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WIA Weldmatic 205S User Manual

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WELDING
INDUSTRIES
OF
AUSTRALIA
A
DIVISION
OF
WELDING INDUSTRIES LID
ACN
004
547
l l
l
Head
Qffice
and International Sales
5
Allan Street,
Melrose
Park
South Australia,
5039
Telephone
(08) 8276
6494
Facsimile
(08)
8276
6327
OWNERS
MANUAL
WELDMATIC
205s
MODEL
MO.
CPlO2-6,
REV.
C
MODEL
NO.
CPlO2-7,
REV.
C
220V/240V,
5QHZ
VERSION
09/95
QUALITY
W€LBING
PR05UCTS,
SYSTEMS
AND
SERVICE
4
f
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WIA Weldmatic 205S Specifications

General IconGeneral
Max Output Current200A
Wire Feed Speed2-15 m/min
Protection ClassIP21S
Input Voltage240V
Welding Current Range30-200A
Duty Cycle20% @ 200A
Welding ProcessMIG, Stick, TIG

Summary

Safety Precautions

Introduction to GMAW Welding

Equipment Receiving and Inspection

Technical Specifications

Power Source Controls Overview

Power On Indicator

Indicator light status when machine is energized.

Hi-Lo Voltage Switch

Coarse adjustment of output welding voltage.

Fine Voltage Control

Fine adjustment of output welding voltage.

Wire Speed Control

Varies wirefeed speed, affecting welding current.

Spot Time Control

Controls spot weld duration in Spot Weld mode.

Interval Time Control

Sets period between welds in Cycle Arc mode.

Machine Installation Procedures

Electrical Mains Power Connection

Connecting the welder to the mains power supply.

Gun Cable Fitting

Connecting the welding gun cable to the wirefeeder.

Gas Bottle Connection

Connecting the gas cylinder and regulator.

Consumable Wire Loading

Loading and preparing the welding wire.

Output Voltage Polarity Settings

Positive Wire Setting

Setting up for workpiece negative and wire positive.

Negative Wire Setting

Setting up for workpiece positive and wire negative.

Normal Welding Sequence

Weld Start Sequence

Sequence of events when starting a weld.

Weld End Sequence

Sequence of events when ending a weld.

Basic Welding Information

Choice of Shielding Gas

Selecting appropriate shielding gas for welding.

Shielding Gas Flow Rate

Recommended gas flow rate and causes of porosity.

Establishing Weld Settings

Adjusting wirefeed speed and arc voltage for stable arc.

Weld Quality and Technique

Good Weld Characteristics

Description of a properly executed weld.

Bad Weld Characteristics

Description of a faulty weld.

Gun Positioning

Correct gun placement for fillet welding.

General Maintenance

Dust Removal

Cleaning dust from the power source.

Wirefeed Maintenance

Maintaining smooth wirefeed for optimal results.

Troubleshooting Guide

Wirefeed Troubleshooting

Identifying and fixing wirefeed issues.

Welding Circuit Troubleshooting

Checking work clamp and polarity for welding circuit.

Wirefeed/Arc Voltage Troubleshooting

Troubleshooting wirefeed and arc voltage relationship.

No Welding Current Troubleshooting

Diagnosing why the machine is not producing current.

Service Information

Parts Lists - Power Source

Gun Assembly Parts List

Motor & Two Roll Drive Assembly Parts

Remote Wirefeeder Assembly Parts

Safe Practices in Welding

Eye Protection

Necessary precautions for eye safety during welding.

Burn Protection

Protective measures against burns from welding.

Toxic Fumes

Hazards and precautions related to welding fumes.

Fire and Explosion Prevention

Measures to prevent fires and explosions during welding.

Shock Prevention

Safety measures to prevent electrical shock.

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