north american canadian distributor - welding€¦ · synchro-pulse cdt manual page 5 volt# iohl...

MANUFACTURED BY WELDING INDUSTRIES OF AUSTRALIA PTY LTD

NORTH AMERICAN / CANADIAN DISTRIBUTOR:

CRC-EVANS AUTOMATIC WELDING 11601 North Houston - Rosslyn Road Houston, Texas 77086

Phone: 999 8920 Telex: 230 240714 CRC AWUR

WELDMATIC SYNCHRO-PULSE CDT

MODEL NO. CP34

(CP34-2 6OHz. Multi Voltage)

CAT. 1 2 / 8 7

THE INFORMATION CONTAINED IN THE FOLDER IS SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER IS KEPT IN A SAFE PLACE FOR READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NO. OF THE MACHINE AND PART NO. OF THE ITEM REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT IN UNNECESSARY DELAYS IN SUPPLYING THE CORRECT PARTS.

-SAFETY-

Before thls equipment is put into operation, t h e SAFETY PRACTICES section a t t h e back of the Manual MUST BE READ COMPLETELY. This will help avoid possible injury d u e to misuse o r improper welding applications.

[ CONTENTS I 1 . SPECIFICATIONS 1 . 1 Technical 1 . 2 Standard Package 1 . 3 Optional Accessories 1 . 4 Welding schedules

2 . RECEIVING

3. INSTALLATION 3.1 Machine Location 3.2 Connection to Electr

Mains Supply

Page 3

Page 3

ical

3 . 3 Cable & Hosk Connections

4. CONTROLS Page 7

5. WELDING SET-UP Page 9 5. I Electrode Wire and

Shielding Gas 5.2 Work Lead 5.3 Welding Current

Presetting Guide 5.4 Normal Welding Sequence

6 . GENERAL MAINTENANCE Page 12 6 . 1 Dust 6.2 Wire-feed

7 . TROUBLE SHOOTING Page 12 7.1 Unsatisfactory Welding

Cond i t i o n s 7.2 No Welding Current 7 . 3 Uncontrolled Welding

Current

8. PRINCIPLE OF OPERATION Page 16 8 .1 Pulsed-arc Metal Transfer 8.2 High-Current Switch 8 . 3 Control Circuits

9 . PRINTED CIRCUIT BOARDS Page 20 9 . 1 Main Control Board 9 . 2 Diagnostic LED Indicators 9.3 Diagnostic Test Points 9 . 4 Wire-feeder Control board

CP34-85

10. SERVICE INFORMATION Page 27 10.1 Dis-assembly of the

Rectifler/Switch Unit 10.2 Parts list, CDT Power Source 10.3 Parts List,

1 0 . 4 Parts L i s t , Bernard E2 Gun 10.5 Parts List,

Rectifier/Switch Assembly

Two Roll Drive Assembly

11. PUSH-PULL OPTION Page 37 1 1 . 1 Fitting Instructions f o r

Pull Type Welding Gun 1 1 . 2 Par t s Lists and

Assembl y Drawings

1 2 . SAFETY PRACTICES

Fig. 1 2 3 4 5 6 7 8 9 IO 1 1 12 13 1 4 15 16 1 7 18 19 20

U

U

I,

m

n

U

U

H

Y

L(

U

U

H

U

U

H

n

Supply and Voltage Selection Terminals Welding Transformer Voltage Selection Cable and Hose Connections Power Source Controls Arc Sensing Connections Welding Current and Droplet Transfer High Current Switch Typical Welding Current Waveform Block Diagram - Control Circuits Main Control Board Overlay Wire Feeder Control Board Overlay Circuit Diagram CDT Power-Source Assembly Rectifier/Switch Assembly Bernard E2 4 0 0 Amp Gun Assembly Two R o l l Drive Assembly Drive Roll and Wire Guide Table Hulftegger/WIA Pull Gun & Cable Assembly Hulftegger Gun Exploded View Bernard/Hulftegger Torch Neck Assembly

Page 4 3

SYNCHRO-PULSE CDT MANUAL PAGE 2

J, 1 TECHNICAL

- Output : 40-350 Amps k - Duty Cycle : 350 Amps, 100% - Open circuit voltage : 70 volts - Weight : 530 lbs - Wire Speed Range : 40-630 Ingheslmin - Insulation : Class 'H' - 225 F rise at 104'F ambient - Enclosure : Drip-proof

(* o r as programmed)

1 . 2 STANDARD PACKAGE

- CP34 Synchro-Pulse CDT Welding Power Source - W21-5 Wire Feeder - CP34-36 Remote Control Pendant - AM167 Accessory Lead K i t - Bernard G u n Cable Assembly - K2 Gas Regulator & Flow Meter - K4 Argon Gas Elbow

1 , 3 OPTIONAL ACCESSORIES

- A M 1 6 6 P u s h - p u l l Gun Cable A s s e m b l y a n d C o n t r o l - AM117 Mobile K i t : - AM167-0/9 Thirty F o o t Accessory Lead K i t

I. 4 WELDING S C H E D U M

Information g i v e n for EPROM #l0500

Schedule Electrode pre -gas ramp ( a e c ) (sec)

A- 1 Mild Stee l .035 " .3 .3 A- 2 Mild S t e e l 0 4 5 " .3 .3 A- 3 316 Stainless .035" .3 .3 A-4 316 Stainless .045" . 3 .3 A-5 5356 A l u m i n i u m .045" . 3 .3 A-6 5356 Aluminium , 0 6 2 " .3 - 3

B- 1 Si 1 icon Bronze ,030" * 3 .3 B- 2 Silicon Bronze .035" . 3 .3 B- 3 Mild Steel .05 2 " .3 . 3 B-4 LINDE-95 ,045 " .3 .3 R-5 316 Stainless ,030" . 3 .3 B-6 5356 Aluminium .035" . 3 . 3

f i l l

.6

. 6

. 6

. 6

. 6

.6

0 0

. 6

. 6

. 6

. 6

0 burnback

( s e c ) . 072 .072 , 0 7 2 .072 .07 2 .072

.072

. 0 7 2 , 0 7 2 .072 ,072 .07 2

p05t-ga5 " 0 . 6 0.6 0.6 0.6 0.6 0.6

0.6 0.6 0.6 0.6 0 . 6 0.6

By fitting a replacement EPROM, other weld schedules and o t h e r selections of timed periods a r e available.


In general it is a good practice to move the equipment to the site of installation before uncrating. Use care in uncrating i n order to avoid damage.

Check the equipment received against the shipping invoice to make sure the shipment is complete and undamaged.

I f any damage has occurred in transit immediately notify CRC Evans Automatic Welding or their authorized agent.

F o r all requested information related t o this equipment give the correct Model Identification and Serial Number. This is 1ocated.on a name plate attached t o the right-hand lower front of the machine.

3. INSTALLATION

3.1 MACHINE LOCATION

Where posslble, in choosing a site for any welding power-source, consideration should be given to the following points:-

- Availability o f electrical and shielding gas supplies.

- Accessibility for t h e replacement o f consumables, i.e. weldlng wire and gas bottles, and f o r any future maintenance requirements.

- The p o w e r - s o u r c e must be p o s i t i o n e d so t h a t t h e f r e e f l o w o f c o o l iny alr’. t h r o u g h t h e machlt-le i s n o t Impeded, such as; by placing t h e r e a r o f t h e machine t o o c l o s e t o a wall.

- Protection from wind and driven rain - Breezes blowing through an open doorway can result i n degradation o f t h e weld shielding gas coverage, which can cause weld porosity. I f such a site is unavoidable, consider.ation should be given to the use of portable welding screens of a suitable material, The outflow of cooling air from the welding power-source can also cause similar problems, and t h e machlne should be positioned with this in mind.

- Airborne dust particles w i l l always accumulate in vented equipment, particularly that wlth forced air coollng and excessive buildup can often be the cause of premature machine failure. A t all times endeavour to position the machine to minimize the intake of contaminated air, particularly that containing metal1 ic particles such as from grinding operations. (See also the GENERAL MAINTENANCE section of this Manual.)

3.2 CONNECTION TO ELECTRICAL MAINS POWER SUPPLY

A l l electrical work shall o n l y be undertaken by a qualified electrician.

-CAUTION-

I Ensure that the Power-source is disconnected f rom the Electrical Malns before undertaking this procedure. I


SUITABLE MAINS VOLTAGES

The Synchro-Pulse CDT is designed f o r connection to a 3 Phase 60Hz Electrical Mains power supply. The chart below lists the suitable electrical mains voltages (phase to phase) and the appropriate current demand.

NOTE: I t i s mandatory that the correct Electrical Mains voltage taps be selected before the equipment is operated.

Failure to do so may v o i d warranty.

