WELDMATIC

WIREFEEDER

Model W - l 4

""""

CAT. 7 5 3 0

7 / 8 0

THE INFORMATION CONTAINED I N THE FOLDER I S S E T OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM O P E R A T I N G E F F I C I E N C Y .

PLEASE ENSURE THAT THIS FOLDER I S KEPT I N A SAFE PLACE FOR READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NO, OF THE MACHINE ANDTIE PART NO. OF THE ITEM REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT I N UNNECESSARY DELAYS I N S U P P L Y I N G T H E C O R R E C T P A R T S .

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

S A L E S AND S E R V I C E D I V I S I O N S

Melbourne 4 2 9 4 7 6 6 Sydney 5 3 4 2 1 4 4 N e w c a s t l e 6 1 1 6 6 8 A d e l a i d e 3 5 2 3 0 2 2 P e r t h 3 6 1 7 0 8 8 B r i s b a n e 4 4 1 3 9 1 L a u n c e s t o n 3 1 7 0 0 4 Darwin 8 1 6 4 2 7 & 8 4 3 0 7 6

I N D E X

Page No.

I n t r o d u c t i o n , a n d F i t t i n g of Co i l Moun t ing , NO. W l l - l 6

Pa r t s L i s t - General Assembly - No. W14.0

General Assembly Drawing - N o . W14.0

F i t t i n g S u s p e n s i o n B r a c k e t - N o . Wl1-14 & C o n t r o l C a b l e

Accesso ry Tab le , N o . W2-19 Drive R o l l s & Wire Guides

F i t t i n g of Feed Rolls

S e t t i n g Up Wire Feede r

2-Roll Drive Assembly Par t s L i s t , No. 1272-0

2-Roll Drive Assembly Drawing No. F72-0

F u n c t i o n of E lec t r i ca l Components, Electr ical Adjus tments

C i r c u i t D i a g r a m - No. W14-Cl

S c h e m a t i c C i r c u i t D i a g r a m N o . W14-C2

T r o u b l e S h o o t i n g , M a i n t e n a n c e P o i n t s

Par t s L i s t - No. W14-11, Motor Speed Cont ro l Pane l

Assembly Drawing - No. W l 4 - 1 1 , Motor Speed Control P a n e l

Par t s L i s t - No. Wll-7 Wire Feed C o n t r o l P a n e l

Assembly Drawing - N o . W l l - 7 , Wire F e e d C o n t r o l P a n e l

Accessory Leads Table

Spool Holder V1-38 & C o i l B r a c k e t Wl-48

4

5

4 & 6

6

7

8

9 ,l2

10

11

13

14

1 5

1 6

1 7

18

19

- 1 -

W14 SOLID STATE WIRE FEEDER

OPERATING INSTRUCTIONS

DESCRIPTION

The \!?l4 S o l i d S t a t e Wire F e e d e r h a s b e e n d e s i g n e d t o f e e d a r a n g e o f h a r d , s o f t , a n d f l u x c o r e d wires f o r t h e (2s MetalA-cc P rocess and i s s u i t a b l e f o r c o n n e c t i o n t o a 3 0 v o l t 50 h e r t z s i n g l e p h a s e s u p p l y . The wel l proven V . I . A . 2 R o l l D r i v e A s - sembly i s c o u p l e d t o a Low I n e r t i a P r i n t e d C i r c u i t M o t o r / G e a r - b o x . T h i s P r i n t e d C i r c u i t (P.M.) Motor i s c o n t r o l l e d by a f u l l wave s i l i c o n c o n t r o l l e d r e c t i f i e r m o t o r c i r c u i t , w h i c h e n s u r e s c o n s t a n t m o t o r s p e e d and. t o r q u e o v e r a n y p r e - s e t s p e e d r a n g e . T h e m o t o r c o n t r o l c i r c u i t a n d t h e e lec t r ic f u n c t i o n c i r c u i t a re on p r i n t e d c i r c u i t p a n e l s w i t h a l l components , t e s t p i n s , e t c . , c lear ly i d e n t i f i e d .

The e l ec t r i ca l f u n c t i o n c o n t r o l p a n e l i n c o r p o r a t e s a n i n f i n i t e l y v a r i a b l e b u r n - b a c k c o n t r o l , w h i l s t t h e m o t o r c o n t r o l p a n e l h a s a t o r q u e f e e d b a c k c i r c u i t , a n d a c o n t r o l v o l t a g e s t a b i l i s a t i o n c i r c u i t .

The Kire Feeder i s s u i t a b l e f o r e i t h e r s p o o l e d or c o i l e d wire. Vire a l i g n m e n t b e t w e e n i n p u t wire g u i d e s , f e e d r o l l s a n 6 g u n c a b l e i s p r e - s e t and. m a i n t a i n e d o v e r t h e c o m p l e t e r a n g e of wire s izes . A r a n g e of l i g h t w e i u h t q u n a n d c a b l e a s s e m b l i e s a re a v a i l a b l e , t o s u i t t h e wire types and s i z e s b e i n g u s e d .

The Wire F e e d e r c a n b e u s e d . i n b o t h h o r i z o n t a l a n d v e r t i c a l p o s i t i o n s , s w i v e l m o u n t e d , o r s u s p e n d e d o v e r h e a d w i t h s t a n d - a r d e a s y f i t t i n g a d a p t o r s a v a i l a b l e f o r e a c h i n s t a l l a t i o n s i t - u a t i o n .

