WIA Weldmatic 396 Manuel utilisateur

CP126-40 Rev B

Weldmatic 396 [external wirefeeder]

Operators Manual

Weldmatic 396 MIG welder

Model No. CP126-2, Iss A

05/09

Welding Industries of Australia

An ITW Company

ABN 18 004 547 111

Telephone: 1300 300 884

Facsimile: 1300 301 884

Email: [email protected]

www.welding.com.au

Weldmatic 396

Model No CP126-2, Iss A 05/09 1

Contents

Section General Information Page

Safe Practices 2

1 Introduction 5

2 Receiving 5

3 Speciﬁcations 6

4 Controls 7

5 Installation 8

6 Normal Welding Sequence 10

7 Basic Welding Information 10

8 General Maintenance 12

9 External Trouble Shooting 13

10 Circuit Diagram 15

11 Assembly and Parts Lists 16

12 Warranty information 18

Operators Manual

Quality •Reliability •Performance

Safe Practices When Using

Welding Equipment

These notes are provided in the interests

of improving operator safety. They should

be considered only as a basic guide to Safe

Working Habits. A full list of Standards

pertaining to industry is available from

the Standards Association of Australia,

also various State Electricity Authorities,

Departments of Labour and Industry or

Mines Department and other Local Health

or Safety Inspection Authorities may have

additional requirements. Australian Standard

AS1674.2 provides a comprehensive guide to

safe practices in welding.

Eye Protection

NEVER LOOK AT AN ARC WITHOUT

PROTECTION. Wear a helmet with

safety goggles or glasses with side shields

underneath, with appropriate ﬁlter lenses

protected by clear cover lens. This is a MUST

for welding, cutting, and chipping to protect

the eyes from radiant energy and ﬂying

metal. Replace the cover lens when broken,

pitted, or spattered.

Recommended Shade Filter Lens

Amps TIG MMAW MIG

Pulsed

MIG

0-100 10 9 10 12-13

100-150 11 10 10 12-13

150-200 12 10-11 11-12 12-13

200-300 13 11 12-13 12-13

300-400 14 12 13 14

400-500 — 13 14 14

500 + — — 14 14

Read ﬁrst

The information contained in this

manual is set out to enable you to

properly maintain your new equipment

and ensure that you obtain maximum

operating efﬁciency.

Please ensure that this information is

kept in a safe place for ready reference

when required at any future time.

When ordering spare parts, please

quote the model and serial number of

the wirefeeder and part number of the

item required. All relevant numbers are

shown in lists contained in this manual.

Failure to supply this information

may result in unnecessary delays in

supplying the correct parts.

Safety

Before this equipment is put into

operation, please read the Safe

Practices section of this manual.

This will help to avoid possible

injury due to misuse or improper

welding applications.

Handle on Power Source

Please note that the handle ﬁtted to

the Weldmatic 396 power source is

intended for carrying the equipment by

hand only.

DO NOT use this handle for

suspending or mounting the power

source in any other manner.

Weldmatic 396

Model No CP126-2, Iss A 05/09 3

Burn Protection

The welding arc is intense and visibly bright.

Its radiation can damage eyes, penetrate

light-weight clothing, reﬂect from light-

coloured surfaces, and burn the skin and

eyes. Burns resulting from gas-shielded arcs

resemble acute sunburn, but can be more

severe and painful.

Wear protective clothing - leather or heat

resistant gloves, hat, and safety-toe boots.

Button shirt collar and pocket ﬂaps, and

wear cufﬂess trousers to avoid entry of sparks

and slag.

Avoid oily or greasy clothing. A spark may

ignite them. Hot metal such as electrode

stubs and work pieces should never be

handled without gloves.

Ear plugs should be worn when welding in

overhead positions or in a conﬁned space.

A hard hat should be worn when others are

working overhead.

Flammable hair preparations should not be

used by persons intending to weld or cut.

Toxic Fumes

Adequate ventilation with air is essential.

Severe discomfort, illness or death can

result from fumes, vapours, heat, or oxygen

depletion that welding or cutting may

produce. NEVER ventilate with oxygen.

Lead, cadmium, zinc, mercury, and beryllium

bearing and similar materials when welded

or cut may produce harmful concentrations

of toxic fumes. Adequate local exhaust

ventilation must be used, or each person in

the area as well as the operator must wear

an air-supplied respirator. For beryllium, both

must be used.

Metals coated with or containing materials

that emit fumes should not be heated unless

coating is removed from the work surface,

the area is well ventilated, or the operator

wears an air-supplied respirator.