MAINS VOLTAGE I CURRENT DEMAND PER PHASE

240 460 480 510 575

44A 23A 22A 2 1 A 18A

Access to the machine supply terminals and the combined welding transformer and control transformer voltage selector is gained by removing the Power-source side panel adjacent to the front panel meters. The location of each point is indicated below,.

FIGURE 1. SUPPLY A N D VOLTAGE SELECTION TERMINALS

When making connection to the Machine Supply terminals, ensure that local codes are adhered to, and that the EARTH connection is secure 1 y made. A cable anchor f o r flexible power cables is supplied with the machine.

WELDING A N D CONTROL TRANSFORMER VOLTAGE SELECTION

The Welding and Control Transformer voltage selection taps are combined in one unit, as illustrated in figure 2 (following).

Install the links (total o f s i x ) in the manner shown in the figure.

NOTE: I n this diagram, links a re connected for 575V.

STAR/DELTA CONNECTION

For the mains voltages applicable to this model CDT, DELTA connection is required f o r 240V mains supply only,

For all other supply voltages (460, 4 8 0 , 510, 575) use S T A R (WYE) connection.


VOLT# IOHL WELDIN0 TAANaFORMER CONTROL YRAN8. 2 4 0 V 0 0 0 0 0 0 0 0 0

460v 0 0 0 0 0 0 0 0 0 480V 0 0 0 0 0 0 0 0 0

5 l O V 0 0 0 0 Q 0 0 0 0

I T A R OELTA CONNECTION6

DELTA

460 240 480 610 675

FIGURE 2 . WELDING AND CONTROL TRANSFORMER VOLTAGE S E L E C T I O N T A P S

3.3 CABLE AND HOSE CONNECTIONS

A l l welding c u r r e n t , c o n t r o l a n d shielding as connections a re s h o w n i n figure 3, page 6. The complete set o f necessary c a b l e s a n d h o s e s are contained in t h e standard accessory kit A M 1 6 7 .

SHIELDING GAS HOSES:

The accessory kit contains two gas h o s e s . The shorter length Is used t o j o i n the output of the shielding gas regulator / flowmeter to the gas nipple on the rear panel of the Power-source. The second hose is used to make the gas connection from the power source front panel to the rear of the W21 wire feeder.

CONTROL CABLES:

Engage the remote control and the wire feeder control cable plugs i n t o their respectively marked sockets on the power source f r o n t pane l . The control cable connections f o r the wire feeder are shown in figure 3 .

Where a ‘Hulftegger’ pull gun is to be used , the wire feeder will be fitted with a ‘Cannon’ socket a n d a gas outlet, v i a which t h e necessary connections t o the welding gun are made. For field installation refer t o chapter 1 1 . T h e wiring associated with this socket is shown i n dashed lines in t h e diagram.

r


WELDING CURRENT CABLES:

Pulsed arc G . M . A . welding is conducted with the electrode polarity positive, and the workpiece negative. The positive output of the power source i s connected to t h e welding g u n v i a an adapter mounted with the wire drive mechanism. Ensure that both t h e positive welding cable AND the voltage sensing wire are securely bolted to t h i s adapter.

The negative output of the power source . i s connected t o the welding cable incorporating the work clamp. Both leads are secured at the power source by inserting the plug into i t s appropriate socket and rotating clockwise t o 1 ock

e GAS REGULHOR

REMOTE CONTROL

t

+TO GUN CABLE CONTROL CABLE

CANNON EP8 PLUG 9 CORE FLEX W21 WIRE FEEDER TO FULb GUN

Green - - -- Whfte-<Gun Switch) - Red Red- (Motor) Green/Yellow--- White-(Gun Switch) - Red/Black Black-(Motor) White Grey-(Arc Volts Sense)

i GUN SWITCH)

Blue- - - Blue c - -- - - - 7 Brown - - -- Brown- - - - - - (MOTOR 1

B1 ue /White (Spare )

CANNON XLP PLUG 3 CORE FLEX PEMOTE CONTROL

2 Bluelx-/”’””rrent’ Brown l“ 3 Gree

l t A r c L e n g t h ’

(both 1K ohms)

FIGURE 3. CABLE AND HOSE CONNECTIONS

SYNCHRO-PULSE CDT M A N U A L PAGE 7

4 . CONTROLS

GROUP

CURRENT CONTROL ARC LENGYH COMROL - REMOTE PENDANT

FIGURE 4. CDT WELDING POWER SOURCE CONTROLS

POWER OFF/ON:

Use to energise o r de-energise the Power-source and wire feeder.

POWER ON INDICATOR:

Tbis is illuminated when the Power-source is energised, indicating that the power c o n t r o l circuits are activated.

FUSES :

Upper 3 Amp .slow-blow t y p e 3AG - P r o t e c t s t h e contactor circuit.

Lower - 10 Amp standard action t y p e 3 A G - Protects t h e wire f eeder circuit.

SYNCHRQ-PULSE CDT MANUAL PAGE 8

INCII/PURGE SWITCH:

This is a dual function switch, moving down operates the gas solenoid valve and provides the gas PURGE function. This function enables the gas lines to be purged with the selected shielding gas and permits the gas flow rate t o be adjusted t o its correct operating condition, e.g. 20 to 30 cflhour.

Moving the i n c h purge switch up operates the wire f e e d motor, feeding the wire into the gun cable system. The wire feed speed during INCH is determined by the setting on the current control pendant.

PROGRAMME SWITCH:

This switch must be s e t according t o the welding consumable i n use. The standard Synchro-Pulse CDT is supplied with a weld programme set comprising 1 2 individual schedules as detailed on page 2. Other schedules are available from the manufacturer.

GROUP SWITCH:

The 12 weld schedules referred to above are accessed in t w o groups ( A and B > each of six schedules. The group switch is used to select the desired group of schedules.

AMMETER:

The Ammeter indicates the welding current (amp5 a v e r a g e ) .

VOLTMETER :

The Voltmeter i n d i c a t e s the welding voltage (volts a v e r a g e ) .

CONTROL PENDANT:

Consisting o f a metal box and a flexible cord connected to the Power Source, this unit provides:-

Current control Arc length control.

‘CURRENT’ CONTROL - is obtained via a 10 turn vernier control. This one control adjusts all the welding parameters together, e g . wire-feed rate, arc voltage, pulse frequency and background c u r r e n t .

‘ARC LENGTH’ CONTROL - is achieved by turning the potentiometer from its mid-point position. Turning towards ‘ i ” increases arc length and towards ‘-’ d e c r e a s e s arc length.

NOTE: The mos t ideal welding conditions are achieved when the arc length is adjusted t o be a5 short as practicable whilst maintaining a stable spray mode o f welding arc. (An occasional short circuit associated with a crackle sound is acceptable.)

Changes in weld preparation and/or work piece temperature may require adjustment o f the arc length in order to maintain the above conditions.


5. WELDING SET-UP

5.1 ELECTRODE WIRE/SHIELDING GAS

Select the desired consumable electrode wire and f i t to the wire feeder. Ensure that the wire feeder i s fitted with the correct drive rollers - see page 36. Connect to the gas regulator/flowmeter a supply o f shielding gas appropriate t o the welding consumable. See list below.

RECOMMENDED SHIELDING G A S MIXTURES

M I L D STEEL High Purity Argon t 5 % C02 STAINLESS STEEL High Purity Argon t 5% C02 A L U M I N I U M Argon S I LT CON BRONZE Argon -i- 0.5% Oxygen L I N D E 95 High Purity Argon t 5% CO2

Select the appropriate Synchro-Pulse CDT schedule. Use only the correct Combination o f consumable / shielding gas / schedule. Incorrect combinations will produce unsatisfactory welding results.

S e t the gas flow rate to suit t h e welding procedure. This is usually i n the r ange of 20 to 30 cf/hour, h o w e v e r particularly f o r high current welding of aluminium, i n c r e a s e d f l o w rates may he required.

NOTE:- Excessive g a s f l o w is costly and may adversely affect t he welding conditions.

5 . 2 WORK LEAD

Firmly fix the ‘work clamp’ to the work piece, as close as possible t o the welding zone . Ideal welding conditions will only be achieved i f all connections are properly secured. It is preferable wherever possible to weld towards the work clamp,


5 .3 AVERAGE WELDING CURRENT-PRESETTING GUIDE

The chart below may be used a5 a guide in presetting the Synchro- Pulse CDT to deliver a given welding c u r r e n t . I t is presented as a guide only, as the actual welding current can be influenced by o t h e r factors, such as the e l e c t r o d e wire stickout.