The w e l d i n g c u r r e n t r a t i n g of t h e Wire Feede r i s u n l i m i t e d , as t h e w e l d i n g c u r r e n t b y - p a s s e s t h e Wire Feeder and i s d e t e r m i n e d by t h e power source , gun cab le , and s i z e ( d i a . ) of t h e w e l d i n s wire.

SETTING UP F7IRE FEEDER

The Wire Feede r i s s h i p p e d a s a c o m p l e t e , s t a t i o n a r y m o u n t e d u n i t f i t t e d w i t h o n e s e t o f f e e d r o l l s , wire gu ides and spool h o l d e r . T h e f o l l o w i n g a c c e s s o r i e s a re a v a i l a b l e as s t a n d a r d a t t a c h m e n t s .

F ITTING FOR C O I L I IOUNTING - PART NO. N l l - 1 6

D e t a c h t h e spool h o l d - e r s p r i n d l e a s s e m b l y by r emov ing t hc 3 / 8 " w h i t . n u t and. washer w h i c h s e c u r e s t h e s p i n d l e t o t h e Wire Feeder Cover . F i t t h e c o i l b r a c k e t p l a t e W11-16 t o t h e c o v e r by t h e t h r e e 3 /8" b o l t s a n d n u t s s u p p l i e d t o t h e 3 t o p h o l e s o n t h e s i d e of t h e c o v e r , s o as t h e p l a t e p o i n t s o u p - wards and outwards a t an anglB of 25 . R e - f i t t h e s p o o l h o l d e r S p i n d l e a s s e m b l y t o t h e 3 / 8 " g5 c l e a r a n c e h o l e p r o v i d - e d a t t h e e n d o f t h e c o i l b r a c k e t p l a t e .

. . ./2

- 2 -

DRAWING NO. 1414-0 P A R T S L I S T

ITEM NO.

1 2

3

4 5

6 7

7 7

8

9

10 l1 12 1 3

14 1 5

16 17 17-1 1 7 - 2

13 19 20 21 22 23 24 24 2 5

2 6

27

PART N O . D E S C R I P T I O N

F71 1- 2

W1 1- 3

1411-4 P71 1 - 5

W14-11 W l l - 7

W l l - 0 / 7

\ 4 1 1 - 0 / 3 3

Wl l -0 /3 4 W l l - 9

v 7 2

b J 1 - 3 3 / 1

WL-3 5 /1

W l l - O / 1 2

W l l - 0 / 1 3

W l l - 0 / 1 4

W11-02/1.5

W11-0/16 V?11-02/17 r.J11-0/21 W l l - O l / b 7

P I C l S - O / l O

M C l l - 3 2 / 2

WIN4 4 Wl- 4 1 Wll-13

m 1 - 1 l T C 2 6 2

T C 2 6 2 N

W l l - 0 1 / 2 9

C P 3 - 0 / 2 3

W1 4 - 13

BASE WITH PIVOT PlOUNTING ASSElr?BLY

FRONT AND COMPONENT PIOUIJTING PANEL

CONTROL BOX

DOOR/DRIVE COVER

MOTOR SPEED CONTROL PANEL

WIRE FEEDER CONTROL PANEL

WIRE FEED MOTOR 5 0 : l

WIRE FEED MOTOR 2 5 : l

WIRE FEED MOTOR 33 : L

COIL BRACKET SPINDLE ASSEMBLY

2 ROLL DRIVE ASSENBLY

GAS VALVE

PLUG SOCKET

I N D I C A T O R L I G H T

ON/OFF SWITCH

INCH/PURGE SWITCH

WIRE SPEED POTENTIOMETER

POTENTIOMETER KNOB

LOOM ASSEMBLY AND PC CONNECTORS

T E R M I N A L S T R I P

P . C . BOARD EDGE CONNECTOR

CABLE CLAMP

NYLON INSULATING BUSHES

TYPE NO, /SERIAL NO. NAMEPLATE

DOOR CATCH

MOUNTING INSULATORS

HOSE BARBS ON GAS VALVE

3 / 1 6 " GAS N I P P L E

GAS NUT

R E S I S T O R $ OHM HTR.50

RUBBER GROMMET

TERMINAL NAMEPLATE

1 - 4 -

F i t t h e c o i l b r a c k e t W1-48 t o t h e s p i n d l e e n s u r i n g t h a t o n e t h r u s t w a s h e r i s f i t t e d f i r s t , t h e n t h e c o i l b r a c k e t , a f u r - t h e r t h r u s t w a s h e r , a Keyed s teel l o c k w a s h e r , t e n s i o n s p r i n g , a n d t h e t e n s i o n screw i n t h a t o r d e r .

FITTING SUSPENSION BRACKET - PART NO, Wll-14 P o s i t i o n t h e s u s p e n s i o n b r a c k e t o n t h e s i d e p a n e l b e n e a t h t h e s p o o l b r a c k e t h o l d e r , s o as t h e t w o 3 /8" c l e a r a n c e h o l e s i n t h e b r a c k e t l i n e u p w i t h t h e . b o t t o m 2 h o l e s o f t h e c o v e r . A l s o c h e c k t h a t t h e L s h a p e b r a c k e t i s p o i n t i n g p a r a l l e l a n d u p w a r d s f r o m t h e b a s e . S e c u r e t h e b r a c k e t i n p o s i t i o n by t h e two 3/8"Hex. h e a d b o l t s .