Work in a conﬁned space only while it is

being ventilated and, if necessary, while

wearing air-supplied respirator.

Vapours from chlorinated solvents can be

decomposed by the heat of the arc (or

ﬂame) to form phosgene, a highly toxic

gas, and lung and eye irritating products.

The ultra-violet (radiant) energy of the arc

can also decompose trichlorethylene and

perchlorethylene vapours to form phosgene.

Do not weld or cut where solvent vapours

can be drawn into the welding or cutting

atmosphere or where the radiant energy

can penetrate to atmospheres containing

even minute amounts of trichlorethylene or

percholorethylene.

Fire and Explosion Prevention

Be aware that ﬂying sparks or falling slag can

pass through cracks, along pipes, through

windows or doors, and through wall or ﬂoor

openings, out of sight of the operator. Sparks

and slag can travel up to 10 metres from the arc.

Keep equipment clean and operable, free of

oil, grease, and (in electrical parts) of metallic

particles that can cause short circuits.

If combustibles are present in the work

area, do NOT weld or cut. Move the work if

practicable, to an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage

areas, ventilators. If the work can not be

moved, move combustibles at least 10

metres away out of reach of sparks and heat;

or protect against ignition with suitable and

snug-ﬁtting ﬁre-resistant covers or shields.

Walls touching combustibles on opposite

sides should not be welded on or cut. Walls,

ceilings, and ﬂoor near work should be

protected by heat-resistant covers or shields.

Operators Manual

Quality •Reliability •Performance

A person acting as Fire Watcher must be

standing by with suitable ﬁre extinguishing

equipment during and for some time after

welding or cutting if;

• Combustibles(includingbuilding

construction) are within 10 metres.

• Combustiblesarefurtherthan10metres

but can be ignited by sparks.

• Openings(concealedorvisible)inoors

or walls within 10 metres may expose

combustibles to sparks.

• Combustiblesadjacenttowalls,ceilings,

roofs, or metal partitions can be ignited

by radiant or conducted heat.

After work is done, check that area is free of

sparks, glowing embers, and ﬂames.

A tank or drum which has contained

combustibles can produce ﬂammable

vapours when heated. Such a container must

never be welded on or cut, unless it has ﬁrst

been cleaned as described in AS.1674-2.

This includes a thorough steam or caustic

cleaning (or a solvent or water washing,

depending on the combustible’s solubility),

followed by purging and inerting with nitrogen

or carbon dioxide, and using protective

equipment as recommended in AS.1674-2.

Water-llingjustbelowworkinglevelmay

substitute for inerting.

Hollow castings or containers must be

vented before welding or cutting. They can

explode. Never weld or cut where the air

may contain ﬂammable dust, gas, or liquid

vapours.

Shock Prevention

Exposed conductors or other bare metal

in the welding circuit, or ungrounded

electrically alive equipment can fatally shock

a person whose body becomes a conductor.

Ensure that the equipment is correctly

connected and earthed. If unsure have the

equipment installed by a qualiﬁed electrician.

On mobile or portable equipment, regularly

inspect condition of trailing power leads and

connecting plugs. Repair or replace damaged

leads.

Fully insulated electrode holders should be

used. Do not use holders with protruding

screws. Fully insulated lock-type connectors

shouldbeusedtojoinweldingcablelengths.

Terminals and other exposed parts of

electrical units should have insulated knobs

or covers secured before operation.

If the supply cable is damaged

it must be replaced by the

manufacturer, their service agent

or a similarly qualiﬁed person.

Weldmatic 396

Model No CP126-2, Iss A 05/09 5

1 Introduction

Gas Metal Arc Welding (G.M.A.W.) is an arc

welding process where a consumable wire is

fed by motor driven feed rolls to a welding

gun, and where welding current is supplied

from the welding power source. The welding

arc is struck between the work piece and

the end of the wire, which melts into the

weld pool. The arc and the weld pool are

both shielded by gas ﬂow from the gun, or

in the case of “self shielded” wires, by gases

generated by the wire core.

The process is very versatile in that by

selection of the correct wire composition,

diameter and shielding gas, it can be used

for applications ranging from sheet-metal to

heavy plate, and metals ranging from carbon

steel to aluminium alloys.

The Weldmatic 396 has been designed to

be used with consumable wires in the range

from 0.6mm to 1.2mm diameter. The smaller

wire sizes are used when welding at lower

currents, such as sheet-metal applications.

Increasing the wire diameter permits higher

welding currents to be selected.

