WIA W67 Wirefeeder Instruction Manual

WIA W67 Wirefeeder

Product Information

The Wirefeeder is a welding equipment accessory manufactured by Welding Industries Australia, a division of ITW Australia Pty Ltd. It is designed to be used with Weldmatic W67 welding machines. The Wirefeeder is used to feed welding wire into the welding torch, allowing for precise and controlled wire feeding during the welding process.

Specifications

• Model: W67-40
• Serial numbers : W67A* and above

Contact Information
For inquiries and support, please contact

• Welding Industries Australia
  • Phone: 1300 300 884
  • Email: info@welding.com.au
  • Website: welding.com.au
• Weldwell New Zealand:
  • Phone: 0800 9353 9355
  • Email: info@weldwell.co.nz
  • Website: weldwell.co.nz

Product Usage Instructions

Handle on Wirefeeder
The handle fitted to the Weldmatic W67 wirefeeder is intended for carrying the equipment by hand only. DO NOT use this handle for suspending or mounting the wirefeeder in any other manner.

Safe Practices when using Welding Equipment

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

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.

To protect yourself from burns

• 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.

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 power source 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 WIREFEEDER
Please note that the handle fitted to the Weldmatic W67 wirefeeder is intended for carrying the equipment by hand only.
DO NOT use this handle for suspending or mounting the wirefeeder in any other manner.

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

Burn Protection
The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate light-weight clothing, reflect from lightcoloured 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 perchloroethylene 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 perchloroethylene.

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.
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 floors 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-filling 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.

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 W67 4RD has been designed to be used with consumable wires in the range from 0.9mm to 1.6mm 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.
The Weldmatic W67 4RD wirefeeder has been designed to feed a range of hard, soft, and flux-cored wires for the G.M.A.W. process. A compact motor with integral gear box is coupled to a 4 roll drive assembly forming the basic component of the wirefeeder. The motor is controlled by an electronic speed control which provides speed regulation and compensation for supply voltage variations.

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 W67 package contains;

• Weldmatic 4RD Enclosed Wirefeeder W67 with drive rolls 0.9/1.2mm V Groove 1.2/1.6 V Groove 0.9/1.2 1.2/1.6 Knurled Roller.
• Interconnecting leads
• (This) Operating Manual W67-40.
• If the W67, 4RD Wirefeeder is included in a package with a Weldmatic MIG welder, it will also contain the following;
• Welding gun and cable assembly (see Section 10.4 for details)
• Work lead
• Gas hose
• Argon/mixed gas regulator/flowgauge.

SPECIFICATIONS

CONTROLS

Digital Display Volts
The voltage display will show the voltage adjustment for MIG modes. It will also show the actual weld volts during welding. The actual voltage will be retained for 10 seconds after the weld has finished. If the optional voltage measurement clamp at the wirefeeder is disconnected, the display will indicate weld volts as measured at output terminals. If the measurement clamp is connected, the display will indicate weld volts as measured at measurement clamp.

Digital Display AMPS/Wire Speed
For MIG modes the display will show the wire speed setting. During welding, the display will show actual weld amps and retain for 10 seconds after the weld has finished.
For STICK & TIG MIG modes the display will show the AMPS setting. During welding, the display will show actual weld amps and retain for 10 seconds after the weld has finished.
When the operator start the wire feeder or adjust the wire speed value , the Digital Display Wire speed will indicate the Wire speed (2-22m/min).
When the operator adjust the ARC START value, the Digital Display Wire speed will indicate the arc start value (0 to 1).
When the operator adjusts the wirefeed setting, the display will show the adjusted values.

Arc Start
This control can be set to modify arc starting conditions. For many applications the control can be set at the mid point.
Rotating the knob clockwise will provide faster wire acceleration at arc start giving quicker starts, suitable for applications such as rapid tack welding.
Rotating the knob anti-clockwise will slow wire acceleration, providing a softer start suitable for larger diameter and aluminium wires.
The range of Arc start value is from 0 to 1. The Arc start value will be indicated on the Digital display wire speed.

Wire Speed Control
This control sets the speed of the wire drive motor to provide 2 – 22 metres per minute of welding electrode wire. Rotate the control clockwise to increase the feed speed.

Inch Button
Press to feed wire without energising the welding power source. The wire will feed at the current wirespeed setting.

Latch Select Button and Indicator
Press to select and deselect ‘Latch’ mode. When ‘Latch’ mode is selected, the operator need close the gun switch momentarily only to commence welding, and again momentarily to end welding. This can help to reduce operator fatigue during long welding run.

Purge
Press Purge to Purge the gas line when the gas bottle has been changed or the gas line has been opened. The gas value will come on without wirefeed or output volts.

Voltage Control
Weld Voltage Adjustment Knob for MIG process.

Wirefeeder Settings

Pre Gas Control
Sets the time period of gas flow from gun switch on until welding commences, and can be set for 0 – 10 seconds.

Post Gas Control
This sets the time period of gas flow after welding ceases, and can be set for 0 – 10 seconds.

Spot Time Control
When the setting is other than fully anticlockwise, the welder will operate for a short time after each trigger press. Turn clockwise to increase the weld duration up to a maximum of 10 seconds.