GROUP A

"Current" Setting

1.0 2 . 0 3.0 4.0 5.0 6.0 7 . 0 8 .0 9 .0

10.0

GROUP B

.035 M/Steel

45 6 5 85

105 125 145 170 190 210 230

.045 M/Steel

5 0 85

115 150 185 215 250 285 315 350

"Currentu/ .030 I .035 Setting S / B r o n z e S / B r o n z e

l . o 2 . 0 3 . 0 4 . 0 5 . 0 6.0 7 . 0 8.0 9.0

10.0

35 40 5 0 5 5 65 70 80 85 95

100

5 0 G5 85

100 115 135 150 165 185 200

.035 S / S t e e 1

40 55 75 95

110 130 145

. l 6 5 180 200

.045 S / S t e e l

50 8 0

110 145 175 205 2 35 270 300 330

6 0 9 0

1 2 5 155 190 2 2 0 255 285 320 350

x M / S t e e l LINDE-95

45 7 5

100 130 160 185 215 245 270 300

.045

35 6 0 8 5

110 130 160 180 205 230 255

3 0 45 5 5 7 0 8 5 9 5

110 I25 135 150

70 100 125 155 180 210 2 35 265 290 320

. 0 3 0 . 0 3 5 S/Steel A l u m i n i u m

25 35 45 55 65 75 85 9 5

105 115

SYNCHRO-PULSE CDT MANUAL PAGE I 1

5.4 NORMAL WELDING SEQUENCE:

Closing the welding gun switch w i l l initiate the following sequence of events:

- PRE-WELD GAS FLOW. The Power Source contactor is turned o n , the gas v a l v e will open and shielding gas flows for a pr-e-set period.

- ARC INITIATION. At t h e end of t h e pre-gas p e r i o d , the Power Source welding output is turned on, and welding voltage is applied between the work-piece and the electrode wire. Simultaneously, the w i r e drive motor w i l l be started, and will begin to f eed electrode w i r e at a slow rate.

During this phase, the Power-source is set to produce welding current pulses at a relatively high frequency to facilitate arc initiation.

- RAMP UP. Following the electrode wire making contact with the the work-piece, and the establishment of t h e arc, the p u l s e frequency immediately d r o p s to a low frequency consistent with the wire f e e d rate. As the wire f eed rate ramps up to the chosen ‘CURRENT’ setting, so also does the pulse frequency.

- CRATER FILL. To end welding, the gun switch is released. This initiates a period o f ‘Crater Fill’ during which the wire-feed rate ramps down t o a fixed point over a s e t period.

- WELD END. A t the completion o f t h e Crater F i l l p e r i o d , t h e wire drive motor is dynamically b r a k e d to s t o p . A f t e r a short, p r e - s e t period, known as t h e ‘hurn-back’ t i m e , t h e Power S o u r c e welding output i s turned off. This period e n s u r e s t h a t t h e e l e c t r o d e wire d o c s n o t ‘freeze’ i n the weld p o o l .

- POST-WELD GAS FLOW. The gas v a l v e will remain open f o r a pre-set time, providing shielding gas to protect the cooling weld poo l from atmospheric contamination. The c o n t a c t o r is turned off.

These functions are represented in the diagram below:

Gun Sw i tch

P r e Pos t Shielding Gas

Welding Output /Burn Rack 4

Wire Feed Rate


6 . GENERAL MAINTENANCE

6 . 1 DUST

A 5 mentioned elsewhere in this Manual, care should be taken to prevent excessive build-up o f d u s t and dirt within t h e welding Power-source. It is recommended that at regular intervals, according to the prevailing conditions, t h e machine covers be removed and any dust accumulation be removed by the use of dry, low pressure compressed air, o r a vacuum cleaner.

Ensure that the CDT Power-source is disconnected f r o m the Mains v01 tage power supply b e f o r e any covers are removed.

6.2 WIRE-FEED

A 5 with any G . M . A . welding process, in o r d e r t o obtain the most satisfactory welding results, the wire feed should be smooth and constant. It is therefore important t o observe the following points:

- Keep t h e gun cable liner clear o f dust and swarf build-up. When replacement becomes necessary, fit only the correct liner t o suit the g u n cable model, and electrode type and size. The build-up of dust in a cable liner can be minimized by regular purging of the liner with dry compressed air. T h i s may be conveniently done e a c h t ime t h e wirc spool is r e p l a c e d .

- Replace t h e welding t i p as it becomes w o r n o r damagod.

- Keep the w i r c drive mechanisn cI.eat1. P e r i o d i c a l l y check t h e drive rollers f o r wear and for free rotation.

- Check that the electrode wire spool holder rotates smooLhly and that the braking action is not excessive. This also may be conveniently done each time the wire s p o o l is replaced.

r 7.TROUBLE SHOOTING

To simplify the fault procedure, the following checklists have been arranged under three separate headings. When fault-finding, refer to the most appropriate section.

- Machine welds , but with unsatisfactory results Refer Section 7.1

- Machine delivers no welding current Refer Section 7.2

- Machine delivers uncontrolled welding current Refer Section 7 . 3

7 . 1 UNSATISFACTORY RESULTS

BASIC CHECKS

- Check shielding gas and schedule s e l e c t e d a r e correct f o r the electrode wire in use;


- Check for correct gas flow rate at the welding torch nozzle and ensure there are no gas leaks, as porosity and arc blow-out could occur. The gas nozzle must be free from spatter and firmly attached to the welding nozzle to ensure that atmosphere is not drawn into the shielded area;

- Check for good wire feed conditions, ie: s p o o l holder brake not over-tightened, drive rollers not clogged with dust build-up, drive rollers the correct size and type to suit the welding wire, and the drive roll pressure is adequate for consistent feeding. Check also that the gun cable liner is of correct size and not blocked, and that the welding tip is in good condition and not excessively worn.

Any of the above can cause erratic welding conditions and ARE THE MOST LIKELY CAUSES OF FAILURE IN ALL GAS METAL ARC WELDING. They should therefore be the first points checked when problems occur.

- Ensure that t h e work clamp is securely tightened onto the work- piece so that good electrical contact i s achieved;

- Establish that the arc length is correctly set. An arc length which is too short will cause excessive crackle, shorting and spatter, while an arc length too long may r e s u l t in weld undercut and/or loss of arc 'direction';

- If the arc length is excessively long and cannot be adjusted with the arc length control, c h e c k t h a t the arc voltage sensing wire has not become broken or disconnected (see figures 3 and 5 ) .

Poor wire feed conditions can also g i v e the same symptoms by n o t permitting the wire to approach the arc at; the selected speed. R e f a r , again to the earlier paragraphs.

- Work-piece surface contamination b y water, oil, grease, galvanizing, paint or oxide layers can severely disturb the welding arc resulting in a poor weldmet. Should this condition occur, surface cleaning of the work piece will be necessary;

- Magnetic arc blow may be encountered particularly when welding ferrous metals. Magnetic fields which r e s u l t from the welding current being conducted through the work-piece can severely disturb the welding arc. This problem may be overcome by re-positioning the 'work' clamp (welding current return) so as to weld towards it, welding towards a heavy tack weld, or in severe cases utilizing the 'back stepping' welding technique;

- Lack of one Mains supply phase can either completely disable the CDT Power Source, or merely adversely affect welding conditions. Have a qualified electrician confirm that 3 phase Mains supply is available at the CDT Power Source, and that the primary voltage taps have been correctly selected f o r both the welding and control transformers;

- I f the above checks have failed to locate the cause of unsatisfactory welding conditions, it is possible that the background current circuit may have failed. L o s s of background current is characterized by a weld which appears "dry", coupled with an inability to establish correct operating arc length.

In this case, check for background current with the following test:

SYNCHRO-PULSE CDT MANUAL PAGE 1 4

TEST FOR BACKGROUND CURRENT

1 ) Select "WIRE INCH" and feed about 40" of welding wire from the gun. This will be used as a temporary load on the power source.

2 ) With reference to figure 10 on page 21, r emove fuses 6 and 7 which will disable the welding pulse.

3) Set the "CURRENT" control on the remote pendant to 0.0, disengage the wire drive mechanism, and select *WIRE INCH".

4 ) Close the gun switch with the end o f the welding wire shorted to the work lead.

5) The Ammeter fitted to the power source should now indicate approximately 15 amps. Increasing the setting o f the "CURRENT- control should increase the current reading. (The exact minimum and maximum background current levels are a function of the weld schedule in use).

NOTE: I f "WIRE INCH' is not selected, the background current will not be adjustable by the setting of the "CURRENT" control.

6 ) I f the above determine that there is no background current:

- Check LED 15 (refer figure 1 0 ) . I f LED 15 is not lit, there has been a failure of the power supply to the driver circuit for the background current. C h e c k and replace if required, fuse F5 ( 1 . 6 Amp> and confirm 15 v o l t s AC b e t w e e n pins 2 and 7 o f plug P4;

- Check the wiring Prom plug P5 to the b a c k g r o u n d transistor assembly (item 2 in figure 1 4 on page 3 0 ) for continuity;

- Replace printed circuit board CP34-105.

