wire..negative. Refer.to the anufacturers data for the particuar consuabe to be used. To set the achine for this condition; insert the. ORK ead pug into the (+) output socket on the front of the power source. nsert inter-connecting ELD ead pug into the (-) output socket on the front of the power source. See Figure 5 beow. L FGURE 4. POSTVE RE CONTROL LEAD FGURE 5. NEGATVE RE

9 ELDMATC 255s MANUAL Page 9 6. NORMAL ELDNG SEQUENCE ELD START Cosing the weding gun switch initiates this sequence of events: ELD END The gas vave is energised, gas fow coences; The power source contactor function is initiated. eding votage is appied between the work piece and the consuabe wire. The wire drive otor is energised. irefeed Coences and the arc is estabished. Reeasing the gunswitch. initiates.this sequence of-events: The wire drive otor is de-energised, and is dynaicay braked to a stop; After a short pre-set period, known as the burn-back tie, the Power-source contactor function is reeased. This period ensures that the consuabe wire does not freeze in the wed poo. To adjust the burn-back tie, refer to Figure/Section 12. The gas vave is de-energised and the fow of shieding gas ceases.

10 ~ Page O ELDMATC 255s MANUAL 7. BASC ELDNG NFORMATON CHOCE OF SHELDNG GAS The choice of shieding gas is argey deterined by Many proprietary shieding gas ixtures are avaiabe. the consuabe wire to be used. The recoended shieding gases for use with the ELDMATC 255s are : Mid Stee... Argon + 5 to 25% Carbon Dioxide; Auiniu... Argon; Stainess Stee... Argon + to 2% Oxygen. Consut your gas suppier if ore specific inforation is required. SHELDNG GAS FLO RATE n G.M.A. weding, one of the functions of the shieding gas is to protect the oten wed poo fro the effects of oxygen in the atosphere. ithout this protection the wed deposit becoes 'honeycobed' in appearance, an effect which is described as wed porosity. n draft-free conditions the gas fow rate required to give adequate protection is typicay 1 itredin. n situations where drafts cannot be avoided, it ay be necessary to increase this rate and/or to provide screening of the work area. ed porosity can aso be caused by air entering the gas strea through a daaged hose, oose gas connection, or.fro restriction in the nozze, such as fro excess buid-up of spatter. ESTABLSHNG A ELD SETTNG Once the consuabe wire type, wire size and shieding gas have been chosen, the two variabes which are adjusted in order to obtain a stabe arc are; irefeed speed, eding arc votage. The wirefeed rate deterines the weding current; increasing the feed rate increases the current, and decreasing it decreases current. The seected wirefeed rate ust be atched with sufficient arc votage; an increase of wirefeed rate requires an increase of arc votage. f the votage is too ow the wire wi stub and stutter, and there wi not be a steady arc. f the votage is too high the arc wi be ong with the eta transfer within the arc occurring as a series of arge dropets. The weding current shoud be chosen to suithe thickness of the eta to be weded. t is iportant to check that the deposited wed provides sufficient strength to suit the appication.

11 ELDMATC 255s MANUAL Page 11 A "good" wed wi have the characteristics iustrated in Figure 6. The wed has penetrated into the parent eta, fusing the root of the joint where the two pates eet, and the wed bends soothy into the side was. A "bad" wed is shown in Figure 7. The wed has not penetrated the joint root, and there is poor side wa fusion. This ack of fusion woud noray be corrected by increasing the arc votage, or by increasing both wirefeed rate and arc votage to achieve a higher current wed setting. si L FGURE 6. "GOOD" ELD FGURE 7. "BAD" ELD GUN POSTON For "down hand" fiet weding, the gun is noray positioned as shown in Figure 8 beow with the nozze end pointing in the direction of trave. v 4 LAF FGURE 8. GUN POSTON

12 Pacte 12 ELDMATC 255s MANUAL DUST Care shoud be taken to prevent excessive buid-up of dust and dirt within the weding power source. t is recoended that at reguar intervas, according to the prevaiing conditions, the achine covers and encosed wirefeeder covers be reoved and any accuuated dust be reoved by the use of dry, ow pressure copressed air, or a vacuu ceaner. REFEED n order to obtain the.t.satisfactory.,:weding -resuts fro the G.M.A.. process, the wirefeed ust be sooth and constant. t is therefore iportant to observe the foowing points; Keep the gun cabe iner cear of dust and swarf buid-up. hen repaceent becoes necessary, fit ony the correct iner to suit the gun cabe ode. See page 23. The buidup of dust in a cabe iner can be iniised by reguar purging of the iner with dry copressed air. This ay be convenienty done each tie the wire spoo is repaced. Repace the weding tip as it becoes worn. Keep the wire drive echanis cean. Periodicay check the drive roers for wear and for free rotation. H Check that the consuabe wire spoo hoder rotates soothy and that the braking action is not excessive. This aso ay be convenienty done each tie the wire is repenished.,