If s p o o l e d wire i s b e i n g u s e d s u s p e n d t h e Wire F e e d e r f r o m t h e 4 6 ho le wh ich i s 2 / 2 3 " f r o m t h e e n d , f o r c o i l e d wire u s e t h e h o l e l" f r o m t h e e n d . U F I T T I N G CONTROL CABLE 0. Remove t h e Wire F e e d e r s i d e p a n e l a n d t h e n r emove t he U t i lux cab le c l amp f rom rear of Wire F e e d e r . Pass t h e c a b l e t h r o u g h t h e 7/8" 6 h o l e a t rear of Wire F e e d e r . S l i d e t h e U t i l u x c a b l e c l a m p over t h e c o n t r o l c a b l e w i t h t h e t a p e r e d s i d e s o f t h e c l a m p f a c i n g i n w a r d s , when the c l amp i s inser t - e d f r o m t h e o u t s i d e of t h e Wire F e e d e r . P o s i t i o n c l a m p s o 6"-8" of c a b l e , p l u s t e r m i n a l e n d s , p r o t r u d e t h r o u g h t h e c l a m p .

Squeeze c l amp f i rmly and push t ape red end t h r o u g h t h e h o l e i n t h e Wire F e e d e r u n t i l { t h e s h o u l d e r of t h e clamp comes a g a i n s t t h e s h e e t metal. I n t h i s p o s i t i o n t h e cable w i l l EE Til

b e s e c u r e l y h e l d . II 'a C o n n e c t t h e c a b l e t e r m i n a l s t o t h e t e r m i n a l s t r i p as f o l l o w s : ( R e f e r C i r c u i t Drg. W 1 4 - C l )

Brown WonPlugP in A T e r m i n a l S t r i p N o . 10 Black 9

4 I1

I t c I t It

Green Blue

I I

I1

'l D It E

11 I t

11 I1

7 It 8 C o n t r o l C a b l e

Connec t ion . FITTING OF FEED ROLLS

The wire s i z e o r p a r t numbers are s t a m p e d o n t h e s i d e of t h e f e e d roll. Drawing no. W2-19 d i a g r a m a t i c a l l y i l l u s t r a t e s t h e d i r e c t i o n of t h e wire f e e d , t h e p o s i t i o n o f t h e f e e d r o l l s a n d t h e wire g u i d e s .

The t a b l e s g i v e t h e wire s i ze i n b o t h metric a n d i n c h d i a m e t e r s . By r e a d i n g down t h e t a b l e u n t i l t h e p r o p o s e d wire diameter i s r e a c h e d a n d t h e n r e a d i n g a c r o s s t h e t a b l e t h e correct s e l e c t i o n o f d k i v e r o l l s a n d wire g u i d e s i s o b t a i n e d .

T o c h a n g e t h e d r i v e r o l l s , release the Tens ion Sc rew ( P a r t N o . W2-10) a n d h i n g e o p e n t h e t o p d r i v e r o l l h o u s i n g ,

W2 DRIVE ROLL & WIRE GUIDE_ ?

ACCESSORY TABLE.

-pL

I FLAT ROLLER, I I

a030 1 *8 l W2 - 20.

1-1 w 2 - 2 0 .

PLAIN VEE I 1 I ROLLER.

-4 I l /?6 1 1.6 l W2 -22 .

- I I E 3 b o d 5 1.2 w2-20 . - z PLAIN VEE E l I I ROLLER.

$ 1/16 1.6 W2 - 2 2 . 3 / 3 2 214 W2- 2 3.

DRAWING W2-19.

D PLAIN VEE ROLLER.

W 2 - 21 *

W 2 - 2 2 .

PLAIN VEE ROLLER.

W2 - 2 2 . KNURLED VEE

ROLLER.

W%-21;.

W2 -25. W2 -26. w2-27. W2-28.

"

-.-___j

" "

PLAIN VEE ROLLER. "P

W2 - 2 2 . PLAIN VEE

ROLLER. W 2 - 2 2 I

W 2 - 2 3 . ._

-

F

w2-31

W2 -32. "P

W2 -32. I" __3

W2-33.

W2-3L.

"

w2-3'1. "

"P

w 2 - 3 2 . w2-33. "

v"

BOTTOPI D R I V E ROLL

- 6 -

RemGve t h e caphead r e t a i n i n g screw and washe r l oca t ed on t he e n d o f t h e g e a r b o x o u t p u t s h a f t . Ext rac t t h e d r i v i n u g e a r a n d d r i v e r o l l f r o m t h e s h a f t . D e t a t c h d r i v i n g r o l l f r o m g e a r by r e l e a s i n ? t h e 3 caphead screws. R e f i t t h e d r i v i n g g e a r o n t h e o u t - p u t s h a f t m a k i n g s u r e t h a t t h e s l o t i n t h e b a c k o f t h e g e a r e n - g a g e s w i t h t h e p i n . Then s l i d e t h e new d r i v e r o l l o n t o t h e s h a f t a n d s e c u r e t h e d r i v e r o l l t o t h e gea r by t h e 3 caphead screws. Replace t h e c a p h e a d r e t a i n i n g screw and w a s h e r , s e c u r i n g t i g h t l y .

