The Weldmatic 215 is an internal wirefeeder MIG welder designed for Gas Metal Arc Welding (G.M.A.W.) applications. This robust machine is manufactured to Australian Standard AS1966.1 and rated to ISO 60974-1, ensuring compliance with industry standards. It is suitable for a wide range of welding tasks, from sheet-metal to heavy plate, and can handle various metals including carbon steel, aluminum alloys, and stainless steel, depending on the chosen consumable wire and shielding gas.
Function Description
The core function of the Weldmatic 215 is to facilitate Gas Metal Arc Welding. In G.M.A.W., a consumable wire is fed by motor-driven feed rolls to a welding gun, while welding current is supplied from the power source. The welding arc is established between the workpiece and the end of the wire, melting the wire into the weld pool. Both the arc and the weld pool are shielded by gas flow from the gun (or by gases generated by the wire core in the case of self-shielded wires).
The Weldmatic 215 wirefeeder is engineered to feed a variety of hard, soft, and flux-cored wires. A compact motor with an integral gearbox drives a two-roll drive assembly, forming the essential component of the wirefeeder. An electronic speed control regulates the motor speed and compensates for supply voltage variations, ensuring consistent wire feed.
The machine offers several operational modes and controls:
- Weld Start Sequence: Initiated by closing the welding gun switch, this sequence energizes the gas valve (commencing gas flow), activates the power source contactor (applying welding voltage), and energizes the wire drive motor. The arc is established when the wire touches the workpiece.
- Weld End Sequence: Releasing the gun switch de-energizes the wire drive motor (which is dynamically braked to a stop), and after a pre-set "burn-back" time, the power-source contactor is released. This prevents the consumable wire from freezing in the weld pool. The gas valve is also de-energized, stopping shielding gas flow.
- Spot Weld Mode: Allows for precise spot welding with adjustable spot weld time (0.4 – 3.0 seconds). This feature can be turned off by rotating the control anti-clockwise to its minimum position.
- Cycle Arc Mode: Enables pulsed welding by setting a period between welds (0.4 – 1.8 seconds) using the interval control, while the spot time control sets the welding period. Both controls can be turned off by rotating them fully anti-clockwise.
- Output Voltage Polarity Selection: The Weldmatic 215 allows for selection of output voltage polarity. For solid consumable wires (e.g., Mild Steel), the workpiece is typically Negative and the welding wire Positive. For some self-shielded flux-cored wires, the workpiece is Positive and the consumable wire Negative. This is configured by connecting the 'WORK' lead and 'WELDING' lead to the appropriate (+) or (-) output sockets on the power source.
Important Technical Specifications
- Power Source:
- Primary Voltage: 240 Vac, 50/60Hz
- Rated Primary Current: 16 Amps
- Maximum Primary Current: 42 Amps
- Recommended Generator kVA: 10.1 kVA
- Rated Output @ 40°C (10min cycle time):
- 215 Amp, 24.8 V, 15% duty
- 90 Amp, 18.5 V, 100% duty
- Welding Current Range: 40-215 Amps
- Open Circuit Voltage: 20-45 V
- Shipping Weight: 75 Kg (including lead kit)
- Mains Circuit Breaker Rating: 20 Amps
- Supply Plug: 15 Amp
- Fitted Supply Cable: 50/0.25 Three Core, Heavy Duty PVC
- Cooling: Fan cooled, air drawn in through front grille.
- Insulation: Class H, 140°C Rise
- Spool Sizes: 5Kg, 15Kg
- Wirefeed Assembly:
- Wirespeed Range: 0 - 160 RPM (0 - 15 Metres per min.)
- Wire Size Range:
- 0.6mm - 1.2mm diameter (solid wire)
- 0.8mm - 1.2mm diameter (cored wire)
- Gun and Cable Assembly (BEQ1510AO7CE - 180 amp):
- Includes components like nozzle assembly, contact tip, head, cap, body tube (2", 30° or 45°), switch assembly, handle kit, strain reliefs, and Euro Direct Plug Kit.
