OWNERS MANUAL WELDMATIC 215s MODEL NO. CPlO9-0, REV. B

Transcription

1 - WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ABN : 547 I Head Office and Internationa Saes 5 Aan Street, Merose Park South Austraia, 5039 Teephone (08) Facsimie (08) info@wedingindustries.com.au OWNERS MANUAL WELDMATIC 215s MODEL NO. CPO9-0, REV. B 1 /2000 QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE

2 Page 2 WELDMATIC 21 5s MANUAL The information contained in this manua is set out to enabe you to propery maintain your new equipment and ensure that you obtain maximum operating efficiency. Pease ensure that this information is kept in a safe pace for ready reference when required at any future time. When requesting spare parts. pease quote the mode and seria number of the machine and part number of the item required. A reevant numbers are shown in ists contained in this manua. Faiure to suppy this information may resut in unnecessary deays in suppying the correct parts. SAFETY Before this equipment is put into operation. the Safe Practices section at the back of the manua must be read competey. This wi hep to avoid possibe injury due to misuse or improper weding appications. CONTENTS Sec.1... Introduction... P.3 Sec2... Receiving... P.3 Sec.3... Specifications... P.4 Sec.4... Power Source Contros... P.5 Sec.5... Instaation... P Connection To Eectrica Mains Power Suppy... P Fitting The Gas Botte... P Fitting The Gun Cabe... P Fitting The Consumabe Wire... P Feeding The Consumabe Wire... P Output Votage Poarity Seection... P.8 Sec.6... Norma Weding Sequence Wed Start... P.9 P Wed End... P.9 Sec.7... Basic Weding Information... 7.'... Choice Of Shieding Gas... P.9 P Shieding Gas Fow Rate... P Estabishing A Wed Setting...?.4... Gun Position... B.9 P. 10 Sec.8... Genera Maintenance... P. 11 Shooting Troube Sec Sec Service Information P Sec Sec Parts List - Power Source Assemby... Parts List - Wire Drive Assemby... P. 16 P. 18 Sec Parts List - Gun Cabe Assemby... P. 19 Sec Safe Practices... P.20 FIGURES FiEp.1... Power Source Contro Locations... P.5 Fig.2... Connection of Suppy Cabe... p.6 Fig.3... Positive Wire Connection... P.8 Fig.4... Negative Wire Connection... P.8 Fig.5... "Good" Wed... p. 10 Fig.6... "Bad" Wed... p. 10 Fig.7... Gun Position... p. 10 Fig.8... CPO9-10 Contro Board... P.14 Fig.9... CP'O9-0 Circuit Diagram... P. 15 Fig Power Source Assemby... P. 17 Fig Wire Drive Assemby... P. 18 Fig Gun Cabe Assemby... p. 19

3 WELDMATIC 21 5s MANUAL Page 3 -. INTRODUCTION Gas Meta Arc Weding (G.M.A.W.) is a weding process where a 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 shieded by gas fow from the gun, or in the case of "sef shieded" wires, by gases generated by the wire core. By seection of the correct wire composition, diameter and shieding gas, G.M.A.W. can be used for appications ranging from sheetmeta to heavy pate, and metas ranging from carbon stee to auminium aoys. The WELDMATIC 215s has been designed to be used with consumabe wires in the range from 0.6mm to 1.2mm diameter. The smaer wire sizes are used when weding at ower currents, such as sheet-meta appications. Increasing the wire diameter permits higher weding currents to be seected. A common appication of G.M.A.W. is for weding Mid Stee. In this appication, a Mid Stee soid consumabe such as AUSTMIG ES6 is used with a shieding gas of Argon mixed with 5-25% Carbon Dioxide. Aternativey, Fux-cored consumabes are avaiabe in both gas shieded, and 'gasess' sef shieding types. Stainess stee and Auminium can be weded with G.M.A.W. using the correct consumabe wire and shieding gas. 2. RECEIVING Check the equipment received against the shipping invoice to make sure the shipment is compete and undamaged, If any damage has occurred in transit, pease immediatey notify your suppier. The CP109-0 package contains; WELDMATIC 215s Power source. BEXT2-4E21OAE BERNARD Gun cabe, 3 metre, Euro connector. R WGAC24 Reguator and Fow gauge. (Argon) (This) Owners Manua.