TOP D R I V E ROLL

Remove t h e 2 round head s e t screws s e c u r i n g t h e t o p d r i v e r o l l b e a r i n g c o v e r s i n p o s i t i o n . ( I t is n o t n e c e s s a r y t o s e p a r a t e t h e b e a r i n g c o v e r f r o m t h e s h a f t . )

By means o f the knur led screw e x t r a c t t h e t o p r o l l s h a f t a s s e m b l y c o m p l e t e w i t h t h e f r o n t b e a r i n g a n d b e a r i n g c o v e r . The d r i v e r o l l and d r iven g e a r c a n b e s e p a r a t e d by removing the 3 f i x i n g screws. U s i n g t h e t o p r o l l e r s h a f t a s a m a n d r e l s e c u r e t h e new d r i v e r o l l t o t h e d r i v e n g e a r . Once t h e a s s e m b l y i s c o m p l e t e r e f i t t h e t o p r o l l e r s h a f t i n t o p o s i t i o n s e c u r i n g t h e a s s e m b l y w i t h t h e b e a r i n g c o v e r by t h e 2 r e t a i n i n g screws.

D R I V E ROLL ALIGNMENT

A s r e f e r r e d t o e a r l i e r , t h e d r ive r o l l s , i n p u t g u i d e s a n d g u n c a b l e l i n e r s are p r e a l i g n e d when a s s e m b l e d i n t h e f a c t o r y a n d , t h e r e f o r e , no a d d i t i o n a l a l i g n m e n t i s n e c e s s a r y when us ing any of t h e d r i v e ro l l s . However e n s u r e g u n c a b l e l i n e r f e r r u l e i s a d j u s t e d as c l o s e as poss - i b l e t o d r i v e ro l l s w i t h o u t t o u c h i n g .

THREADING WIRE THROUGH WIRE FEEDER

2 R o l l Dr ive : Release t h e p r e s s u r e a d j u s t i n g screw and open t h e t o p feed r o l l y a t e a s s e m b l y . C u t t h e e n d o f t h e wire c l e a n - l y so i t i s f r e e of a l l b u r r s and k i n k s , a n d i s p e r f e c t l y s t r a i g h t . I n s e r t t h e wire by hand t h r o u g h t h e i n p u t g u i d e o v e r t h e b o t t o m f e e d r o l l a n d e n t e r i t i n t o t h e g u n c a b l e , e n s u r i n g wire f i t s i n groove of f e e d r o l l . P r e s s u r e i s t h e n a p p l i e d t o t h e t o p f e e d r o l l by l o w e r i n q t h e t o p g a t e and a d j u s t i n g t h e k n u r l e d screw u n t i l t h e wire i s g r i p p e d s n u g l y b y t h e f e e d r o l l .

NOTE: Do n o t e x e r t u n d u e p r e s s u r e o n t h e d r i v e rolls . Examine t h e g u n c a b l e l i n e r and t i p i f wire i s n o t f e e d i n g c o r r e c t l y , as e x c e s s i v e d r i v e r o l l p r e s s u r e w i l l c a u s e t h e wire t o deform and "p ick up" w i t h r e s u l t a n t wire k inks wh ich w i l l cause uneven wire f e e d .

CONNECTION OF TJIRE FEEDER TO POWER SOURCE

l . / Connect the c o n t r o l c a b l e f r o m t h e wire feed.er t o t h e c o n t r o l p l u g s o c k e t s i t u a t e d o n t h e f r o n t p a n e l of t h e Power S o u r c e l a b - e l l e d "To Wire F e e d e r " .

2 . / C o n n e c t t h e w e l d i n g l e a d t o t h e g u n c a b l e s e c u r i n g f i r m l y . P l u g t h e w e l d i n g l e a d i n t o t h e " p o s i t i v e " s o c k e t m a r k e d "Gun C a b l e " a l s o l o c a t e d o n t h e f r o n t p a n e l o f t h e power source . NOTE C o n n e c t t h e work l e a d t o t h e n e g a t i v e s o c k e t of power source atall times. 3 . / Connect g a s h o s e t o g a s o u t l e t o n t h e f r o n t p a n e l o f t h e power source o r if t h i s o u t l e t i s n o t p r o v i d e d , d i r e c t t o t h e

- . " .

gas f l owmete r . .

I TErl NO.

l

3 .

5 .

6 >

7.

8 .

9.

10.

12.

13.

14.

1 5 .

16.

1 7 .

20-30

31-35

36.

37.