13 ~ ~~ ~~ ~~ ~ ~ ~ ~ ~~ ~ ELDMATC 255s MANUAL Page TROUBLE SHOOTNG Power source has no power 1 Turn on ains suppy switch Check ains votage, fuses or circuit breaker Check a priary connections in power source and in priary pug Power source has no output Check contro ead is pugged to front socket of power source when gun switch is cosed and Check wirefeeder has no power but : 5A wirefeeder fuse on power source. Repace if bown Check a connections to 42-1 circuit board in wirefeeder ) power source fan is running Check contro ead for daage or broken soder joints in the 6 pin pug 2) wirefeeder power ight is off.: Check contro transforer in power source for an input votage of.. Power source has no output when gun switch is cosed but: 24Vac.and an output votage of 32Vac. Repace if fauty Repace 42-1 circuit board in wirefeeder Gun switch circuit incopete. Check gun switch for continuity with Oh eter when switch is pressed. Repace if fauty ) power source fan is running Gun switch circuit incopete. Check the 2 pin receptaces in euro 2) wirefeeder power ight is on adaptor of wirefeeder are aking contact with the 2 pins fro the gun 3) there is no wirefeed cabe. f the pins have been accidentay pushed in, push and fix the Power source has no output when gun switch is cosed but ) power source fan is running 2) wirefeeder power ight is on pins back in pace with gue or Loctite Check the two wires fro wirefeed otor are connected to 42-1 circuit board Repace 42-O circuit board. -. ~~~ ~~ ~~~ ~ Power source overheated. Aow therostats to coo with fan on Check contro ead for daage or broken soder joints in the 6 pin pug After cooing, check rectifier therostat and inductance therostat for open circuit. Repace if fauty 3) there is wirefeed Check a connections to CP17-O circuit board in power source ReDace CP17-O circuit board in Dower source < ~~ ~ ~~ ~ Repace 42-1 circuit board in wirefeeder -. Live output a the tie when Check soid state reay in power source. Switch off ains power and power source is switched on disconnect wires fro terinas 3 & 4 of soid state reay. Switch on and gun switch is off ains power and if output is sti ive, repace soid state reay Repace CP17-O circuit board in power source Repace 42-1 circuit board in wirefeeder Power source has ow wed Check a cabe connections in power source for hot spots. QUtpUt aking Check weding circuit is good eectrica connection irefeeder fuse bows Check contro ead for interna bridging of wires instanty when power source Repace 42-1 circuit board in wirefeeder is switched on Repace CP17-O circuit board in power source irefeeder fuse bows after a period of weding Too uch drive roer pressure on wire. Reduce pressure Check gun iner for buid up of dirt or bockage. Repace if dirty '~

14 ~~~ ~ ~~~ ~ Check that gun iner is notoo short and is fitted correcty. Refer to jpage 23 for fitting instructions. Page 14 - ~~ ELDMATC 255s MANUAL TROUBLE SHOOTNG cont. Mains fuses bow or circuit breaker trips instanty when power source is switched on Check weding transforer for a faut to earth. Repace if fauty Check fan in power source for short circuit or faut to earth. Repace if fauty Check contro transforer for short circuit or fauto earth. Repace if fauty Mains fuses bow or circuit Check weding transforer for shorted turns. Repace if fauty breaker trips instanty when gun switch is cosed Check rectifier for shorted diodes. Repace if fauty Mains fuses bow or circuit breaker trips when weding Check that the recoended fuse or circuit breaker rating has been used UNSATSFACTORY ELDNG PERFORMANCE AND RESULTS caused by poor wirefeed Check if wire is sipping on roer asseby. Repace feed ro if worn Check if there is too uch drive roer pressure on wire Check spoo hoder is rotating soothy Constant poor arc Check correct poarity has been seected for work and wed cabes. characteristics 3 Refer to page 8 Check shieding gas is correct for the consuabe in use Check weding circuit is aking good eectrica connection Check a connections in power source and wirefeeder for hot spots 1 Porosity in wed caused by Check gas soenoid. Repace if fauty ack of shiedin gas Check that the correct gas fow rate has been set 1Check for eaks in gas hose. Repace if eaking Check for eaks in gun cabe, eg. O-rings. Repace if eaking Check nozze is firy attached to gun and that no air is being drawn in