4 Page - 4 WELDMATIC 215s MANUAL 3. SPECIFICATIONS Manufactured to Austraian standard AS Rated to ISOAEC (10 minute duty cyce) WELDING INDUSTRIES of AUSTRALIA Wedmatic 2 15s Made in Austraia 1- M "- RATED TO ISOAEC (21 N803 I D W CLASS INS H PF = 0.89 (215A) 0.93 (9OA) UdV) LAN I V 50Hz I,em(A) S,(kVA) I COOLINGAF I IP21 I I I I WNsosR Under ISO/IEC , duty cyce is defined as the ratio of arcing time to an operating time of 10 minutes, expressed as a percentage.

5 - WELDMATIC 21 5s MANUAL Page 5 4. POWER SOURCE CONTROLS I WIRE SPEED CONTROL SPOT TIME CONTROL INTERVAL CONTROL OVERLOAD INDICATOR POWER ON INDICATOR FINE VOLTAGE CONTROL e * & COARSE VOLTAGE CONTROL FIGURE 1. POWER SOURCE CONTROL 1. POWER ON INDICATOR This is iuminated when eectrica mains power is connected to the weding power source. 2. COARSE VOLTAGE CONTROL This switch provides Coarse adjustment of the Output Weding Votage over three ranges. 3. FINE VOLTAGE CONTROL This switch provides Fine adjustment of the Output Weding Votage over three ranges. 4. WIRE SPEED CONTROL This contro provides adjustment of the wirefeed speed. Rotating the dia in a cockwise direction wi increase the wirefeed speed, thereby increasing the weding current. 5. SPOT TIME CONTROL When operating the machine in Spot Wed mode, this contro wi vary the spot wed time. Rotating the dia in a cockwise direction wi increase the spot wed time, in the range seconds. If the Spot Wed mode is not required this feature may be turned off by rotating the contro anti-cockwise unti it 'cicks' into the minimum position. 6. INTERVAL CONTROL When operating the machine in Cyce Arc mode this contro sets the period between weds. The spot time contro sets the weding period. Rotating the dia in a cockwise direction wi increase the interva time, in the range seconds. If the Cyce Arc mode is not required this feature may be turned off by rotating both contros fuy anti-cockwise. 7. OVERLOAD INDICATOR This is iuminated when the weding oad exceeds the operating duty cyce. In this event the machine wi not deiver weding current unti the machine has cooed sufficienty. The overtemperature thermostats wi reset automaticay - do not switch the machine off as the cooing fan wi assist the resetting of the thermostats.

6 ~~ ~ Page 6 W WELDMATIC 215s MANUAL 5. INSTALLATION 5.1 CONNECTION TO ELECTRICAL MAINS POWER SUPPLY NOTE. A eectrica'work sha ony be undertaken by a quaified eectrician. The WELDMATIC 215s is factory fitted with a 3 metre, 3 core 50/0.25 Heavy Duty PVC mains power suppy cabe with mouded 3 pin, 15 Amp, Singe Phase pug. A 15 Amp pug and socket is recognisabe by a wide Earth pin. Power Suppy authorities require that equipment fitted with 15 a Amp pug sha ONLY be connected to a 240 Vot, 15 Amp power point. DO NOT modify the pug. The minimum capacity of the mains wiring and power outet suppying a weder is seected according to the effective primary current of the machine. The effective primary current for a Wedmatic 215s is 16 Amps. The minimum recommended circuit breaker rating for a Wedmatic 215s is 20 Amps. Note : The tripping time of a typica 20A circuit breaker may imit the duty cyce avaiabe from the Wedmatic 215s. A higher rated circuit breaker can be seected, but the mains wiring capacity must be increased to suit. The current rating of the mains cabe depends on cabe size and method of instaation. Refer to AS/NZS , Tabe 9. If it becomes necessary to repace the mains fexibe suppy cabe, use ony cabe with correct current rating. Access to the machine suppy terminas is gained by removing the power source eft hand side pane. (Power source viewed from front). Pass the cabe through the bush fitted to the machine back pane. The cabes are terminated at the termina bock as shown in Figure 2. Tighten the cabe camp eaving just sufficient wires are not in tension. sack in the cabe so that the terminated WN BLUE CABLE BACK BLOCK 3 CORE POWER CABLE WIRE YELLOW CONNECTION BUSH FIGURE 2. CONNECTION OF SUPPLY FLEXIBLE CABLE