PART NO

- 7 -

DRAWING W2-0 - PARTS L I S T I S S U E 1 " t

D E S C R I P T I O N

W 2 - 1

142-3

W2- 5

W2 - 6 ' W2-7

W2-8

W2 - 9

w2-10

W 2 - 12

0 4 0 2 0 2 4

0 4 0 5 0 2 4

W2-15

1\72-16

W2-17

142-20-30

W2-31-3 5

0302029

0305023

2 ROLL DRIVE ALUFlINIUEl BODY

2 ROLL DRIVE T@P ROLLER HOUSING

P I V O T

TOP ROLLER SHAFT

KNURLED SCREW

BEARING

BEARING COVER

TENSION SCREW

COMPRESSION SPRING

SCREW

SCREW

DRIVEN GEAR WHEEL

DRIVING GEAR WHEEL

WASHER

DRIVE ROLLS

I N P U T W I R E GUIDE

SCREW

SCREW

- 8-

i:: n

- 9 -

FUNCTION O F ELECTRICAL COMPONENTS I N CONTROL ASSEMBLY

A l l components a r e h o u s e d i n a h e a v y d u t y s t ee l c a b i n e t a p p r o x - i m a t l e y 1 9 0 mm ( 7 % " ) wide x 2 0 0 mm (11") h i g h x 432 mm ( 1 7 " ) d e e p . The motor s p e e d c o n t r o l i s s i t u a t e d o n thrz f r c n t p a n e l , b e n e a t h it are t h e "Power On" i n d i c a t o r l i g h t a n d t h e "Power On" s w i t c h a n d t h e "Gas Purge" , "Wire I n c h " , c o m b i n a t i o n s w i t c h . B e n e a t h t h e s e two s w i t c h e s are t h e "Gun S w i t c h " o u t l e t s o c k e t a n d t h e "Gas t o Gun" o u t l e t . S i t u a t e d o n t h e rear p a n e l i s t h e c o n t r o l c a b l e e n t r y a n d t h e gas s u p p l y e n t r y . T h e P.M. motor g e a r b o x d r i v e r o l l assembly i s b o l t e d d i r e c t v i a i n s u l a t o r s t o t h e base o f t h e Wire Feede r . A l l o the r componen t s a r e mounted on the Wire Feede r d i v i s i o n wal l which i s a t t a c h e d t o t h e f r o n t p a n e l . F o r c o n n e c t i o n o f t h e e l e c t r i c supp ly and fo r t h e c h a n g i n g of t h e c o n t r o l p a n e l s a l l o w i n g t h e Wire F e e d e r t o be a d a p t e d f o r d i f f e r e n t f u n c t i o n s , e . g . p l u g a n d s p o t w e l d i n g e t c . , and t he check ing o f componen t s f o r m a i n t e n a n c e p u r p o s e s , t h e s i d e p a n e l of t h e Wire Feeder has been made removable. On r e m o v i n g t h e p a n e l t h e f o l l o w i n g c o m p o n e n t s become a c c e s s i b l e s t a r t i n g f r o m t h e l e f t h a n d s i d e .

( a ) The e l e c t r i c a l t e r m i n a l s t r i p f o r a l l incoming and ou tgoing

(b) The Wll -7 wire f e e d p r i n t e d c i r c u i t c o n t r o l p a n e l .

( c ) The W14-11 m o t o r s p e e d c o n t r o l p a n e l .

( d ) The f r o n t p a n e l , e x p o s i n g a11 t h e e l e c t r i c a l c o n n e c t i o n s f o r

e l ec t r i ca l s e r v i c e s .

t h e items on i t . PRINTED C I R C U I T CONTROL PANELS

1. W 1 4 - l 1 Motor Speed Control Pane1

T h i s p a n e l p r o v i d e s t h e f o l l o w i n g : - ( a ) 3 0 V - D . C . C o n t r o l V o l t a g e S u p p l y

( b ) A f u l l wave S . C . R . h y b r i d b r i d g e c o n t r o l l e d b y a p h a s e s h i f t m o t o r c o n t r o l p i r c u i t p r o v i d i n g s t e p l e s s motor c o n t r o l a d j u s - tmen t .

( c ) A D . C . m o t o r f e e d b a c k c i r c u i t t o e n s u r e c o n s t a n t m o t o r s p e e d a t maximum t o r q u e .

2 . P1711-7 P r i n t e d C i r c u i t C o n t r o l P a n e l T h i s p a n e l p r o v i d e s t h e electrical c o n t r o l , f o r t h e f o l l o w i n g f u n c t i o n s :-

( a ) Gas s o l e n o i d valve c o n t r o l .

( b ) Gas Purge

( c ) Wire f e e d i n c h c o n t r o l

(dl M o t o r R e l a y c i r c u i t ( e ) Dynamic b reak ing o f wire speed motor c i r c u i t

( f ) Power Source Con tac to r Swi t ch ing Con t ro l .

( g ) I n f i n i t e l y v a r i a b l e b u r n b a c k c o n t r o l .

-10-

l 1

I

l

l

T a

II l ? - n ( .(

d

1- x p l

I

I

I r 1" "7

J l

DRAWING No W14-C2 -11- jo

@l CIRCUIT DIAGRAM FOR W14 WITH l? C. PANELS Wt4-l1 & W11 - 7

: I / -07 7

l

- l 2 - B o t h p r i n t e d c i r c u i t p a n e l s p l u g i n t o sockets mounted on the d i v i d i n g wal l o f t h e c a b i n e t . When r e m o v i n g , a n d r e f i t t i n g p a n e l s care s h o u l d b e t a k e n n o t t o d a m a g e c o n t a c t s o r t h e c o n - t a c t str ips. T h e c o n t a c t s a n d t h e c o n t a c t t r a c k s are g o l d p l a t e d t o e n s u r e good e l e c t r i c a l c o n d u c t i v i t y . I f f o r some r e a s o n t h e s e p a n e l s h a v e t o be c l e a n e d u s e a s o f t r a g dampened w i t h w h i t e s p i r i t or similar s o l v e n t . S t o r e u n u s e d p a n e l s i n a d u s t p r o o f c o n t a i n e r .