15 ~ ELDMATC 255s MANUAL Page 15 O. SERVCE NFORMATON. POER SOURCE SOLD STATE RELAY CONTROL BOARD CP17-1 The Soid State Reay Contro board and associated Soid State Reay provides the foowing functions, when Power Source is connected to irefeeder. eding transforer ON/OFF contro in response to an output fro the wirefeed contro board, (the contactor function). Output votage contro by eans of Phase-shifting of the eding transforer priary votage, as adjusted by the wirefeeder front pane "FNE VOLTAGE SELECTON" knob. Connectionsito the.board-are:detaied. in the:drawing beow. RECTFER THERMOSTAT CONTROL q F 3v MOUNTNG HOLES SOLD STATE RELAY SOLD STATE RELAY (-V ) (+VE) FNE VOLTAGE () FNE VOLTAGE (C) 1 M #$o ooo@na $ii'q (J(J L.E.D. S LT HEN FNE VOLTAGE POTENTOMETER CRCUT S COMPLETE a (d [ ~ a ~ ~ FGURE 9. SOLD STATE RELAY CONTROL BOARD

16 Page 16 ELDMATC 255s MANUAL 11. PARTS LST ELDMATC 255s POER SOURCE TEM #... PART #... DESCRPTON 1... CP Rectifier Asseby ncudes 1... CP16-/1... Rectifier Asseby with Thera overoad CP Soid State Reay Heatsink Assy (24V) CP17-O... PCB Assy Soid State Reay Contro CP16-/2... Soid State Reay 24V CP17-41/2... Heatsink CP17-41/1... Dust Shied 2... CP17-3L... eding Transforer Asseby inc. ire Loo CP nductance Asseby inc. Overoad 4... CP _... Capacitor Bank ncudes CP Mounting Bracket CP12-12/8... Capacitor (4) CP15-31/2... Capacitor Rai (2) 5... CP16-2/2... Discharge Resistor (4) 6... CP Base Asseby ncudes CP42-24/6... Castor hee (2) 7... CPO 7-22Y... Front Pane 8... CP4 3-21Y... Back Pane 9... CP43-24Y... Side Pane (2) 1... CP16-25Y... Top Pane CP Shef Pane CP42-/3... Rubber Tyre hee (2) MC1 1-53/6... Ratchet Cap (2) MK6/3... Terina Bock, 3 position Fuse Hoder F3AG5A... Fuse 5 Ap Standard Action CP Cooing Fan CP17-/1... Auxiiary Transforer CP Cabe nductor End to Capacitor Neg. Rai 2... CP Cabe Transforer to Rectifier AC CP Cabe Capacitor Pos. Rai to Pos. O/P Terina CPO Cabe Liit nd. Start to Rectifier Neg CP Cabe Capacitor Pos. Rai to Rectifier Pos CP Cabe nductor Start to Neg. O/P Terina CP Busbar Transforer to Rectifier AC /1... Switch Coarse CP Loo Asseby -High Votage (Not Shown) CP Loo Asseby -Low Votage (Not Shown) ncudes CP17-49/1... Socket 6 pin H Cup Terina 3... H asher H Earth Tab H97... Cabe Cap MC1 4-/1... Mae nsuating Bush MC14-/ Feae nsuating Bush CX58... Output Terina Asseby (2) SCG3M... Stee Chain a=ab3c5ohd... 25A 3 Core Fex CL156P A 25V 3 Pin Pug (Not Suppied & Not Shown) CP Hande Asseby

17 ELDMATC 255s MANUAL Page 17 + f cn t- z cn t- (r Q a C.\ U Q - A > E v > v) v, Q x " 8 /-. U d " -J > 3 2 >- v, Q E FGURE Q. ELDMATC 2553 POER SOURCE ASSEMBLY