7 ~ ~ - L WELDMATIC 215s MANUAL Paae 7 U 5.2 FITTING THE GAS BOTTLE Depending on configuration of the cyinder to be used, the gas fowmeter / reguator may 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 of the gas inet hose from the back of the machine to the connector suppied with the fow reguator, and secure with the camp aso suppied. 5.3 FITTING THE GUN CABLE The BERNARD BEXT2-4E21OAE gun cabe is equipped with a 'Euro' wirefeeder connector which incorporates a required connection points to the gun cabe for weding current, shieding gas and gun switch contro. To attach the gun cabe to the wirefeeding mechanism, engage the mating parts of the mae and femae Euro connectors, then rotate the ocking ring cockwise to firmy secure the connection. 5.4 FITTING THE CONSUMABLE WIRE The quaity of the consumabe wire greaty affects how reiaby a gas meta arc weder wi operate. For best resuts when weding mid stee, we recommend quaity WIA AUSTMIG ES6. Dirty, rusty or kinked wire wi not feed smoothy through the gun cabe and wi cause erratic weding. Deposits from the wire wi cog the gun cabe inerequiring it to be repaced prematurey. Pace the spoo of weding wire onto the spoo hoder. The ocation pin shoud mate with a hoe provided on the wire spoo body. Fit the spoo retaining 'R cip suppied. Check the adjustment 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 motor. The braking can be adjusted by the Nyoc nut using a 15/16'' AF or 24mm socket wrench. ' 5.5 FEEDING THE CONSUMABLE WIRE With reference to Figure 11, reease the pressure screw (6), and rotate the pressure arm (4) to the open position. The end of the weding wire can now be passed through the inet guide (1 ), over the bottom driven roer (91, and into the output wire guide tube. Check that the drive roer groove is correct for the wire in use. The appropriate size is stamped on the visibe side of the instaed roer. Check aso that the correct size contact tip is fitted at the gun end. Drive roer and tip detais are avaiabe in Section 11 of this manua. Return the pressure arm to the cosed position and, adjust the pressure screw to provide sufficient camping of the drive ros drive to achieve constant wirefeed. Do not over tighten.

8 ~ - Page 8 WELDMATIC 21 5s MANUAL 5.6 OUTPUT VOLTAGE POLARITY SELECTION. The design of the WELDMATIC 215s aows externa seection of the output votage poarity - positive wire or negative wire POSITIVE WIRE Most soid wire G.M.A.W. is carried out with the work piece Negative and the weding consumabe wire Positive. To set the machine for this condition, insert the WORK ead pug into the (-) output socket on the front of the power source. Insert inter-connecting WELD ead pug into the (+) output socket on the front of the power source. See Figure 3 beow NEGATIVE WIRE Some sef-shieded fux cored consumabes are intended to be operated with the work piece Positive and the consumabe wire Negative. Refer to the manufacturers data for the particuar consumabe to be used. To set the machine for this condition, insert the WORK ead pug into the (+) output socket on the front of the power source. Insert inter-connecting WELD ead pug into the (-) output socket on the front of the power source. See Figure 4 beow. B WORK LEAD d & & v W! & 215s J e 5 e G FIGURE 3. POSITIVE WIRE e I) WORK LEAD FIGURE 4. NEGATIVE WIRE

9 WELDMATIC 215s MANUAL Page 9-6. NORMAL WELDING SEQUENCE 6.1 WELD START Cosing the weding gun switch initiates this sequence of events: The gas vave is energised, gas fow commences; The power source triac function is initiated. Weding votage is appied between the work piece and the consumabe wire; The wire drive motor is energised. Wirefeed commences and the arc is estabished. 6.2 WELD END Reeasing the gun switch initiates thisequence of events: The wire drive motor is de-energised, and is dynamicay braked to a stop; The power source triac function is de-energised; The gas vave is de-energised and the fow of shieding gas ceases. 7. BASIC WELDING INFORMATION 7.1 CHOICE OF SHIELDING GAS The choice of shiedingas is argey determined by the consumabe wire to be used. Many proprietary shieding gas mixtures are avaiabe. The recommended shieding gases for use with the WELDMATIC 21 5s are : Mid Stee... Auminium... Stainess Stee... Argon + 5 to 25% Carbon Dioxide; Argon; Argon + 1 to 2% Oxygen. Consut your gas suppier if more specific information is required. 7.2 SHIELDING GAS FLOW RATE In G.M.A. weding, one of the functions of the shieding gas is to protect the moten wed poo from the effects of oxygen in the atmosphere. Without this protection the wed deposit becomes honeycombed in appearance, an effect which is described as wed porosity. In draft-free conditions the gas fow rate required to give adequate protection is typicay 10 itredmin. In situations where drafts cannot be avoided, it may be necessary to increase this rate and/or to provide screening of the work area. Wed porosity can aso be caused by air entering the gas stream through a damaged hose, oose gas connection, or from restriction in the nozze, such as from excess buid-up of spatter. 7.3 ESTABLISHING A WELD SETTING Once the consumabe wire type, wire size and shieding gas have been chosen, the variabes which are adjusted in order to obtain a stabe arc are; two Wirefeed speed, Weding arc votage. I ~~ -