Burnback Control
This control sets the time period that welding voltage continues after the gun switch is released, and wirefeed ceases. The extra time allows the wire to “burn back” slightly toward the tip.
When set correctly ‘Burnback’ prevents the welding wire freezing in the weld pool at the end of a weld. Adjustment is 0 – 1 second.

INSTALLATION

Do Not Touch Live Electrical Parts
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also
live when power is on. In semi-automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching
the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. ELECTRIC SHOCK can kill. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

Remote Wirefeeder
The remote wirefeeder is connected to the Weldmatic power source via the composite cable interconnecting lead. Check all connections are firmly made to ensure good electrical contact, and to prevent gas leaks.

Fitting The Gun and Cable Assembly
The supplied welding gun/cable assembly is equipped with a ‘Euro’ wirefeeder connector which incorporates all required connection points for welding current, shielding gas and gun switch control.
To attach the gun/cable assembly to the wirefeeder mechanism, engage the mating parts of the male and female Euro connectors, then rotate the locking ring clockwise to firmly secure the connection.

Fitting the Consumable Wire
Place the spool of welding wire onto the spool holder. The location pin should mate with a hole provided on the wire spool body. Secure the spool with plastic nut.
Check the adjustment of the spool brake, which should be set to prevent over run of the wire spool at the end of a weld, without unduly loading the wirefeed motor. The braking can be adjusted by using an allen key to adjust Hex head bolt inside the hub.
The quality of the consumable wire greatly affects how reliably a gas metal arc welder will operate. For best results when welding mild steel, we recommend quality WIA AUSTMIG ES6. Dirty, rusty or kinked wire will not feed smoothly through the gun cable and will cause erratic welding. Deposits from the wire will clog the gun cable liner requiring it to be replaced prematurely.

Feeding the Consumable Wire
At the wirefeeder, release the compression screw and rotate the top roller arms to the open position. The end of the welding wire can now be passed through the inlet guide, over the first lower roller, through the intermediate guide, over the second lower roller and into the output wire guide tube. Check that the drive roll grooves are correct for the wire in use. The appropriate size is stamped on the visible side of the installed rollers. Check also that the correct size contact tip is fitted at the gun end. Feed roller and tip details are shown in Section 10 of this manual.
Return the top roller arms to the closed position and adjust the compression screw to provide sufficient clamping of the drive rollers to achieve constant wirefeed. Do not over tighten.
With the equipment energised, operate the gun switch to feed wire through the gun cable.

BASIC WELDING INFORMATION

Refer to the Weldmatic power source Operators Manual for gas and weld setting and gun position information.

GENERAL MAINTENANCE

Before removing the equipment cover, ENSURE that the equipment is disconnected from the mains power supply. When the equipment is energised LETHAL VOLTAGES are present.

Dust
Care should be taken to prevent excessive build-up of dust and dirt within the welding power source. It is recommended that
at regular intervals, according to the prevailing conditions, the equipment covers be removed and any accumulated dust be removed by the use of a dry, low pressure compressed air, or a vacuum cleaner. The machine should be blown out with compressed air at least every 12 months as grinding dust can settle on PCB componentry causing failure. Failure to maintain machines may void warranty.

Wirefeed
In order to obtain the most satisfactory welding results from the G.M.A.W. process, the wirefeed must be smooth and constant. Most causes of erratic wirefeed can be cured by basic maintenance. Check that the:

1. Feed rolls are the correct size and type for the wire in use. Check also that the drive groove is aligned with the wire and that the groove is not worn;
2. Gun cable liner is clear of dust and swarf build-up. When replacement becomes necessary, fit only the correct liner (see page 20). The build-up of dust can be minimised by regular purging of the liner  with dry compressed air.
   • This may be conveniently done each time the wire spool is replaced;
   • Welding tip is free of obstructions such as spatter build-up. Ream out the tip bore with a suitable size oxy-tip cleaner. Replace the welding tip as it becomes worn;\
   • Welding tip is free of obstructions such as spatter build-up. Ream out the tip bore with a suitable size oxy-tip cleaner. Replace the welding tip as it becomes worn;
   • Welding tip is free of obstructions such as spatter build-up. Ream out the tip bore with a suitable size oxy-tip cleaner. Replace the welding tip as it becomes worn;
   • Welding wire is straight and free of buckles or ‘waviness’. To check, remove 2 or 3 metres of wire from the spool. Clamp one end in a vice or similar, then holding the other end pull the wire out straight. Look down the length of the wire, any buckles will be obvious. Buckled wire is extremely difficult to feed reliably and should be replaced;
   • Welding wire is free of surface rust. Replace if rust is evident.

EXTERNAL TROUBLE SHOOTING

Refer to the Weldmatic power source Operators Manual for trouble shooting tips. If these checks do not identify the fault condition, the equipment should be returned to a WIA Service agent. Phone 1300 300 884 for details of your nearest service agent.