18 + Page 8 ELDMATC MANUAL + := Z+ +2 -O azx c 3ZZ TZU 3JE 9 O c 3: Z wuo c * * * * Lorn 4 1 * - 3 n.z + U +-+ J Z Z L ) -> i -a X - n T n, E wao c v r s L a38-8 xa 4u a n Y - z ou - z+ a z- -UT n3 p-, 4r JQ Z - 3-d a Y-:- - E J :E -O zl o =: w * C-4 E u L J e >* epb 1, Y J Z 7 ;,NV) L = 12 z - Y 3 : - - = 1% L J ZZL v1 N - d F L -,+,b. wwx 4, b. J J Z C Y $g - > 3 u p Z 411..,,,: ;;:z<!a! no1 LL!. -J Z 3 E J sz -1s -,, - - % - 4 a Z N a > d N FGURE. CP17- CRCUT DAGRAM

19 - ~ ELDMATC 255s MANUAL Page SERVCE NFORMATON. REMOTE REFEEDER REFEED CONTROL BOARD 42-1 The refeed contro board provides the foowing circuit functions, when Power Source is connected to irefeeder: irefeed otor ON / OFF contro in response to the gun-switch. w Speed contro of the wirefeed otor. 'Burn-back" contro. Braking of the wirefeed otor at end of wed. Spot-wed tier. nterva tier. Contro of the gas soenoid vave. Connections to the board, and Service points are detaied in the drawing beow. The circuit is factory adjusted to provide a axiu drive roer speed of 16 rp. - -g U 3 L5 6 2 U> 64 -o w u AAA BURNBACK ADJUSTMENT (MOUNTED ON THE REAR SDE OF THE PCB) -3"rn- MAX SPEED CONTROL RE FEED MOTOR Y YYYT Z i-i- B - 3u U!= QL - b 5 AT: v)w 'z E zc p Q nu, Ek y z% g g FGURE 12. REFEED CONTROL BOARD

20 ~ ~ ~ ~~ ~ - ~~ Page 2 ELDMATC 255s MANUAL 13. PARTS LST 42- REFEEDER (TH CONTROLS) TEM #... PART #... DESCRPTON PCB Asseby irefeed Contro Y... Base Pane Y... Front Pane Y... Back Pane Y... Top/Side Pane Y... Door Pane Y... Divider Pane Motor and 2 Ro Drive 9... MC1 1-32/2... nsuating Bush (2) Motor nsuator (2) TC396-~2 euro Adaptor CP11-/18... Gas Vave /... Hose Tai (2) OCL8... '' Cip 5/16" AM Spoo Hoder Asseby ncudes AM 'R' Cip Loo Asseby, Gas Vave Loo Asseby, Fine Votage ncudes CP34-36/2... Potentioeter, 1 K Loo Asseby, Reote Pots ncudes CP27-11/26... Potentioeter, 5K, Switched (2) CP1 1-11/8... Potentioeter, 1 OK. A Type /11... ndicator Light HF2-1/15... S~ppOrt Foot (4) 2... MC36-56/21... Mae Bush CP5-/8... Feae Bush H97... Cabe Cap /1... Hinge L.H /2... Hinge R.H /2... Sa Action Latch (2) /19... Sa Knob (2) /16... Large Knob (2) S14-/1... Hande CP12-/18... PCB Support (4)

21 ELDMATC 255s MANUAL Page 21 v, - Q + 1:; o w L + e U S c3w d. - _ C 1 P E S w g a r Z L v) >-'G + h & g A " Q@ 1 FGURE REFEEDER (TH CONTROLS)

22 Page 22 ELDMATC 255s MANUAL c D 1 L Kt3-3f U wa Z!3 L -4 F k Li - = K+%T -p. " v z K %K " - 33 q-+ 4"- p. 3 V U 3 v 4) D+ 3DDre 3 a ac 1 1 Orx- L L J L 3n >n n L ED v? v? L L + o U +- z c.- 33 E v -N~VL~~OPCO - u *L c = V rt L a 1-4 U& > 3 C 2 - C D +" > \ L & & & 6 J - d ".+ J d L 1 : 3 h5?5 ccn bra E za a ow O1 X Y e a U v4 : c c 1 U 3 " -L.1 L4 \ \ -. =i Y 3 v J v e 3 c 3 -. L e L a L c L c n X 2 ~, ~ : p w 3 34 :-J u E UU 1 3, 3 do i & -2.Loo *e 2 Ez UE Y U c x U H FGURE RE FEEDER CRCUT DAGRAM (TH LEAD KT)