Wll-7 Wire Burn Back Adjustment

T h i s i s c o n t r o l l e d b y t h e p o t e n t i o m e t e r R 5 , t u r n i n g t h i s a d j u s t - ment c l o c k w i s e w i l l decrease t h e b u r n b a c k time, a n t i - c l o c k w i s e movement w i l l i n c r e a s e t h e time. OPERATION - METHOD & SEQUENCE - REFER SCHEMATIC C I R C U I T Iir14-C2

The 3 0 v . a . c . s u p p l y i s c o u p l e d t o t h e c o n t r o l r e c t i f i e r b r i d - g e 1 4 - D 9 a n d t h e SCR h y b r i d b r i d g e 1 4 - D I O . Diodes 1 4 - D 1 and. 14-D2 form a n e g a t i v e s u p p l y p o i n t w h i c h i s e l e c t r i c a l l y common w i t h t h e n e g a t i v e c o n t r o l v o l t a g e . Resistor 1 4 - R 9 and zener d. iode 14-D7 form a c l i p p i n q c i r c u i t t o s u p p l y t h e u n i j u n c t i o n o s c i l l a t o r com- pr is ing 14-R5,?4-Hl ,Tl and 1 4 - C l . T1 i s a p u l s e t r a n s f o r m e r h a v i n g t w o s e c o n d a r y w i n d i n g s w h i c h p r o v i d e t h e a p p r o p r i a t e g a t e vo l tage t o t h e two SCR's 1 4 - D 1 . 1 . I t i s t h e u n i j u n c t i o n o s c i l l a t o r w h i c h f a c i l i t a t e s p h a s e s h i f t c o n t r o l of t h e h y b r i d b r i d q e . V h i l e t h e m o t o r r e l a y K 1 r e m a i n s d e - e n e r g i s e d , 1 4 - C 1 has no cha rg ing p a t h , h e n c e t h e u n i j u n c t i o n o s c i l l a t o r c a n n o t o p e r a t e , a n d t h e S C R ' s a r e n o t t r i g g e r e d .

When t h e g u n s w i t c h i s c l o s e d , t h e g a s v a l v e i s e n e r g i s e d v i a d i o d e l l - D 8 . C o n t a c t o r r e l a y K 2 i s e n e r g i s e d v i a t r a n s i s t o r 11-Hl, and t h e b u r n - b a c k t i m i n g c a p a c i t o r l l - C 2 i s charged.. The motor r e l a y K 1 i s e n e r g i s e d v i a d i o d e s 1 1 - D l , l l - D 3 a n d r e s i s t o r l l - R 3 . Diode 1 1 - D 4 w i t h r e s i s t o r - c a p a c i t o r n e t w o r k 1 1 - R 6 and l l - C 1 e n s u r e s t h a t K 1 i s t h e l a s t r e l a y i n t h e s e q u e n c e t o e n e r g i s e .

With K 1 e n e r g i s e d , t h e o u t p u t of t h e SCR h y b r i d b r i d g e i s connec ted t o t h e wire d r i v e motor. C a p a c i t o r 1 4 - C 1 i s now p r o v i d e d w i t h a c h a r g i n g p a t h , v i a t r a n s i s t o r 1 4 - H 2 and r e s i s to r 1 4 - R 6 . When t h e c h a r g e i n c a p a c i t o r 1 4 - C 1 r e a c h e s a pre-de termined l e v e l , t h e u n i - j u n c t i o n t r a n s i s t o r 1 4 - H 1 c o n d u c t s , d i s c h a r g i q t h e c a p a c i t o r i n t o t h e p r i m a r y w i n d i n g o f p u l s e t r a n s f o r m e r T I . T h i s c a u s e s a v o l t a g e p u l s e t o a p p e a r a t t h e g a t e s o f t h e two SCR's. The SCR which i s f o r w a r d b i a s e d ( a n o d e p o s i t i v e ) w i l l t u r n on a t t h i s p o i n t . The motor now b e g i n s t o r o t a t e , b u i l d i n g u p t o t h e p r e - s e t s p e e d . T h e amount o f phase-sh i f t i s de te rmined by t h e c h a r g i n g time of 1 4 - C 1 , w h i c h i n t u r n i s de te rmined by t he level of c o n d u c t i o n o f t r a n s i s t o r 1 4 - H 2 . The base v o l t a g e o f 1 4 - H 2 i s c o n t r o l l e d by t h e s p e e d p o t - e n t i o m e t e r s e t t i n g , w h i l e i t s emit ter v o l t a g e i s i n p r o p o r t i o n t o t h e b a c k e . m . f . o f t h e d r i v e m o t o r . Moving t h e p o t e n t i o m e t e r t o i n c r e a s e t h e m o t o r s p e e d m a k e s t h e b a s e of 1 4 - H 2 , more nega t ive . 14:-F2 then ' , i s t h e summing^. p o i n t OF a s i r cp le f eed back sys t em w h i c h c o m p a r e s t h e p o t e n t i o n e t e r v o l t a y e w i t h t h e m o t o r b a c k e . m . f . t h e r e s u l t a n t d e t e r m i n i n g t h e t u r n - o n p o i n t of t h e SCR's i n t h e hy- b r id b r id -ge . The above e n a b l e s t h e n o t o r s p e e 6 . t o remain r e l a t - i v e l y c o n s t a n t a g a i n s t v a r y i n g load c o n d i t i o n s .

On re lease of t h e g u n s w i t c h , the g a s valve i s de -ene rg i sed , mo to r r e l a y K1 opens, and i t s n o r m a l l y c l o s e d c o n t a c t s p l a c e a low res- i s t a n c e across t h e motor a r m a t u r e , p r o v i d i n g d y n a m i c b r a k i n g . Contactor r e l a y K 2 i s h e l d e n e r g i s e d f o r a s h o r t t ime, de t e rmined by t h e s e t t i n g of potentiometer l l - R 5 which forms t h e d i s c h a r g e p a t h f o r c a p a c i t o r l l - C 2 . T h i s i s c a l l e d b u r n - b a c k time, and h a s t h e e f f e c t o f p r e v e n t i n g t h e w e l d i n g wire f r o m " f r e e z i n g i n the we ld pudd le a t t h e e n d of a weld.