7 - 2 MACHINE D S I V R R S NO WELDING CURRENT

BASIC CHECKS

- Check that Mains Supply is available at the CDT Power Source, ie: f a n running and indicator light on;

- Check continuity of the welding current circuit, ie: work lead, work clamp and gun cable connections;

- If the gas v a l v e is 'clicking' repeatedly, the Power Source has detected a fault in either the shunt connection o r the switching assembly - see section 7.3 for procedure. As a safety measure, the Power Source will not operate again until it has been turned o f f ;

- Inspect the fuses on the CDT Power Source front panel, replacing them if necessary;

- Check operation of the welding gun switch, ie: gas valve operates and wire-feed motor runs when the gun switch is closed. I f not, replace the gun cable assembly and re-test,


INTERNAL CHECKS

With reference to figure 10 on page 21, check the following diagnostic LEDs:

- All of the following must be lit whenever the welding power source is on .. . LEDs 1 , 2 , 3, 15, 16, 17 and 18. I f any of t h e above are not l it, check the related f u s e and i f necessary, AC supply voltage (refer to section 9 . 2 on page 20) .

NOTE particularly LEDs 16, 17 and 18, also LEDs 13 and 14: LED 16 is the indicator for the Main FET driver PSU ( i e , high current switch-off), LED 17 is the indicator for the SCR driver PSU ( i e , high current swltch-on) and LED 18 is the indicator f o r the current amplifier PSU. LEDs 13 and 14 indicate that the pendant connection is intact. I f any of these are not l i t , all drivers feeding t h e power semi-conductors in the rectifierlswitch assembly are disabled t o prevent possible damage t o these components.

- One o f the following must be l f t .. . LEDs 4 , 5 , 6 , 7, 8 o r 9. I f not, operate the programme switch through all positions. I f none of the LEDs are lit by this procedure, check the wiring loom and p l u g and socket connection to t h e programme switch. I f LEDs are l i t in some b u t n o t all switch positions, the programme switch should be replaced;

- Check that o p e r a t i o n o f t h e gun SW i tch 1 ights LED 12, and tha t t h e INCH/PURGE switch lights LEDs 11/19 when o p e r a t e d .

7.3 MACHINE DELIVERS UNCONTROLLED WELDING CURRENT

- Ensure that this arc voltage sensing wire is correctly terminated at the wire-feeder. Check f o r electrical continuity from the G u l l Cable connection to the connector S 1 of the Main Control B o a r d ,

(Very l o n g a r c - l e n g t h )

CHECK FOR CONTINUITY THESE POINTS\

I G R A Y TO INDUCTANCE

URRENT SHUNT

R E D f TO WORK L E A D

- I t is now necessary to establish whether the fault is in the control circuitry or t h e rectifieriswitch assembly:

Unplug the loom from PCB plug P5. Feed out approximately a foot ( 1 2 " ) of electrode wire from the welding gun. Short the e n d of this wire to t h e work-piece and c l o s e t h e gun switch.


If no current flows in the welding circuit, it is likely that the fault lies in the control o f the rectifieriswitch assembly: - Check that the wires connecting the current shunt to the PCB are firmly terminated with the correct polarity ( s e c figure 51, and that the contacting surface5 a r e clean; - Replace the PCB C P 3 4 - 1 0 5 and the current shunt.

I f current does flow in the welding circuit, the f a u l t lies in the rectifieriswitch assembly. The two possibilities a re :

l . The main S C R has failed short circuit; 2 . The h i g h current switch-off power m o s f e t s have failed.

Measure the resistance o f the S C R (ie, between the two large heatsinks in the middle o f the switching assembly). A short-circuit SCR w i l l g i v e a reading of nea r 0 ohms in both directions.

Failure of the high current switch-off power Mosfets may be indicated by burnt-out resistors on the CP34-11 P C B or by v i s i b l e damage to the individual devices. Chapter 10 gives directions for the replacement of these devices.

8. PRINCIPLE OF OPERATION

8 . 1 PULSED ARC METAL TRANSFER

The WIA Synchro-Pulse CDT is a Pulsed Gas Metal Arc Welder, where the metal t r a n s f e r is ideally in t h e fo rm of single droplets o f electr-ode materiLL1, approximately the diameter o f t h e electrode wire, transferrcd with each current p u l s e .

This is achieved b y the CDT Power-source supplying t h e arc with a DC welding current: which is n o t continuou~, but; wtlich is modulated between t w o distinct current levels. These are known as:

1 . the Background current, and 2. the Pulse current, a s represented in the figure below -

L TIME ”+

FIGURE 6 . WELDING CURRENT AND D R O P L E T T R A N S F E R


The Background Current, which is normally a small proportion of the peak Pulse Current value, serves mainly to keep the arc alight between pulses. I t is during the period o f pulse current that transfer of the molten weld metal is initiated, with ideally the droplet travelling through the arc and arriving at the weld p o o l during the quieter background period.

In order to maintain a constant arc length, it is necessary to repeat the pulse at a frequency which will Lransfer through the arc, in discrete metal droplets, the same metal volume of electrode wire which i s being fed into the arc from the wire feeder.

In general terms, a low wire feed rate requires a low pulse frequency, and a high wire feed rate a high pulse frequency.

8.2 HIGH CURRENT SWITCH

As mentioned previously, the output current of the CDT Power-source is made up of a background current, upon which is superimposed high current pulses. These pulse5 are formed by a "high current switch" which i s based around a large capacity SCR (Silicon Controlle$ Rectifier). A circuit of the switch unit is shown below.

The "high current; switch" is physically part of the Rectifier/Switcb assembly as shown in figure 1 4 , page 30.

Welding A r c

L1

S C R l

(PAIN SWITCH

SWITCH OFF 1

ON 1

FIGURE 7. HIGH CURRENT SWITCH

With reference to the diagram, the operation of the switch is as follows:

SCRl is triggered 'ON' by the application of a signal to its gatel cathode junction f r o m the pulse-on driver. Welding current; then flows from the rectifier and capacitor bank combination Rl/Cl, through t h e welding arc, the pulse shaping inductance L I , and SCR1.

To turn SCRl 'OFF', the transistor bank S 1 is gated on momentarily to reverse bias SCRl with the power supply comprising R2 and C2. The energy stored in L1 is now dissipated by causing a current to flow through Dl and the welding arc.

L


8 . 3 CONTROL CIRCUITS

The main control circuits o f the Synchro-Pulse CDT are located on the printed circuit board ( P C B ) CP34-105. These circuits respond to information from the o p e r a t o r controls, eg: the programme selection switch and the remote control pendant, and also to current and voltage feedback signals from the welding arc.

The control circuits in turn output d r i v e signals to the power semiconductors which . . . - Generate the welding Current Pulses; - Control the Background current; - Set the Wire-feed rate;

- Control the shielding gas soleno i d valve.

l

I Gun switch

FIGURE 9 . BLOCK DIAGRAM .- CONTROL CIRCUITS

SYNCHRO-PULSE C D T MANUAL P A G E 20

19. PRINTED CIRCUIT BOARDS I 9 . 1 M A I N CONTROL BOARD CP34-105

The PCB CP34-105 incorporates the following circuit blocks.

- Regulated power supplies 5V, t15V / -15.36V, +15V / -15V;

- Unregulated power supplies: 20V ( 3 O f f ) ;

- Constant current supplies to remote control pendant: IOmA (2 O f f ) ;

- Welding current signal amplifier; - Micro-processor based control incorporating EPROM data storage; - Output drivers t o power semiconductors for:

- Background current (power mosfets); - High current switch-on (SCR trigger); - High current switch-off (power mosfets).

- Additional output drivers for: - Gas solenoid operation; - Wire-feed motor run/brake control command; - Analog output f o r w i r e - f e e d motor speed control circuit.

A number o f test pins and diagnostic LED indicators a re provided o n t h i s printed circuit b o a r d .

S e e F i g u r e 10 f o r t h e location o f t h e s e p o i n t s , and t h e following lists f o r explanation of t h e function of each.

9 . 2 DIAGNOSTIC LED INDICATORS

ON-BOARD POWER SUPPLIES.

LED #

1 5 ~ AC P1/3 - P114 P2<1,6A) - 1 5 . 3 6 ~ DC reg. LED 2

8 . 5 ~ AC P1/6 - P118 F3(1.6A) t 5 v DC regulated LED 1

AC SUPPLY ACROSS PINS FUSE # INDICATOR FOR PSU

LED 3 1 5 ~ AC P1/1 - P113 Fl(1.6A) + 1 5 v DC reg.