23 ELDMATC 255s MANUAL Page 23 BEXT-4E31OAE GUN ASSEMBLY 1... BE Nozze 2... BE Contact Tip.6... BE Contact Tip.8... BE Contact Tip.9... BE Contact Tip BE Head 4... BE4323R... Cap 5... BE Nut nsuator 6... BE nsuator 7... BE Body Tube 8... BE1 786 Hande Kit 9... BE Trigger Asseby 1... BE1 884 Screw Kit BE Cabe Asseby 3M BE4E213B.. End Fitting BE Cone Nut BE2661.Terina BE1528.Cap BE25217.Strain Reief, Fexibe 2... BE1477. Bushing BE88135.Strain Reief, Rigid BE2282.Screw H nsuated Link BE Nut BE56... Euro Bock BE ' ' Ring BE '' Ring (Sa) BE Liner To repace iner: Disconnect gun cabe asseby fro the Euro adaptor on the achine case, reove nozze (1) and head (3). ithdraw od iner fro the wire feeder end. nsert new iner and refit gun cabe asseby to Euro adaptor on the achine case. At the gun end, copress the iner within the gun cabe, then cut it one contact tip ength past the end of the body tube (7). Refit head, tip and nozze. FGURE 15. BEXT-4E31OAE (3 AMP) GUN CABLE ASSEMBLY

24 Page 24 ELDMATC 255s MANUAL 4-1 MOTOR & TO ROLL DRVE ASSEMBLY TEM #... PART #... DESCRPTON O/... Motor & Gearbox /3... Screw M6x /4... Key /1... Feed Pate Feed Ro.9-1.2rn /9... Positioning Screw /2... Axe /4... Pressure Ar copete ncudes /5... Axe Pressure Ar /7... Spacer (narrow) /8... Pressure Ro /,9... S pacer (arge) /1... Axe Cip /13... net Guide / 1... Pressure Screw copete ncudes /12... Thubscrew /2... Spring / 4... Base /15... Pressure Link /16... Pressure Screw Axe / 7... Spring /18... Pin /3... Externa Circip 4rn D /19... Externa Circip 5 D ALTERNATVE PARTS (5) /8... Feed Ro O (5) /8... Feed Ro 1.O (5) /8... Feed Ro 1.O Au. (5) /8... Feed Ro (5) Feed Ro (5) /8... Feed Ro , Knured. (5) /8... Feed Ro 1.O + 1.2, Knured. (9) /13... net Guide 3 (9) /13... net Guide 2 (9) /13N... net Guide 2, Nyon FGURE TO ROLL DRVE ASSEMBLY

25 ELDMATC 255s MANUAL Page 25 AM283 NTER-CONNECTNG LEAD KT TEM #... PART #... DESCRPTON 1... AM28-1/5... ork Lead ncudes.a CAB25... eding Cabe cx21... Pug C232-CM... ork Cap 3Ap H Cabe Lug 2... AM ed Lead ncudes CAB25... eding Cabe cx21... Pug H Cabe Lug 3... AM Contro Lead ncudes CAB8C32... Cabe 8 Core AM Pug 6 Pin H1 972ET... Quick Connect Lug, Feae (6) H nsuator (2) 4... AM Gas Hose ncudes Gas Hose OCL 3... Cip 1/2 (2) ORK LEAD ELD LEAD CONTROL LEAD AM28348 Q Q P 2 GAS HOSE AM2848 FGURE 17. AM283 NTER-CONNECTNG LEAD KT,