L

TROUBLE SHOOTING - 13 - Only a q u a l i f i e d e l e c t r i c a l se rv iceman shou ld service t h e u n i t . W . I . A . S e r v i c e T e c h n i c i a n s a re t r a i n e d t o e f f e c t i m m e d i a t e r e p a i r s t o t h e e q u i p m e n t i n t h e e v e n t o f f a i l u r e . T h e f o l l o w i n g f a u l t s , however , can be checked .

A . DRIVE P-IOTOR WILL NOT TURN WHEN G U N SWITCH I S OPERATED AND SPEED CONTROL I S SET TO THE DESIRED SPEED.

- "

1. Check t h a t 3 0 v o l t s A . C . power i s turned on and a l l f u s e s a re i n t a c t .

2 . Press I n c h S w i t c h , i f m o t o r t u r n s , f a u l t c a n e i t h e r be i n gun swi t ch or t h e s w i t c h wires i n t h e g u n cable . If motor d o e s n o t t u r n v i s u a l l y c h e c k b o t h p r i n t e d c i r c u i t b o a r d ' s and make s u r e t h a t a l l component ry , wi r ing , and e l e c t r i c a l c o n n e c t i o n s a re s e c u r e . C h e c k m o t o r r e l a y K 1 o n p r i n t e d c i r c u i t b o a r d a n d e n s u r e it i s o p e r a t i n g c o r r e c t l y .

B . FUSES BLOW REPEATEDLY WHILST WELDING

l. Check t o see t h a t sl.ow-blow t y p e f u s e s a r e b e i n q u s e d . S t a n d -

2 . Motor may b e o v e r l o a d e d - check: -

( a ) Wire Reel Brake - r ee l s h o u l d o n l y h a v e e n o u g h b r a k e p r e s s u r e a p p l i e d t o p r e v e n t i t f rom over - running a f t e r t h e d r ive motor S t o p s .

a r d f u s e s may hea t and b low even a t low motor l o a d s .

( b ) Feed R o l l P r e s s u r e s h o u l d o n l y be s u f f i c i e n t t o p u s h t h e wire e v e n l y . E x c e s s i v e p r e s s u r e c a n d e f o r m b o t h f l u x c o r e d a n d s o l i d wires.

( c ) Dirt i n t h e wire f e e d t u b e - blow o u t

( d ) O b s t r u c t i o n i n t i p - r e a m o u t . R e p l a c e t i p when worn o v e r s i z e . ( e ) Buck les i n weld wire - c u t o u t

(f) Rusty Wire - - r e p l a c e

(g) Check Feed r o l l g e a r t e e t h f o r i n t e r f e r i n g m a t e r i a l , d i r t or wire " b i t s " .

3 . Motor r e l a y K 1 c o u l d h a v e c o n t a c t s f u s e d t o - g e t h e r c a u s i n g a s h o r t c i r c u i t i n t h e m o t o r c i r c u i t . R E P L A C E RELAY

MAINTENANCE POINTS TO WATCH FOR M A X I M U M EFFICIENCY

Good wire f e e d i s more than dependent on good gun and cab le main- t e n a n c e , a n d t h e f o l l o w i n g p o i n t s s h o u l d b e c h e c k e d a t a l l times:-

( a ) Blow o u t g u n cables a n d l i n e r w i t h d r y c o m p r e s s e d a i r a t r e g u l a r i n t e r v a l s a n d , p r e f e r a b l y , a f t e r e a c h spool o r c o i l of wi re .

(b) C o n t a c t t i p s s h o u l d be k e p t c lear o f s p a t t e r a n d h o l e s i z e s h o u l d b e c h e c k e d r e g u l a r l y .

( c ) R e g u l a r l y c h e c k g a s l i n e s a n d c o n n e c t i o n s fo r t i g h t n e s s t o p r e v e n t p o r o s i t y o c c u r r i n g i n weld .

( d ) K e e p g u n c a b l e f r e e from sharp bends and loop same i n a ' ' C " c u r v e i n p r e f e r e n c e t o a n "S" c u r v e . I f Wire Feede r can be s u s p e n d e d o v e r h e a d , t h i s g r e a t l y i m p r o v e d c o n s i s t e n c y o f f e e d r a t e .

( e ) For C 0 2 g a s , u s e gas p r e h e a t e r a t a l l times t o e l i m i n a t e g a s f l o w i r r e g u l a r i t i e s c a u s e d by g a s " f r e e z i n g " o f t h e r e g u l a t o r .

F u l l m a i n t e n a n c e a n d o p e r a t i o n i n s t r u c t i o n s f o r good gun cable ma in tenance are s e t o u t i n O p e r a t i o n M a n u a l o n W . I . A . Gun C a b l e s .

ITEM NO . 1 2 3 4 5 R1 R2 R3 R4 R5 R6 R7 R8 R9 c1 c2 H1 H2 TI Dl D2 D3 D4 D5 D6 D7 D8 D9 D10 Dl1

PART NO.