TROUBLE SHOOTING CHART

W67 WIREFEEDER CIRCUIT DIAGRAM

Fig 4 Wirefeeder Circuit Diagram

ASSEMBLY AND PARTS LIST – W67 WIREFEEDER

ASSEMBLY AND PARTS LIST – WF042 WIREFEED ASSEMBLY

Fig 6 Wirefeed Assembly

Wirefeeder W67 | Operator Manual | Model No W67-40

ASSEMBLY AND PARTS LIST – 300 AMP TORCH

Fig 8 300 Amp Torch Supplied with Weldmatic 350. Use Centre Fire Tip Consumables. 18

ASSEMBLY AND PARTS LIST – 400 AMP TORCH

Fig 9 400 Amp Torch Supplied with Weldmatic Fabricator. Use Centre Fire Tip Consumables. 19

Nozzles

Tips

To replace liner: Disconnect gun/cable assembly at the Euro adaptor. Remove nozzle (1), gas diffuser (3) and insulator
(4). Withdraw old liner from the wirefeeder end. Insert new liner and refit gun/cable assembly to the wirefeeder.
At the gun end, compress the liner within the gun cable, then cut it approx 20 mm past the end of the body tube/neck (5) (the diameter of the gas diffuser is 20 mm and can be used as a guide) – see Figure 8.
Refit insulator and screw gas diffuser on firmly with a wrench.
Insert tip (2) into gas diffuser then thread nozzle onto gas diffuser/tip and tighten firmly by hand.

Fig 12 Replacing the gun cable liner

ASSEMBLY AND PARTS LIST
WORK LEAD & INTERCONNECTING LEAD KIT (350)

Fig 13 Work Lead & Interconnecting Lead Kit supplied with Weldmatic 350.

ASSEMBLY AND PARTS LIST
WORK LEAD & INTERCONNECTING LEAD KIT (500)

Fig 14 Work Lead & Interconnecting Lead Kit supplied with Weldmatic 500.

AUSTRALIAN WARRANTY INFORMATION

WIA Weldmatic MIG Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
Welding Industries of Australia (WIA) warrants to the original retail purchaser that the Weldmatic welding machine purchased (Product) will be free from defects in materials and workmanship for a period of 3 years from the date of purchase of the Product by the customer. If a defect in material or workmanship becomes evident during that period, Welding Industries of Australia will, at its option, either:

• Repair the Product (or pay for the costs of repair of the Product); or
• Replace the Product.

In the event of such a defect, the customer should return the Product to the original place of purchase, with proof of purchase, or contact Welding Industries of Australia on 1300 300 884 to locate an authorised service agent.
Products presented for repair may be replaced by refurbished products of the same type rather than being repaired. Refurbished parts may be used to repair the product. Replacement of the product or any part does not extend or restart the Warranty Term. The repair of your products may result in the loss of any user-generated data. Please ensure that you have made a copy of any data saved on your product.

Any handling and transportation costs
(and other expenses) incurred in claiming under this warranty are not covered by this warranty and will not be borne by Welding Industries of Australia.
Welding Industries of Australia will return the replacement product, if original found to be faulty, freight free to the customer.
This warranty covers the Weldmatic power source and wirefeeder only, and does not extend to the regulator, gun assembly
or accessories included in the original purchase package.
The obligation of Welding Industries of Australia under this warranty is limited to the circumstances set out above and is subject to

• The customer being able to provide proof of purchase of the Product and the purchase price paid for the Product;
• The relevant defect in materials or workmanship;
• The Product not having been altered, tampered with or otherwise dealt with by any person in a manner other than as intended in respect of the relevant Product; and
• The Product not having been used or applied in a manner that is contrary to customary usage or application for the relevant Product or contrary to any stated instructions or specification of Welding Industries of Australia.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits given by this warranty are in addition to other rights and remedies which may be available to the customer under any law in relation to goods and services to which this warranty relates.

Warranty provided by

• Welding Industries of Australia
• (ABN 63 004 235 063)
• A Division of ITW Australia Pty Ltd
• 5 Allan Street, Melrose Park
• South Australia 5039 1300 300 884
• Email: info@welding.com.au
• Web: www.welding.com.au

NEW ZEALAND WARRANTY INFORMATION

WIA Weldmatic MIG Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
WIA Weldmatic Fabricator machines purchased in New Zealand have identical warranty conditions as Australia, with the below conditions
In the event of defects listed in the Australian warranty conditions, the customer should return the Product to the original place of purchase, with proof of purchase, or contact Weldwell on 0800 9353 9355.
The warranty shall not apply to parts that fail due to normal wear.

For customers located in New Zealand, you can contact

• Weldwell New Zealand
• Division of ITW New Zealand
• 64 Thames Street
• Napier 4110
• New Zealand 0800 9353 9355
• Email: info@weldwell.co.nz
• Web: www.weldwell.co.nz

WELDING INDUSTRIES AUSTRALIA

• A Division of ITW Australia
• Pty Ltd AB N: 63 004 235 063 1300 300 884
• Email: info@welding.com.au
• welding.com.au

WELDWELL NEW ZEALAND

• A Division of ITW New
• Zealand NZBN : 9 429 039 833 129
• GST NO : 080177186 0800 9353 9355
• Email: info@weldwell.co.nz
• weldwell.co.nz

References

• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ
• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ

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