10 2 Page 10 WELDMATIC 21 5s MANUAL 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. IMPORTANT: Do not operate the Votage Contro switches during weding. 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 providesufficient strength to suit the appication. A "good" wed wi have the characteristics iustrated in Figure 5. 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 6. The wed has not penetrated the joint root, and there is poor side wa 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. L L FIGURE 5. "GOOD" WELD FIGURE 6. "BAD" WELD 7.4 GUN POSITION For "down hand" fiet weding, the gun is normay positioned as shown in Figure 7 beow with the nozze end pointing in the direction of trave. i!!?? FIGURE 7. GUN POSITION

11 ~ WELDMATIC 215s MANUAL Page GENERAL MAINTENANCE I Before removing the machine cover, ENSURE that the unit is disconnected from the mains power suppy. When the unit is energised LETHAL VOLTAGES are present on the eectrica components encosed. I I DUST Care shoud be taken to prevent excessive buid-up of dust and dirt within the weding power source. It is recommended that at reguar intervas, according to the prevaiing conditions, the machine covers and encosed wirefeeder covers be removed and any accumuated dust be removed by the use of dry, ow pressure compressed air, or a vacuum ceaner. WIREFEED In order to obtain the most satisfactory weding resuts from the G.M.A.W. process, the wirefeed must be smooth and constant. It is therefore important to observe the foowing points; ' Keep the gun cabe iner cear of dust and swarf buid-up. When repacement becomes necessary, fit ony the correct iner to suit the gun cabe mode. See page 19. The buid-up of dust in a cabe iner can be minimised by reguar purging of the iner with dry compressed air. This may be convenienty done each time the wire spoo is repaced. Repace the weding tip as it becomes worn. Keep the wire drive mechanism cean. Periodicay check the drive roers for wear and for free rotation. Check that the consumabe wire spoo hoder rotates smoothy and that the braking action is not excessive. This aso may be convenienty done each time the wire is repenished..

12 ~~ ~~ - Paae 12 v WELDMATIC 21 5s MANUAL 9. TROUBLE SHOOTING, ' ', F,AUL-T;,, ' REMEDY I Power source has no power, ie. Turn on mains suppy switch ) power ight is off I 2) fans are not running I Check a primary connections Check mains votage, fuses or circuit breaker in power source and in primary pug I Check a connections to CP contro board in power source Power source has no output but : is off 2) fans are running Repace CP contro board 1) power ight Power source has no output and Power source overheated. Aow thermostats to coo with fans on no wirefeed when gun switch is cosed but: ) power ight is on After cooing, if probem sti persists, check rectifier thermostat and transformer thermostat for open circuit. Repace if fauty Check a connections to CP contro board in power source i 1) power ight is on 2) overoad ight is off 3) fans are running the time when mains power is appied and gun switch is off variation when coarse and fine Switches are operated I I pains fusesboworcircuit I Checkwedingtransformerforaprimaryfauttoearth. breaker trips instanty when mains votage is appied Repace if fauty Check fan in power source for short circuit or faut to earth Repace if fauty Mains fuses bow or circuit gun switch is cosed Check weding transformer for shorted turns. Repace if fauty Check rectifier for shorted diodes. Repace if fauty breaker trips instanty when Mains fuses bow or circuit Check that the recommended fuse or circuit breaker rating has been breaker trips when weding used. Consider upgrading to arger fuse or circuit breaker & wiring. I 1 I