W14-11/1 W1-53/2 \41-53/3 Wll-6/4 W14-11/5 Wll-7/9 Wll-7/9 Wll-7/13 W11-7/13 CP23-17/16 AM69-1/14 Wll-7/9 W11-25/12 1~711- 2 5/12 CP23-17/9 Iil11-6/15 Wll-7/20 W11-25/17 W11-7/23 Wll-7/18 W11-7/18 Wll-7/18 W14-11/22 W11-7/18 Wll-7/18 W11-25/25 Wll-6/18 W11-6/17 MC36-2/16 W11-10/4

- 14 -

DRAWING NO. Wl4-11 PARTS LIST ISSUE NO. 1.

DESCRIPTION

PRINTED CIRCUIT PANEL FASTENING SCREW FASTENING BUSH TEST PINS ALUMINIUM HEAT S INKS CARBON RESISTOR 1K. OHM %W, 5% CARBON RESISTOR 1K. OHM %W. 5% CARBON RESISTOR 100 OHM %W. 5% CARBON RESISTOR 100 OHM +W. 5% CARBON RESISTOR 390 OH14 $W. 5% CARBON RESISTOR 4.7K OHM $14. 5% CARBON RESISTOR 1K. OHM $W. 5% CARBON RESISTOR 3.3K OHM $W. 5% CARBON RESISTOR 3.3K OHM $W. 5% POLYESTER FILM CAPACITOR 2OOV. 0.47 MFD 20% TANTALUM CAPACITOR 25v 10 MFD 20% UNIJUNCTION TRANSISTOR 2N2646 P.N.P. TRANSISTOR 2N4249 TYPE UE PULSE TRANSFORMER NO. 273543 DIODE ITT EM404 DIODE ITT EM404 DIODE ITT EM404 ZENER DIODE 1.R. 22v 5W IN5358 DIODE ITT EM404 DIODE ITT EM404 ZENER DIODE 1.R. 1 8 ~ 5 . W . IN5355 ZENER DIODE 1.R. 5 . 6 ~ 5W. IN5339 DIODE BRIDGE ED1 PK40 DIODE A.E.I. M16-400 SCR A.E.I. C30D

-15- P C PANEL W14-11

1 I

0

- E 1 I

ISSUE NO2

ITEM N O .

l 2

3

4

5

R 1

R2

R3

R4 R 5

R6

c1 c 2

H 1

K 1

K2

D 1

D2

D 3

D4

D 5

D 6

D7

D 8

D9

PART NO.

W11-7 /104

W1-53/2

W1-53/3

W11-6/4

W11-7/27

~ 1 1 - 7 /4

F J l l - 7 / 1 0

W11-7/6

W l l - 7 / 7 W l l - 7 / 8

W l 1 - 7 / 9

W11-7/19

W11-7/24

W l l - 6 / 2 1

W11-7/26

W11-7/26

W l l - 7 / 1 8

W l l - 7 / 1 8

W l l - 7 / 1 8

W l l - 7 / 1 8

W l l - 7 / 1 8

W11-7/18

W11-7/18

Wl l -7 /18

W l l - 7 / 1 8

- 1 6 - DRAWING N O . Wll-7 PARTS L I S T

DESCRIPTION

PRINTED CIRCUIT PANEL

FASTENING SCREW

FASTENING BUSH

TEST P IN N O . 4 7 2 5 - 0 1 - 0 1

RELAY BASE

CARBON RESISTOR 47 I< OHM %W 5%

CARBON RESISTOR 2 .2K OHM %W 5%

CARBON R E S I S T O R 2 2 OHM %W 5%

CARBON RESISTOR 33 OHM %W 5% CARBON POTENTIOMETER PLESSEY TYPE MP/PC 50K OHPI

CARBON RESISTOR 11< OHM %W 5%

ELECTROLYTIC CAPACITOR ELNA 5 0 V 1 0 0 MFD TYPE RB

ELECTROLYTIC CAPACITOR ELNA 50V 10 MFD TYPE RB

TRANSISTOR BC337

RELAY 24V DC COIL

RELAY 24V DC COIL

DIODE I T T S D 4 0 4

DIODE I T T S D 4 0 4

DIODE I T T S D 4 0 4

DIODE I T T SD 4 0 4

DIODE I T T SD 4 0 4

DIODE I T T S D 4 0 4

DIODE I T T S D 4 0 4

DIODE I T T SD 4 0 4

DIODE I T T S D 4 0 4

-17 -

p. C. PANEL W11-? DRAWING N o W1 1 - 7/05

PARTS LIST ISSUE NO6

k

l

P

DRAWING NoAM113&AM114

COIL BRACKET SPINDLE ASSEMBLY NO. Wll-9

SPOOL HOLDER NO. W1-38

Item No. Description - l 2 & 4

, 3 5 6 7 8 9 L O 11 12 13 1.4 1 5

T h r u s t Wahsers Spindle S h a f t Keyed Washer Tension Spring Tension Screw Spool Holder Spool Retainer Clamp Spool Retainer Clamp Screw Wire Coil Holder Wire Coil Holder Retaining Clamps Tension Springs Tension Wing N u t s Shaft

c o n HOLDER ASSEM~LY NO. w1-4

P a r t No. w11-9

W1-37/5 W11-9/2 W1-37/4 W1-37/6 W1-37/’3 W1-38 W1-38R W1-38s W1-48 W1-48/1 W1 - 4 8 / 2 F!1-48/3 W1-4 8 /4

Wll-9/1