LED t 5

LED 16

LED 17

LED 18

+20v DC Unreg. (Background) +20v DC Unreg.

~ +20v DC Unreg. l (Pulse-off)

( ' P u l s e - o n ) +15/-15v DC reg. (Shunt Amp.)

F5< 1 . 6 A )

F6( 1.6A)

F7( 1.6A)

F4( 1 . 6 A )

1 5 ~ AC P412 - P417

1 5 ~ A C P 4 / 3 - P4/6

1 5 ~ AC P414 - P4/5

1 5 ~ AC P4/1 - P4/8

All of the above L,EDs s h o u l d be l i t whenever t h e welding power source is energ i sed.

SYNCHRO-PULSE CD?' MANUAL PAGE 2 1

-Ti3 ........ < c : + ' + In

_ . D.

ii U a

-0 rl

m W rl

n P W Li

CL U

E- *

d

c) W rl

0

U " LDa €-

m

1

z c

FIGURE 10. M A I N CONTROL BOARD O V E R L A Y


SCHEDULE INDICATORS

The Synchro-Pulse CDT has available twelve individual weld schedules which a r e accessed as two groups of six schedules each.

LED 10 is the group indicator: if LED 10 is off Group A is selected, if LED 10 is lit Group B is selected.

LEDs 4 to 9 indicate which of schedules 1 to 6 has been selected from the selected Group.

Standard weld schedules included in Eprom #l0500 are as presented on page 2 of this manual.

FUNCTION INDICATORS

LED No.

LED 1 1 LED 12 LED 1 3 LED 1 4 LED 19

FUNCTION

Inch switch QN Gun switch ON 'ARC LENGTH' potentiometer connected 'CURRENT' potentiometer connected Purge switch ON

LEDs 13 and 1 4 should be 1

9.3 DIAGNOSTIC TEST POINTS

- CAUTION -

it whenever the CDT is energised.

Permanent damage may be caused if t h e control circuits a r e grounded t o building e a r t h . [Jse only a differential input oscilloscope.

TEST POINT

TPA

TPB

TPC

TPD

TPE

TPF

DESCRIPTION

This point is circuit common for all other test points given below. I t is not common for the current amplifier, o r for the driver supplies for t h e Power Semiconductors.

"Descriptive* Signal - see next page - Welding current signal. Use o n l y a 1O:l oscilloscope probe when observing this waveform, t o avoid loading of the signal.

Negative 15.36 volts DC Regulated power supply.

Analog length" signal f r o m pendant. Varies f rom 0 t o 10 volts DC, increasing t o increase arc length.

Analog "current" signal from pendant. Varies from 0 to 10 volts DC, increasing to increase welding current.


DESCRIPTIVE SIGNAL

5v-F-"3_,:, p- ov i OFF-

The "Descriptive" signal will be present on TPB whenever the CDT Power Source is energised. Each ON period of the waveform represents a welding Current Pulse, hence the signal describes the welding current Pulse Frequency and the Pulse Width.

Normal behaviour of the signal i s as below.

- CDT Power source energised but not welding, "WIRE I N C H " switch o f f , any setting o f the "CURRENT- control.

- " W I R E I N C t I " s w i t ; c h o n , " C U R R E N T " c o n t r o l s e t 1;o m i n i m u m .

r Low pulse frequency.

- The Pulse frequency w i l l increase as the setting of the "CURRENT" control i s increased.

i 9 . 4 WIRE-FEED CONTROL BOARD CP34-85

The PCB CP34-85 contains the following circuit blocks:

- Closed-loop speed control for the ( p u s h > wire feed m o t o r ; - Run and braking control of the (push) wire feed motor; - Driver f o r the gas solenoid valve; - (Part o f ) Speed control f o r a Pull type welding gun where fitted.

Transistor heatsink assembly part # AMl66-1 must be fitted at installation o f a Pull gun.


The speed control for the ( p u s h ) Wire-feed motor incorporates an e r r o r amplifier to ensure that t h e required wirefeed speed is maintained over a wide range of motor load conditions. This motor has an effective speed range o f 8-126 rpm giving a feed- rate range of 40 - 630 inches/min, however this entire range is not necessarily utilized by individual weld schedules.

NOTE: Individual feed motors v a r y in their characteristics, and hence a speed-trimming potentiometer is provided. The maximum speed reference point o f the wire-feed motor is an important parameter, and must be checked and adjusted should the CDT Power source be used with other than its original wire-feeder, o r if this PCB CP34-85 is exchanged at any t ime.

To correctly s e t the maximum speed reference point:

- Unplug the remote control pendant; - Select Mild Steel .035" d Welding Schedule ( A - l > ;

- Select "WIRE INCH";

7"

I 1 0 I I I

"" 7

I 0 1

I I I I

II 0

I 30 Vac SUPPLY -,

3 WIRE-FEED MOTOR SPEED TRlM

P2 -

B

- a5

! + WIRE-FEED MOTOR

- l t LOOPING 30Vsc

F SPARE

PULL GUN MOTOR Ir t

IWherm I l t b d l

Q A S VALVE

SPARE

C 1 " 1 I

FIGURE 11. WIRE-FEED CONTROL BOARD OVERLAY


10. SERVICE INFORMATION

10.1 DISASSEMBLY OF THE RECTIFIER/SWITCH UNIT

To gain complete access to the rectifier/switch unit:

- Remove the side and top panels from the CDT; - Remove the drawer assembly slide guides located on the under-side o f the drawer; - Lift the entire drawer assembly, and place i t across the rear half o f the Power source frame; - Remove both drawer slides. During disassembly of the rectifier/switch unit, note carefully the location o f all fixings, electrical connections and insulation. To simplify correct re-assembly, number each item removed, and its assembled position.

To begin disassembly:

- Remove 4 set screws, one on each end of the two aluminium angles; - Remove 2 bolts, one each securing the two diode flexible leads; - Remove 2 bolts securing the background transistor assembly.

This will allow t h e top section of the rcctifier/switch t o be lifted away giving clear access t o the remainder of the assembly.

Any s p a r e parts required c a n bc o r d e r e d f r o m t h e parts 1 ist and assembly drawing on p a g e s 3 0 and 3 1 .

NOTE: I f it i:; n e c e s s a r y to replace e ither the Main o r B a c k g r o u n d transistors -

- The complete assembly must be replaced with a factory supplied spare part. This i s because both assemblies include items that a r e graded and selected to be suitable f o r this application;

- The main control board CP34-105 must also be replaced, due to the likelihood of damage to the respective driver circuits. Failure to do so may result i n destruction o f the replacement transistor assembly.

h

FIGURE 13. CDT POWER SOURCE ASSEMBLY


10,2 PARTS LIST - CDT POWER S O U R C E

ITEM NO

1 2 2 . 1 3 4 5 6 7 8 9

10 1 1 12 13 14 15 16 17 18 19 20 21 22 22.1 22.2 22.3 24 25 2 6 27 28 2 9 30 31 33 3 3 . I 33.2 33.3 33.4 34 35 36 37 38 40 41 42 43

PART NO.

CP34-20 CP34-72 CP34-60 CP34-24 CP34-25 CP34-2/5

CP34- 14 CP34-02/8 CP33-O/ 10 CP33-O/ 1 1 Ell-23 CP34-O/ 14 W1-35/1 CP34-16 CP34- 102 CP34-18 CP34- 1 9 CP34- 15 CP34-87 A M 1 6 10029F CP34-2/22 CP29-0/20 W 1 7 - 0 / 1 1 AM1 28-3 w1-20 CP34-0/24 CP5-O/ 19 CP34-99 CP34- 105 CP34-76 CP34-2/32 CP34-85 CP34-2/33 W1-33/1 Wll-ll/l AM163 AM162 CP34-47 CP34-48 CP34-44 CP34-88 CP23-17/19 CP34-97 CP34- 103 CP34- 103/ 1 CP34-2/43

DESCRIPTION

BASE ASSEMBLY TRANSFORMER ASSEMBLY PRIMARY/SECONDARY COILS WELDING INDUCTANCE ASSEMBLY BACKGROUND INDUCTANCE ASSEMBLY PAN BLADE FAN MOTOR RECTIFIER/SWITCH ASSEMBLY AMMETER SHUNT 0-400A - 0.5% AMMETER 0-400A VOLTMETER 0-60V FUSE HOLDER WIRE FEEDER PLUG SOCKET REMOTE CONTROL PLUG SOCKET FRONT PANEL BACK PANEL TOP COVER SI DE COVERS BAFFLE PLATE COMPONENT DRAWER OUTPUT TERMINALS EYE NUT MAIN LOOM ON/OFF SWITCH INDICATOR LIGHT INCH/PURGE SWITCH GROUP SWITCH PROCESS SELECTOR SWITCH CONTACTOR CONTROL TRANSFORMER MICROPROCESSOR CONTROL BOARD AUXILIARY TRANSFORMER DUPLEX RECEPTACLE WIRE-FEED CONTROL BOARD GAS VALVE ASSEMBLY GAS VALVE HOSE BARB GAS INLET FITTING CAS OUTLET FITTING 'SIPMOS SAVER' RESISTOR ASSEMBLY RECTIFIER DIODE TAIL INSULATION FILTER BOARD VOLTAGE SELECTION PANEL RELAY LY2 12V AC CONTACTOR CONTROLLER BOARD FAN BRACKET INSULATOR GE-MOV V 150L4A f 0


(I 1"1. k-

FIGURE 1 4 . RECTIFIER/SWITCH ASSEMBLY


10.3 PARTS LIST - RECTIFIER/SWITCH ASSEMBLY

ITEM NO.