13 ~ ~~~~~~ ~. WELDMATIC 2A 5s MANUAL Page 13 TROUBLE SHOOTING cont. UNSATISFACTORY WELDING PERFORMANCE AND RESULTS - FAULT 1 Erratic arc characteristics Check gun iner for buid up of dirt or bockage. Repace if dirty caused by poor wirefeed Check if wire is sipping on roer assemby. Repace feed ro if worn I Constant poor arc characteristics Check if there is too much drive roer pressure on wire Check spoo hoder is rotating smoothy Check that gun iner is not too short and is fitted correcty. Refer to page 19 for fitting instructions. I I Porosity in wed caused by ack of shieding gas Check correct poarity has been seected for work and wed cabes. Refer to page 8 Check shieding gas is correct for the consumabe in use Check weding circuit is making good eectrica connection Check a connections in power source and wirefeeder for hot spots Check gas soenoid. Repace if fauty Check that the correct gas fow rate has been set Check for eaks in gas hose. Repace if eaking Check for eaks in gun cabe, eg. O-rings. Repace if eaking Check nozze is firmy attached to gun and that no air is being I I drawn in I I I

14 ~~ Page 14 WELDMATIC 21 SS MANUAL IO. SERVICE INFORMATION. CP CONTROL BOARD The CP109-IO Contro board provides the foowing functions. Weding transformer ON/OFF contro. w Wirefeed motor ON / OFF contro. Speed contro of the wirefeed motor. w Braking of the wirefeed motor at end of wed. g Spot-wed timer. w Interva timer. Gas soenoid ON / OFF contro. Triac ON / OFF contro, phase seected to minimise transformer inrush current. Triac protection by output short circuit detection. Connections to the board are detaied in the drawing beow. The circuit is factory adjusted to provide a maximum drive roer speed of 160 rpm. MAXIMUM SPEED 7 CALIBRATION ACTIVE 24OVAC THERMOSTAT NEUTRAL 240VAC THERMOSTAT OUTPUT TERMINAL +VE OUTPUT TERMINAL -VE GUN SWITCH TRANSFORMER SECONDARY -VE MOTOR WIREFEED VALVE GUN SWITCH ---"I GASVALVE A GAS 1 1 L." I SECONDARY TRANSFORMER WIREFEED MOTOR +VE FIGURE 8. CPO9-10 CONTROL BOARD

15 . - WELDMATIC 21 5s MANUAL Page 15 pji1 W 4 FIGURE 9. CP109-0 CIRCUIT DIAGRAM

16 - Page 16 WELDMATIC 21 5s MANUAL 11. PARTS LIST WELDMATIC 215s POWER SOURCE ITEM #... PART #...DESCRIPTION 1... CP109- ON... PCB Assy Wirefeed 2... CP109-5L... Wed Transformer Assy inc. Overoad & Wire Loom Incudes CP Therma Overoad 3... CP Inductance Assemby 5... CPI Rectifier Assemby Incudes CP106-0/1... Rectifier with Therma overoad CP Therma Overoad (Not Shown) CP SCR Modue (Not Shown) CP Heatsink (Not Shown) 6... CP Base Assemby Incudes CP Castor Whee (2) 7... CP109-20Y... Front Pane 8... CP109-24Y... Back Pane 9... CP109-21Y... Centre Pane Assemby 0... CP Baffe Pane CP42-27Y... Side Cover-Fixed Lower (Not Shown) CP109-28Y... Door Hinged (Not Shown) CP42-29Y... Top Cover W29-1/20... Sam Action Latch On Door(Not Shown) CP4 3-24Y... Side Cover (Not Shown) CP42-0/3... Rubber Tyre Whee (2) MC11-53/6... Ratchet Cap (2) CP Loom Assemby, Low Votage (Not Shown) CP ~erna Poarity Change Lead CP Loom Assemby, Transformer (Not Shown) CP Loom Assemby, High Votage (Not Shown) SA140-0/2... Socket Dinse 25mm (2) MK6/2... Termina Bock, 2 position CP27-0/15... Cooing Fan (2) CP01-0/18... Gas Vave 24V DC W1 1-11/1... Gas Vave Hose Tai (2) OCL Cip W (2) CP106-0/ A Fex & 15A Pug CP Rod Hinge (Not Shown) W5-1 0/19... Potentiometer Knob, Sma (2) W1 1-0/16... Potentiometer Knob, Large Back Oxy Singe Hose SCG030M... Stee Chain 650mm CP3-0/23... Rubber Grommet CP Hande Assy WFOOI Pastic Cover W39-0/1... Switch (2) H Cabe Camp BBA Busbar Inductance BBA Busbar, Inductance to Output -ve BBA Busbar, Rectifier -ve to Inductance BBA Busbar, Rectifier +ve to Output +ve... MC14-0/10... Mae Insuating Bush For Fex Cord (Not Shown)... MC14-0/ Femae Insuating Bush For FexCord (Not Shown)... CP CP109-0 Owner S Manua (Not Shown)