26 Page 26 ELDMATC 255s MANUAL 14. SAFE PRACTCES HEN USNG ELDNG EQUPMENT These notes are provided in the interests of iproving operator safety. They shoud be considered ony as a basic guide to Safe orking Habits. A fu ist of Standards pertaining to industry is avaiabe fro the Standards Association of Austraia, aso various State Eectricity Authorities, Departents of Labour and ndustry or MinesDepartentandotherLocaHeath or SafetynspectionAuthoritiesayhave additiona requireents. MA Technica Note TN7-98 aso provides a coprehensive guide to safe practices in weding. EYE PROTECTON NEVER LOOK AT ANARC THOUT PROTECTON. ear a heet 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 fro radiant energy and fying eta. Repace the cover ens when broken, pitted, or spattered. Recoended shade fiter ens. Aps T G MMA MG Pused MG " " BURN PROTECTON. The weding arc is intense and visiby bright. ts radiation can daage eyes, penetrate ightweight cothing, refect fro ight-cooured surfaces, and burn the skin and eyes. Burns resuting fro gasshieded arcs resebe acute sunburn, but can be ore severe and painfu. ear protective cothing - eather or heat resistant goves, hat, and safety-toe boots. coar and pocket faps, and wear cuffess trousers to avoid entry of sparks and sag. Button shirt Avoid oiy or greasy cothing. A spark ay ignite the. Hot eta such as eectrode stubs and work pieces shoud never be handed without goves. Ear pugs shoud be worn when weding in overhead positions shoud be worn when others are working overhead. or in a confined space. A hard hat Faabe hair preparations shoud not be used by persons intending to wed or cut. TOXC FUMES. Adequate ventiation with air is essentia. Severe discofort, iness or death can resut fro fues, vapours, heat, or oxygen depetion that weding or cutting ay produce. NEVER ventiate with oxygen. Lead, cadiu, zinc, ercury, and beryiu bearing and siiar aterias when weded or cut ay produce harfu concentrations of toxic fues. Adequate oca exhaust ventiation ust be used, or each person in the area as we as the operator ust wear an air-suppied respirator. For beryiu, both ust be used. Metas coated with or containing aterias that eit fues shoud not be heated uness coating is reoved fro the work surface, the area is we ventiated, or the operator wears an air-suppied respirator. ork in a confinedspaceonywhie it isbeingventiatedand, if necessary,whiewearingairsuppied respirator.

27 ELDMATC 255s MANUAL Page 27 Vapours fro chorinated sovents can be decoposed by the heat of the arc (or fae) to for PHOSGENE, a highy toxic gas, and ung and eye irritating products. The utra-vioet (radiant) energy of the arc can aso decopose trichorethyene and perchorethyene vapours to for phosgene. Do not wed or cut where sovent vapours can be drawn into the weding or cutting atosphere or where the radiant energy can penetrate to atospheres containing even inute aounts of trichorethyene or perchoorethyene. FRE AND EXPLOSON PREVENTON. Be aware that fying sparks or 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 1 etres fro the arc. Keep equipent cean and operabe, free of oi, grease, and (in eectrica parts) of etaic partices that can cause short circuits. f cobustibes are present in the work area, do NOT wed or cut. Move the work if practicabe, to an area free of cobustibes. Avoid paint spray roos, dip tanks, storage areas, ventiators. f the work can not be oved, ove cobustibes at east 1 etres.away out of reach of sparks and heat; or protect against ignition with suitabe.and,snug-fittingfire-resistant covers or shieds. as touching cobustib1es. opposite sides shoud not be weded on or cut. as, ceiings, and foor near work shoud be protected by heat-resistant covers or shieds. A person acting as Fire atcher ust be standing by with suitabe fire extinguishing equipent during and for soe tie after weding or cutting if; ' Cobustibes (incuding buiding construction) are within 1 etres. Cobustibes are further than 1 etres but can be ignited by sparks. Openings (conceaed or visibe) in foors or was within 1 etres ay expose cobustibes to sparks. n Cobustibes adjacent to was, ceiings, roofs, or eta partitions can be ignited by radiant or conducted heat. After work is done, check that area is free of sparks, gowing ebers, and faes. A tank or dru which has contained cobustibes can produce faabe vapours when heated. Such a container ust never bewededon or cut, uness it has first been ceaned as described in AS , the S.A.A. Cutting and eding Safety Code. This incudes a thorough stea or caustic ceaning (or a sovent or water washing, depending on the cobustibe's soubiity), foowed by purging and inerting with nitrogen or carbon dioxide, and using protective equipent as recoended in AS ater-fiing just beow working eve ay substitute for inerting. Hoow castings or containers ust be vented before weding or cutting. They can expode. Never wed or cut where the air ay contain faabe dust, gas, or iquid vapours. SHOCK PREVENTON. Exposed conductors or otherbareetainthewedingcircuit, or ungrounded eectricay aive equipent can fatay shock a person whose body becoes a conductor. Ensure that the achine is correcty connected and earthed. f unsure have achine instaed by a quaified eectrician. On obie or portabe equipent, reguary inspect condition of traiing power eads and connecting pugs. Repair or repace daaged eads. Fuy insuated eectrode hoders shoud be used. Do not use hoders with protruding screws. Fuy insuated ock-type connectors shoud be used join to weding cabe engths. Terinas and other exposed parts of eectrica units shoud have insuated knobs or covers secured before operation.