1 2 3 3.1 4 5 6 7 8 9 10 1 1 12 13 15 16 17 18 19 20 21 2 2 2 3 24 25 26 27 28 29 30

PART NO.

CP34- 1 1 CP34- 12 CP34- 13 CP34-13/1 CP34-14/1 CP34-1412 CP34- I4/ 3 CP34-14/4-1 CP34-14/4-2 CP34-14/4-2 CP34-14/5 CP34-1416-1 CP34-1416-2 CP34- 14/7 CP34- 1 4 / 9 CP34-14/10 CP15-13/2 CP15-13/3 CP34-14/19 CP34-14/20 CP34-14/21 CP34-14/22 C P 1 7 - 1 8 / 5 CP31-31 CP34-34 CP34-35 CP3-9/8 CP34- 1 1 / 15 CP34-11/16 MC36-65/8

DESCRIPTION

MAIN POWER-TRANSISTOR ASSEMBLY BACKGROUND TRANSISTOR ASSEMBLY SCR HEATSINK ASSEMBLY SCR - AEG TYPE T698F 6 0 0 ~ MAIN DIODE HEATSINKS AUXILIARY DIODE HEATSINKS FREE WHEELING & BLOCKING DIODES HEATSINK AUXILIARY CAPACITORS BUSBAR 1 (NEGATIVE) AUXILIARY CAPACITOR§ BUSBAR 2 (POSITIVE) MAIN CAPACITORS BUSBAR l (NEGATIVE) MAIN CAPACITORS BUSBAR 2 ( P O S I T I V E ) TOP MOUNTING RAIL BOTTOM MOUNTING RAIL CONNECTION BRACKETS RECTIFIER TERMINAL BOARDS RECTIFIER MOUNTING INSULATORS DIODE SEMIKRON SKR240104 DIODE SEMIKRON SKN240/04 DIODE SEMIKRON SKR130/04 DIODE SEMIKRON SKN130/04 DIODE SEMIKRON SKN2MZ40/04 ELECTROLYTIC CAPACITORS 1 0 , 0 0 0 u F l O O v ELECTROLYTIC CAPACITOR 6 , 8 0 0 u F 63v SCR TRIGGER BOARD ASSEMBLY SUPPORT P r x m FOR 6 , ~ O O U F CAPACI. TORS SUPPORT PLATE FOR 10,000uF' CAPACITORS THERMOSTAT SMALL HEATSINK FIN LARGE HEATSINK FIN CAPACITOR O.luF 630v


FIGURE 15. B E R N A R D EZ 4 4 1 0 (400 A M P ) GUN CABLE ASSEMBLY


10.4 PARTS LIST - BERNARD E2 4 4 1 0 G U N ASSEMBLY

ITEM

1 1 A 2 3 4 5 6 7

S 9

10 1 1 l 2 13 1 4 15 16 17 18 19

PART NO.

4335 R7 127 R4423 4427

R4416 4408 4426 449 1 4492 459 l

R4417 4432 4428 4434 4422

4910 4941 4925

R4903 4992

R1916

R457

TIPS (SI-IORT SERIES)

D I AME'TEII 1

0.6mm 0.8mm 0.9rnm l .Omm 1.2mm 1.3mm 1 . 6 m m 2. Omm

DESCRIPTION ~~~ ~ ~

H E A D ASSEMBLY "0" R I N G CAP BODY TUBE CONE N U T flANDLE K I T HANDLE FASTENER KIT NOZZLE, STANDARD NOZZLE, TAPERED BRASS NOZZLE, HEAVY DUTY COPPER STEP WASHER ( l E A C H ) BODY ARMOUR BODY INSULATION HANG-UP HOOK KIT TRIGGER SWITCH ASSEMBLY SWITCH TERMINAL Q C BODY ASSEMBLY CABLE E N D PIN st WIRE ASS'Y CABLE E N D ( 2 E A C H ) LOCKING SLEEVE STRAIN RELIEF CLAMP CLAMP

PART NO.

7 497 7488 7489 7496 7490 '9498 7491 7492

L I N E R S - 4 . 5 METRE 15 FOOT) - CUT TO LENGTH

SIZE PART NO.

0.8-1.2mm

4 4 2 1 s 1.3-1.6mm

441 15

44315 2. O m m

c

i

FIGURE 16. TWO ROLL DRIVE ASSEMBLY


10.5 PARTS LIST - TWO ROLL DRIVE ASSEMBLY

ITEM NO.

1 2 3 4 5 6 7 8 9

10 1 1 12 13 14 15 16 17 18 19 20 21 2 2 2 3 24 25 26 27 28 29 30 31 32 33 3 4 35 36 37 38

i PART NO.

W2-44/ 1 W2-44/2 W2-44/25

W2-17

W2-44/6 w2-44/ 13 W2-44/7 W2-4410

w2-15 W2-44/9 0305029 W2-16

w2-. , . . W2-44/12... W2-44/26 W2-44/22

W2-44/5 W2-44/34 4920WIA w2-44/19 W2-44/20

DESCRIPTION

2 ROLL DRIVE BODY 2 ROLL DRIVE TOP ROLLER HOUSING SHAFT SOCKET SET SCREW M5 x 10 WASHER M5 STAR LOCK WASHER CAP HEAD SOCKET SCREW M5 x 10 SOCKET HEAD SHOULDER SCREW M8 x 20 BELLEVILLE WASHER JW417 TENSION ARM SPRING NUT TOP ROLL SHAFT M8 x 40 S.H. SHOULDER SCREW BEARING 60822 BEARING FL608ZZ M6 HEXAGONAL DOME NUT DRIVEN GEAR WHEEL TOP ROLLER BUSH SCREW, No.8-32 X 1 / 2 " U N C SOCK. CAP HEAD DRIVING GEAR WHEEL SLLITTED PAN HEAD SCREW M 3 x G CAP HEAD SOCKET SCREW M5 x 15 CAP HEAD SOCKET SCREW M6 x 12 C/SUNK HEAD SOCKET SCREW M6 x 1 2 DRIVE ROLLERS - SEE TABLE WIRE INPUT GUIDE - SEE TABLE ADAPTER BUSH LOCK NUT M24 x 1 CAP HEAD SOCKET SCREW M8 x 25 SPRING WASHER 5 / 1 6 ' CAP HEAD SOCKET SCREW M8 x 15 FLAT WASHER 5/16" INSULATING RING FLAT WASHER 24mm I.D. x 34mm O . D . BERNARD QUICK CONNECT BERNARD CABLE ADAPTER GUIDE TUBE SOCKET GRUB SCREW M4 x 4

SYNCHRO-PULSE COT MANUAL PAGE 36

W

I FLAT ROLLER PLAIN VE'E ROLLER

0 . 8 W 2 4 0 w2-21 l*l w2-20 1 w2-22

PLAIN VEE PLAIN VEE ROLLER ROLLER

1.6 w 2 - 2 2 W 2 -22 -l I I I ' - KNURLED VEE W ROLLER ROLLER VI 1 . 2 w 2 - S 1 l-

W2-51 l . c

1'1 w 2 - 2 4 W2 -24 1

2 04 w2-25 W2-25 , 3-2 W2 -26 W2 -26 , 4.0 W2 - 27 w2-27

5.0 W2 - 28 W2 -2%

I " I I

W2-49 *

W 2 4 0 I I

W2- 50

I PLAIN V= RQ&$ 1.6 w2-22 w2-22 2 4 W2-23 W2-23

C

N2-44/12-1

N2-44/12-1

H U / 1 2 - 3

v24412 -4

~-

Q-441 12-1 N

FIGURE 17. DRIVE ROLL AND WIRE GUIDE TABLE


1 1 . PUSH-PULL GUN

1 1 . 1 FITTING INSTRUCTIONS - PUSH-PULL WIRE FEEDER

PULL MOTOR REQUIREMENT

To maintain complete synchronization a n d c l o s e d l o o p feedback, pull motor used must be capable o f feeding wire at 630 inches minute when supplied with 24-28 volts DC. Maximum motor current requirement should not exceed 1 Amp.