A common application of G.M.A.W. is for

welding Mild Steel. In this application, a

Mild Steel solid consumable wire such as

AUSTMIG ES6 is used with a shielding gas

of Carbon Dioxide, or Argon mixed with

Carbon Dioxide. Alternatively, Flux-cored

consumable wires are available in both gas

shielded, and ‘gasless’ self shielding types.

Stainless steel and Aluminium can be welded

with G.M.A.W. using the correct consumable

wire and shielding gas.

2 Receiving

Check the equipment received against the

shipping invoice to make sure the shipment

is complete and undamaged. If any damage

has occurred in transit, please immediately

notify your supplier.

The Weldmatic 396 power source package

contains;

• Weldmatic396PowerSourceCP126-2

• (This)OperatingManualCP126-40.

Operators Manual

Quality •Reliability •Performance

3 Speciﬁcations

Power Source

Manufactured to Australian Standard

AS60974-1.

Primary Voltage

415 Vac, 60 Hz

Rated Primary Current

16 Amps

Maximum Primary Current

30 Amps

Recommended Generator kVA

22 kVA

Rated Output @ 40oC

Duty cycle based on 10 min cycle time

395 Amp, 34 V, 30% duty

250 Amp, 26.5 V, 100% duty

Welding Current

55-395 Amps

Open Circuit Voltage

18.4-50 V

Shipping weight

115 kg – Power source only

135 kg – Includes wirefeeder and leads

Mains Circuit Breaker Rating

25 Amps

Supply plug

20 Amp (415 V 3 phase) optional extra

Fitted Supply Cable

50/0.25 Four Core, Heavy Duty PVC

Cooling

Fan on demand, fan operates only as

required to cool internal components.

Insulation

Class H, 140°C Rise.

Wirefeeder Circuit Breaker Rating

5 Amps

Weldmatic 396

Model No CP126-2, Iss A 05/09 7

Fig 1 Power Source Controls

1 Ammeter

This meter displays actual welding current

during welding operation, and a stored

reading for 30 seconds after welding.

2 Voltmeter

This meter displays actual welding voltage

during welding operation, and a stored

reading for 30 seconds after welding.

3 Wirefeeder Control Socket

Connector for control cable from remote

wirefeeder.

4 Circuit Breaker

This circuit breaker protects the 30 Vac

wirefeeder supply circuit.

4 Power Source Controls

5 Coarse Voltage, On/Off Control

This switch provides mains power ON/

OFFandCoarseadjustmentoftheoutput

welding voltage over three ranges.

6 Fine Voltage Control

ThisswitchprovidesFineadjustmentofthe

output welding voltage over ten steps.

7 Gas Outlet

Connector for shielding gas hose from

remote wirefeeder.

8 Negative Welding Output Terminal

9 Positive Welding Output Terminal

Operators Manual

Quality •Reliability •Performance

5 Installation

Connection to Electrical Mains Power

Supply

NOTE. All electrical work shall only be

undertaken by a qualiﬁed electrician.

The Weldmatic 396 is supplied with a

5 metre 4 core 50/0.25 Heavy Duty PVC

mains power supply cable. This cable should

be correctly connected to a suitable 3 Phase

plug top or ﬁxed connection point.

The minimum capacity of the mains wiring

and power outlet supplying a welder is

selected according to the effective primary

current of the machine. The effective primary

current for a Weldmatic 396 is 16 Amps.

The minimum recommended mains circuit

breaker rating for a Weldmatic 396 is

25 Amps. Note: Due to normal variations

of sensitivity, the tripping time of some

25 Amps circuit breakers may limit the

duty cycle available from the Weldmatic

396. A higher rated circuit breaker can be

selected, but the mains wiring capacity must

be increased to suit.

The current rating of the mains cable

depends on cable size and method of

installation. Refer to AS/NZS 3008.1, Table 9.

If it becomes necessary to replace the mains

ﬂexible supply cable, use only cable with

correct current rating. Access to the supply

terminals is gained by removing the power

source side panels.

The replacement cable must be ﬁtted and

retained in the same manner as the original.

Fig 2 Positive Wire

Output Voltage Polarity

The design of the Weldmatic 396 allows

selection of the output voltage polarity.

Positive Wire

G.M.A.W. with solid consumable wires is

carried out with the work piece Negative and

the welding wire Positive.

To setup for this condition, connect the

‘WORK’ lead plug into the (-) output socket

on the Power Source, and the ‘WELDING’

lead from the wirefeeder into the (+) socket

on the Power Source, as in Figure 2.

To wirefeeder

To work clamp

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