- Steel Liner options for 0.6-0.8mm and 0.9-1.2mm wires.
- Nylon Liner option for 0.9-1.2mm wire.
- Work Lead Kit:
- Includes Welding Cable 25mm², Plug, and Work Clamp.
Usage Features
- Controls:
- Wire Speed Control (1): Adjusts wirefeed speed, increasing welding current clockwise.
- Spot Time Control (2): Varies spot weld time (0.4 – 3.0 seconds) in Spot Weld mode.
- Power On Indicator (3): Illuminates when mains power is connected.
- Overload Indicator (4): Illuminates when duty cycle is exceeded, stopping welding current until cooled. Thermostats reset automatically; do not switch off for cooling.
- Interval Control (5): Sets period between welds (0.4 – 1.8 seconds) in Cycle Arc mode.
- Coarse Voltage Control (6): Mains power ON/OFF and coarse adjustment of output welding voltage over three ranges.
- Fine Voltage Control (7): Fine adjustment of output welding voltage over three ranges.
- Positive Welding Output Terminal (8): For connecting welding leads.
- Negative Welding Output Terminal (9): For connecting welding leads.
- Euro Gun/Cable Connector (10): Standard connector for gun/cable assembly.
- Shielding Gas: The choice of shielding gas is crucial and depends on the consumable wire. Recommended gases for Mild Steel include Argon + 5-25% Carbon Dioxide or 100% CO₂. Aluminum typically uses Argon, and Stainless Steel uses Argon + 1-2% Oxygen. Gas flow rate (typically 10-12 litres/min) is important to prevent weld porosity.
- Weld Setting Establishment: Once wire type, size, and shielding gas are chosen, the weld setting is adjusted by varying wirefeed speed (which determines welding current) and welding arc voltage. A higher wirefeed speed requires an increased arc voltage.
- Gun Position: For "down hand" fillet welding, the gun is typically positioned with the nozzle end pointing in the direction of travel, at approximately a 45° angle.
- Safety Features: Includes an in-built over-temperature thermostat to protect against overload. The control board (CP109-12) also features SCR module protection by output short circuit detection.
Maintenance Features
- Dust Removal: Regular cleaning of accumulated dust and dirt from within the power source is recommended using dry, low-pressure compressed air or a vacuum cleaner. Covers should be removed only after disconnecting from mains power.
- Wirefeed Maintenance: To ensure smooth and constant wirefeed, which is critical for satisfactory G.M.A.W. results:
- Feed Rolls: Check for correct size and type for the wire in use, proper alignment with the wire, and wear.
- Gun Cable Liner: Keep clear of dust and swarf. Replace with the correct liner when necessary. Regular purging with dry compressed air can minimize build-up.
- Welding Tip: Ensure it is free of spatter build-up. Ream out the tip bore or replace if worn.
- Feed Roll Pressure: Adjust to be just sufficient for even wirefeed, avoiding excessive pressure that can deform the wire.
- Spool Holder: Ensure smooth rotation and sufficient braking to prevent over-run when the motor stops.
- Welding Wire Quality: Use straight wire free of buckles or waviness. Replace if rust is evident.
- Liner Replacement: Disconnect the gun/cable assembly at the Euro adaptor. Remove the nozzle and head. Withdraw the old liner from the wirefeeder end and insert a new one. At the gun end, compress the liner within the gun cable, then cut it one contact tip length past the end of the body tube. Refit head, tip, and nozzle.
- Troubleshooting: The manual provides a comprehensive troubleshooting guide for common issues such as no output, fan/power light status, low weld output, circuit breaker trips, erratic arc characteristics, and porosity in welds. It emphasizes checking wirefeed components, electrical connections, shielding gas settings, and workpiece surface cleanliness.
- Warranty: The Weldmatic 215 comes with a WIA 'Gold Shield 3 Year Warranty' covering parts and workmanship (effective March 1, 2005). Gas regulators and gun/cable assemblies are warranted for 90 days. Consumable components are not covered. The warranty is void if equipment is modified, improperly installed, misused, or not maintained.
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