ADDITIONAL PARTS REQUlRED

- A M 1 6 6 - 1 Transistor/Heatsink Assembly - A M 1 3 1 - 2 / 4 Cannon Plug S o c k e t MS310 2A 18-18 -85 - w2-. . Grooved Chrome Roller (select using figure 17) - w2-. . Flat Chrome Roller (select using figure 171 - W2-44/12N Nylon Wire Guide - A M 1 6 2 Gas Fitting - TC262N Nut for Gas Fitting - 0.5” ‘ 0 ’ C l i p

FITTING NEW PARTS TO EXISTING EQUIPMENT

W 1 RE FEEDER

- F i t t h e Cannon P l u g S o c k e t and Gas F i t t i n g t o t h e f r o n t p a n e l t h e W21-5 Wire F e e d e r .

C a n n o n P l u g S o c k e t c o n n e c t i o n s ( s e t o u t i n figure 3 o n page 6 ) a r c :

- From Pin F, white wire t o green of c o n t r o l c a b l e . - From Pin G, white w i r e to green/yellow of control cable. - From Fin D, blue wire to b l u e o f control cable. - k’rom Fin H, brown wire to brown of control cable.

Ensure that the grey arc voltage sensing wire is connected to the welding lead, as also detailed i n Figures 3 and 5 .

- Remove existing f e e d rollers. F i t the grooved roller to the motor shaft and the flat roller to the top roller housing.

- Replace the existing brass wire guide with the W2-44/12N nylon guide.

POWER S O U R C E - WIRE-FEEDER CONTROL BOARD CP34-85 - Fit the A M 1 6 6 - 1 Transistor/Heatsink Assembly o n t o the CP34-85 PCB using the mounting f e e t provided. Plug the attached connector o n t o the 4 pin plug assembly P3, as shown in figure 1 1 on page 24.


S Y N C f 1 R O N I Z I N G PULL MOTOR WITH PUSH MOTOR

- Two speed adjustment potentiometers a r e fitted to the CP34-85 PCB, and protrude through the fitted Transistor/Heatsink Assembly. Identification for these is marked on the heatsink: "MIN" and "MAX" (see also figure 1 1 ) .

The following steps are t o be used to synchronize the motors:

COARSE TUNING

( A ) Set the CDT pendant " C u r r e n t " control t o minimum on any weld schedule. Select 'Inch" and measure the surface speed of the driven feed roller on the p u s h wire-feed motor with an accurate digital tachometer.

Multiply the feed roller surface speed by 1.3

(B) Measure the surface speed of the speed of the pull motor driven roller. Where access is difficult, c l o s e the drive mechanism and measure the top idler surface speed. Note that correct spring tension adjustment is required to avoid roller slip.

Adjust the "MIN" Potentiometer (RV3) to obtain the surface speed calculated in ( A ) above.

(C) S e t t h e C D T p e n d a n t " C u r r e n t " c o n t r o l to mhxirnum and w i t h " I n c h " selected f o l l o w t h e same p r o c e d u r e as i n (A) and (I31 a b o v e .

Ca lcu la t e the maximum sur face speed f o r t h e p u l l motor u s i n g a multiply factor of 1 .1

Adjust the " M A X " potentiometer ( R V 2 ) t o obtain t h i s calculated surface s p e e d .

Both m o t o r s are now synchronized in a coarse manner, with the pull motor slightly leading the push motor.

( D ) Do this by laying the gun cable out straight and feeding wire through it. Note that correct drive roller tension should be set f o r b o t h push and pull motors.

While feeding wire, measure the current drawn by the pull motor.

At minimum "CURRENT" setting, adjust the " M I N ' : potentiometer s o that t h e motor curretlt drawn is approximately 400 milliamps.

At maximum " C U R R E N T " setting, adjust the "MAX" potentiometer s o that the motor current drawn is approximately 300 milliamps.

Note that the potentiometer on the pull gun has no effect.

Before final weld testing, we recommend several minutes purge o f the ga5 lines and cable assembly.


1 1 . 2 PARTS LISTS A N D ASSEMBLY DRAWINGS

Lineristee1 Wire J Alu.Wire 8m. I300.161 I 300.166

H6300

CC302/8

300.161

300. 166

HT13

MS32-3

HT16

HT14

HULFTEGGER G U N WITHOUT BARREL - 2 4 V DC MOTOR

HULFTEGGER CABLE ASSEMBLY - 8 metre (26 f o o t )

STEEL WIRE LINER - 8 metre (26 f o o t )

PLASTIC LINER - 8 metre (26 f o o t )

CABLE ADAPTER

PLASTIC LINER RETAINING SLEEVE

STRAIN RELIEF SLEEVE

BERNARD/HULFTEGGER TORCH NECK ASSEMBLY

L


J . .

F'TEGGER GUN EXPLODED VIEW


PARTS LIST - HULFTEGGER GUN

I ter - 1

1

4

5

B 7

8 9

10 1 1

12 13 14

14

15 16

17

10

19

19

20

21 22 23 24 25 26

26 27

Part No

310-021 300-092

300-091 300-090 300-01 1 300-022 300-008 300-007 310-023 300-087 300-047 300-049 300-048 300-026 300- 110

300-093 300-055 300-054 300-003 300- 100 300- 109

300-025 300-023 300-495 300-085 300-485

300-490 300-400

300-48 1

300-05 1

Dcscrlption

Hous Ing Screw M4 x 6 Name plate Screw M2,6 x 6 ProtectI've sleeve Housing cover Cover screw Retaining ring Clamp f4ttlng Screw M3 X 8

Scale dlsc Screw M4 x 6

A m u r e d hose brdcket Inlet wlre gulde Q 0,8-l,i Inlet wire gulde Q 1,6 Screw Pin Screw M3 x 5 Motor block Outlet wlre guide B 0.8-1,

Outlet wire gulde d 1,6 O-r lng Connector Current conductor cable Screw M3 x 4 Drive roll gate for alum. Axle Pressure roll, A1 B 0,8-1, Pressure roll, A I B 1.6

Pressure p1 a t e

I tern

28 29

30 31 32 33 34

34 35 36 37 38 39 40

1/42/44 43 45 46 47 48 49

50 51

52

53

Part No.

300-046 300-052 300-053 300-057 300-045 300-058 300-050 300- 106 300-060 300-059

300-064 1300-460 300-061 300-066 300- 102 300-049 300-056

300-070 300-087 300-099 300-101 300-06a 300-067 300-004 300-009

T

-c Descrlptlon

Pressure adj.bracket C p l .

Spr 1 ng Screw Retalnlng ring Drive roll gate for steel Ax1 e Pressure roll , S t

Pressure rol1,St Nut Drive roll Wedge key Motor ZSV, 36 : 1 Spacer col 1 ar Screw M4 x 14

d 0,8-1,2

Q 1.6

Potentiometer, cornplele Screw M4 x 6 Brdcket Terminal strjp Screw M3 x 8

Rubber buffer Potentlometer knob Switch

TP I gger Gun grip Screw M4 x 12

S Y N C H R O - P U L S E CDT M A N U A L PAGE 42

300-022 SMALL CAP NUT

R 310.076 WIRE GUIDE FOR STRAIGHT TORCH NECK

(135m m. OVERALL 1

U 300.296 CLAMPING NUT

300 a335 INSULATION BUSH

HT14-1 SPACER SLEEVE

4423 INSULATING CAP 1 H p . 4635 HEAD ASSEMBLY

W

1 5 89 04mm CONTACT TIP 1590 1 *2mm. CONTACT TIP 1591 l-Smm CONTACT TIP

4492 BRASS NOZZLE WJTH INSULATOR ASSEMBLY

FIGURE 2 0 . B E R N A R D / H U L F I ' J i G G E R T O R C H NECK ASSEMBLY

SAFE PRACTICES I N U S I N G WELDING EQUIPMENT

Produced by Welding I n d u s t r i e s o f Austral ia P t y . L t d . i n t h e i n t e r e s t s of improving operator safe ty . These no tes should be cons idered on ly a s a basic g u i d e t o Safe Working Habits. A f u l l l ist of S tanda rds pe r t a in ing t o i n d u s t r y i s ava i l ab le f rom the S t anda rds Assoc ia t ion o f Aus t r a l i a , a l so va r ious S t a t e Electr ic i ty Authori t ies , Departments of Labour and Industry or Mines Depart- ment and other Local Heal th o r Sa fe ty In spec t ion Au thor i t i e s may have addi t iona l requi rements .