17 ~ -~~~ WELDMATIC 215s MANUAL Page 17 N N 1 m \ L FIGURE IO. WELDMATIC 215s POWER SOURCE ASSEMBLY - - ~ ~ ~ " -

18 Page 18 WELDMATIC 21 5s MANUAL 12. PARTS LIST CP109-7 MOTOR, TWO ROLL DRIVE & EURO ADAPTOR ASSEMBLY ITEM #... PART #...DESCRIPTION 1... WFOOI-... Motor & Gearbox 2... WFOOI-2... Euro Gun Adaptor inc. Guide & Gas Connector 3... WFOOI Ro Feed Pate 4... WFOOI-4... Pressure Arm (Compete) 5... WF001-4/1... Pressure Ro 30mm Diameter 6... WFOO Pressure Screw Compete 7... WFOOI-6... Insuation Board 8... WFOOI-7... Insuation Washer 9... W26-1/8... Feed Ro 30mm f 1.Omm, Soid Wire W27-0/9... Positioning Screw Main Gear W26-0/13... Inet Guide WFOOI Inet Guide Tube ALTERNATIVE PARTS (9)... W26-0/8... Feed Ro mm, Soid Wire (9)... W Feed Ro mm, Soid Wire (9)... W Feed Ro 1.O + 1.2rnm, Soid Wire (9)... W Feed Ro mm, Soid Wire (9)... W26-3/8... Feed Ro 1.O f 1.2mm, Auminium Wire (9)... W26-7/8... Feed Ro 1.O f 1.2mm, Fux Cored Wire (9)... W26-6/8... Feed Ro mm, Fux Cored Wire FIGURE 11. CPO9-7 TWO ROLL DRIVE ASSEMBLY

19 WELDMATIC 215s MANUAL Page PARTS LIST BEXT2-4E21OAE GUN ASSEMBLY ITEM # DESCRIPTION... PART # ITEM # DESCRIPTION... PART # Nozze... BE4392 Contact tip 0.6mm... BE7497 Contact tip 0.8mm... BE7488 Contact tip 0.9mm... BE7489 Contact tip 1.2mm... BE7490 Head... BE4335 Cap... BE4323R Nut Insuator... BE4780 Insuator... BE Body Tube... BE Hande Kit... BE Trigger... BE5662 Screw Kit... BE Cabe 3m... BE8681TE End Fitting... BE4E2135 Cone Nut... BE4305 Termina... BE Camp... BE Strain Reief... BE Bushing... BE Strain Reief, rigid... BE Screw... BE Insuated Link... H2072 Nut... BE4816 Euro Bock... BE5060 '0' Ring... BE44211 Liner mm... BE To repace iner: Disconnect gun cabe assemby from the Euro adaptor on the machine case. remove nozze () and head (3). Withdraw od iner from the wire feeder end. Insert new iner and refit gun cabe assemby to Euro adaptor on the machine case. At the gun end. compress 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. FIGURE 12. BEXT2-4E21OAE (200 AMP) GUN CABLE ASSEMBLY

20 -~~ - I Page SAFE PRACTICES WHEN USING WELDING EQUIPMENT WELDMATIC 215s MANUAL These notes are provided in the interests of improving operator safety. They shoud be considered ony as a basic guide to Safe Working Habits. fu A ist of Standards pertaining to industry is avaiabe from the Standards Association of Austraia, aso various State Eectricity Authorities, Departments of Labour andindustryorminesdepartmentandotherlocaheathorsafetyinspectionauthoritiesmayhave additionarequirements.wtatechnicanotetn7-98asoprovidesacomprehensiveguidetosafe 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 Pused MIG IO " 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 burn the skin and eyes. Burns 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 worn when others are working overhead. Fammabe hair preparations shoud not be used 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. Workinaconfinedspaceonywhieit is beingventiatedand, ifnecessary,whiewearingairsuppied respirator.

21 WELDMATIC 21 5s MANUAL Page 21 - 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 or faing sag can pass through cracks, aong pipes, through windows or doors, and through waii 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. A person acting as 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. Exposedconductorsorotherbaremetainthewedingcircuit,orungroundedeectricayaive equipmentcanfatayshockapersonwhosebodybecomesaconductor.ensurethatthemachine is correcty connected and earthed. If unsure have machine instaed by a quaified eectrician. On mobie or portabe equipment, reguary inspect condition of traiing power eads and connecting pugs. Repair or 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. ~