1. A n e a t u n c l u t t e r e d work area makes fo r s a fe work ing hab i t s .

2 . Burn Prevent ion

The welding arc is i n t e n s e a n d v i s i b l y b r i g h t . I t s r a d i a t i o n c a n damage eyes , p e n e t r a t e l i g h t w e i g h t c l o t h i n g , reflect f rom l igh t -co loured sur faces , and b u r n the sk in and eyes . Skin burns resemble acute sunburn , those from gas-shielded arcs a r e mre seve re and pa in fu l .

Wear p r o t e c t i v e c l o t h i n g - l e a t h e r ( o r a s b e s t o s ) g a u n t l e t g l o v e s , h a t , a n d sa fe ty - toe boo t s . Bu t ton sh i r t co l l ax and pocke t f laps , and wear c u f f l e s s t r o u s e r s to avo id en t ry o f spa rks and s l ag .

NEVER LOOK AT AN ARC WITHOUT PROTECTION.

Wear he lme t w i th s a fe ty gogg les o r g l a s ses w i th s ide sh i e lds unde rnea th , a p p r o p r i a t e f i l t e r l e n s e s o r p la tes ( p r o t e c t e d by c l ea r cover g l a s s ) . This i s a MUST for welding o r cu t t ing , (and ch ipping) t o p r o t e c t t h e e y e s from rad ian t ene rgy and f l y ing metal. Replace cove r g l a s s when b r o k e n , p i t t e d , o r spattered.

Avoid o i l y o r g r e a s y c l o t h i n g . A spark may i g n i t e them. Hot meta l such as electrode stubs and workpieces should never he handled without gloves.

Ea r p l u g s s h o u l d be worn when welding i n overhead pos i t ions o r i n a confined space . A hard hat should be worn when o t h e r s work overhead.

Flammable h a i r p r e p a r a t i o n s s h o u l d not be used by persons i n t e n d i n g t o w e l d o r c u t .

3. Toxic Fume Prevent ion

Adequate vent i la t ion i s e s s e n t i a l . Severe d i s c o m f o r t , i l l n e s s o r dea th can r e s u l t from fumes, vapor s , hea t , or oxygen enrichment or depletion t h a t w e l d i n g ( o r c u t t i n g ) may produce. P reven t them w i t h a d e q u a t e v e n t i l a t i o n . NEVER vent i la te wi th oxygen .

Lead, cadium, zinc, mercury, and bery l l ium bear ing and similar materials when welded (or c u t ) may produce harmful concentrat ions of toxic fumes. Adequate local e x h a u s t v e n t i l a t i o n m u s t be used, o r e a c h p e r s o n i n t h e area as well as t h e operator must wear a n a i r - s u p p l i e d r e s p i r a t o r . For bery l l ium, bo th mus t be used. Metals coa ted wi th o r con ta in ing materials t h a t emit fumes should n o t be hea ted unless c o a t i n g is remved f rom the work s u r f a c e , t h e area i s w e l l v e n t i l a t e d , o r t h e operator wears a n a i r - s u p p l i e d r e s p i r a t o r .

Work i n a conf ined space on ly whi le it i s b e i n g v e n t i l a t e d a n d , i f n e c e s s a r y , while wear ing a i r - supp l i ed r e sp i r a to r .

Vapors from ch lo r ina t ed so lven t s can be decomposed by t h e h e a t of t h e a r c ( o r f l ame) t o form PHOSGENE, a h i g h l y t o x i c g a s , a n d l u n g a n d e y e i r r i t a t i n g p roduc t s . The u l t r a - v i o l e t ( r a d i a n t ) energy of t h e a r c c a n a l so decompove t r i ch lo re thy lene and pe rch lo re thy lene vapor s t o form phosgene. Do n o t WELD o r cu t where so lven t vapors can be drawn into t h e we ld ing o r cu t t i ng a tmosphe re o r where the r ad ian t ene rgy can pene t r a t e t o a tmosphe res con ta in ing evep minute mmmts of t r i c h l o r e t h y l e n e ox pexcholorethylene.

4 . Fire and Explosion Prevention

Causes of f i r e and explosion are:- Combustibles reached by t h e a r c , f l a m e , f l y - i n g s p a r k s , h o t s l a g , or heated mater ia l ; misuse of compressed gases and cylin- d e r s ; a n d s h o r t c i r c u i t s .

Be aware t h a t f l y i n g s p a r k s or f a l l i ng s l ag can pas s t h rough c r acks , a long p ipes , through windows o r d o o r s , and th rough wal l o r f loor openings , ou t o f s igh t of the goggled operator . Sparks and s l a g can f l y 10 metres .

To preven t f i r e s and exp los ions : - Keep equipment clean and operable, free of o i l , g r e a s e , and ( i n e l e c t r i c a l p a r t s ) of m e t a l l i c p a r t i c l e s t h a t can cause short c i r c u i t s .

If combus t ib l e s a r e i n area, do NOT we ld o r cu t . Move t h e work i f p r a c t i c a b l e , t o a n a r e a f r e e of combust ibles . Avoid p a i n t s p r a y rooms, d i p t a n k s , s t o r a g e a r e a s , v e n t i l a t o r s . If t h e work can not be moved, r o v e c o m b u s t i b l e s a t l e a s t 10 metres away o u t of r each of s p a r k s a n d h e a t ; o r p r o t e c t a g a i n s t i g n i t i o n w i t h s u i t a b l e and s n u g - f i t t i n g f i r e - r e s i s t a n t c o v e r s o r s h i e l d s .

Wal l s touching combust ib les on oppos i te s ides should no t be welded on (or cu t ) . W a l l s t c e i l i n g s t and f l o o r n e a r work should be protected by h e a t - r e s i s t a n t c o v e r s o r s h i e l d s . F i re watcher must be s t and ing by w i t h su i t ab le f i r e ex t ingu i sh ing equ ipmen t during and for some t i m e a f t e r w e l d i n g o r c u t t i n g i f :

(1) combus t ib l e s ( i nc lud ing bu i ld ing cons t ruc t ion ) a r e w i th in 10 metres . (11) combus t ib l e s a r e fu r the r t han 10 metres but can be igni ted by spa rks . (111) openings (concealed or v i s i b l e ) i n f l o o r s o r w a l l s w i t h i n 10 metres

(IV) c o m b u s t i b l e s a d j a c e n t t o w a l l s , c e i l i n g s , roofs , o r m e t a l p a r t i t i o n s may expose combustibles t o spa rks .

can be igni ted by r a d i a n t o r conducted heat.

A f t e r work i s done, check that area is f r e e o f sparks, glowing embers, and flames.

An empty conta iner tha t he ld combust ib les , o r can p roduce f lamable vapors when hea ted , must never be welded on or cut, u n l e s s con ta ine r has first been cleaned a s d e s c r i b e d i n AS.1674-1974, t h e S.A.A . Cutting and Welding Safety Code. This inc ludes : a thorough s team or caus t ic c leaning (or a so lven t o r wa te r wash ing , depending on t h e c o m b u s t i b l e ' s s o l u b i l i t y ) f o l l o w e d by pu rg ing and i ne r t ing w i th n i t r o g e n or carbon dioxide, and using protect ive equipment as recommended i n AS.1674-1974. W a t e r - f i l l i n g just below working l e v e l may substitute f o r i n e r t i n g .

Hollow c a s t i n g s o r c o n t a i n e r s m u s t be vented before weld ing or cu t t ing . They- can explode. Never weld or cut where t h e a i r may contain f lammable dust , gas, o r l i q u i d v a p o r s s u c h a s p e t r o l ) .

5 . Shock Prevention

E x p s e d conductors o r other bare meta l i n t h e weld ing c i rcu i t , o r ungrounded e l ec t r i ca l ly a l ive equ ipmen t can f a t a l ly shock a person whose body becomes a con- duc tor . Ensure tha t the machine is cor rec t ly connec ted and ear thed . If unsure have machine i n s t a l l e d by a q u a l i f i e d e l e c t r i c i a n . On mobile o r por tab le equipment , r e g u l a r l y i n s p e c t c o n d i t i o n of t r a i l i n g power leads and connect ing plugs. Repair or r e p l a c e damaged l e a d s .

6 . Electrode Holders and Connectors

Fu l ly insulated e lec t rode ho lde r s shou ld be used. Do not use holders w i t h p ro t rud ing screws . Ful ly insu la ted lock- type connec tors should be used to jo in weld ing cab le l e n g t h s .

7 . Terminals

T e r m i n a l s and o the r exposed pa r t s of e l e c t r i c a l u n i t s s h o u l d have in su la t ed knobs o r covers secured before opera t ion .

M A I N AUX. "_ -

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0

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t

CP34-1rn

1 4 A - L GROUP SELECT 0

SW1 TC H l I 1

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+ - ~L

I I 1 RED I GRAY

BC ACK

J W E N 1-6 CLOSED 7 -12

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