WIA CP27-9 User manual

WELDING INDUSTRIES OF AUSTRALIA
A BlVlSlQN OF WELDING INDUSTRIES LTD
ACN 004 547 Ill
Head Office and International Sales
5 Allan Street, Melrose Park
South Australia, 5039
Telephone [phone] Facsimile [phone]
OWNERS MANUAL
WELDMATIC
305
MODEL NO. CP27-9, REV. C
MODEL
NO. CP27-IO, REV. C
07195
QUALITY WELDINGPRODUCTS, SYSTEMSAND SERVICE
4:: YLLV

Paae 2 WELDMATIC 305 MANUAL

WELDMATIC 305 MANUAL Page 3
SAFETY
Beforethis equipment is put into operation. theSafe Practicessectionat the back of
the manualmust be read completely . Thiswill help to avoid possibleinjury due to
misuseor improper welding applications .
CONTENTS
Sec.1 Introduction ........................................ P.4
Sec.2 .................................... Receiving .......................................... P.4
Sec.3 ................................. Specifications ....................................... P.5
Sec.4 ......................... Power SourceControls ............................... P.6
Sec5 ................................... Installation ......................................... P.7
Sec.7 ....................... BasicWelding Information ............................. P.ll
..................................
Sec.6 ...................... NormalWelding Sequence ............................. P.11
Sec.8 ........................... GeneralMaintenance ................................. P.14
Sec9 .............................. Trouble Shooting .................................... P.14
Sec.10 .......................... Service Information .................................. P.15
Sec.11 .................................. PartsLists .......................................... P.18
Sec.12 .............................. Safe Practices ....................................... P.24
FIGURES
Fig.1 .......................... Power Source Controls ............................... P.6
Fig.2 ...................... Connection ofSupplyCable ........................... P.7
Fig.3 ................... RemoteWirefeeder Connection ......................... P.9
Fig.4 ......................... PositiveWire Connection .............................. P.10
Fig.6 ................................... "Good"Weld ........................................ P . 13
Fig.7 .................................... "Bad" Weld ......................................... P.13
Fig.8 ................................... Gun Position ........................................ P.13
Fig.9 ................................ Circuit Diagram ...................................... P.16
Fig.10 ........................ Wirefeed Control Board ............................... P.17
Fig.13 .......................... Gun CableAssembly ................................. P.21
Fig.14 .......................... Wire DriveAssembly ................................. P.22
Fig.15 ........................... Remote Wirefeeder ................................... P.23
Fig5 ........................ NegativeWire Connection ............................. P.10
Fig.1 1 ....................... Power Source Assembly ............................... P . 19
Fig.12 .......... Power Source Ass'y (RemoteWirefeeder) ................. P.20

Page LC WELDMATIC 305 MANUAL
_I_. '' ""
The information contained in this manual is setout to enable you to properly
maintainyour new equipment and ensurethat you obtain maximum operating efficiency,
Please ensure that this information is kept in a safe place for ready reference when
requiredat anyfuture time.
When requesting spareparts,pleasequotethe model and serialnumber of the
machine 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.
Gas Metal Arc Welding (G.M.A,W.) is B basically simple weldingprocess,where a
consumable wire is fed by motor driven drive roilers to a welding gun, and where
welding current is supplied from the welding power SQUTCB. The weldin arcisstruck
between the workpiece and the end of the wtre, which melts inta the we1 t pool. The arc
and the weld pool are both shielded by gas flew from the gun, or in the case of"self
shielded" wires, by gases generated by the wire core.
Theprocess is veryversatile in that by selection sf the correct wire composition,
diameter and shielding gas, it can be used for applications ranging from sheetmetal to
heavy plate, and metals ranging from carban steel to aluminium alleys.
The WELDMATIC 305 has been designed to be used with consumable wires in the
range from O.Gmm to -l .6mm diameter. The smaller wire sizes are used when welding at
iuwercurrents, such 8s sheet-metal applications. Increasingthewirediameterpermits
higher weldingcurrentsto be selected,
A common application sf G.M.A.W. isforwelding Mild Steel. tn this application, it
Mild Steel solid consumable such as AUSTMIG €S4 or ES6 is used with a shielding gas
of Carbon Dioxide, or Argon mixed withCarbon Dioxide.Alternatively,Flux-cored
consurnables are availablein both gas shielded, and 'gasless' self shieldingtypes.
Stainless steel and Afuminium can be welded with G.M.A.W. using the correct
consumablewire and shietding gas.
Check the e uipmentreceivedagainstthe shipping invoice to makesurathe
shipment is cornp 7 ete and undamaged. If any damage has occurred in transit, please
immediately notify yaw supplier.
The 027-9 (Internal Wirefeeder) Package contains;
1% WELDMATIC 309 Powersource.
m BEQA31OAE BERNARD Gun cable, 3 metre, Euroconnector.
m HA101-185 Regulator and Flowgauge. (Argon)
a (This) OwnersManual.
The CP2748 (Remote Wirefeeder) Package contains;
WELDMATIC 305 PowerSource.
B W32-0 Wirefeeder.
LB~ AM224-0 IO tnter-connecting lead kit, $6 metre.
U BEQA3f d AE BERNARO Gun cable, 3 metre, Eura connector.
HA181-185 Regulator and Flowgauge.(Argon)
I (This) Owners Manual.

WELDMATIC 305 MANUAL Page 5
3. SPECIFICATIONS
ManufacturedtoAustralianstandardAS1.966.1-l985
PRIMARY VOLTAGE ................................................380 VoltsA.C., Three Phase, 50 hz.
RATED PRIMARY CURRENT .................................. I1 Amps
MAX PRIMARY DEMAND ........................................ 19 Amps, 12 kVA (Minimum
requirementfor supply from engine
driven alternator.)
FUSE RATING .......................................................... 15 Amps
FITTED SUPPLY CABLE .......................................... 30/0.20 Four Core,
Heavy Duty PVC
WIRE SIZE RANGE .................................................. 0.6mm - 1.6rnm diameter
OPEN CIRCUIT VOLTAGE ...................................... 18to 40 Volts in 18 steps.
WIRE SPEED RANGE ............................................... to 15 Metres/min
WELDING CURRENT RANGE ................................. 35 - 305 AMPS
COOLING ................................................................. Fan cooled, air drawn in
through top louvre.
Dutycycle
280 Amps @ 30 Volts, 30%
Duty cycle
RATED OUTPUT ...................................................... 150 Amps @ 23 Volts, 100%
Duty cycle is defined in Australian Standard AS1966.1 asthe ratio of arcingtime to 5
minutesinany 5 minute period, expressedas a percentage.

Page 6 WELDMATIC 305 MANUAL
4. POWER SOURCE CONTROLS
t&T-
WIRE SPEED CONTROL
WIRE SPEED
INDICATOR LIGHT
0 a
‘BL SPOT TIME CONTROL
1
lNTERVAL CONTROL
I
VOL TAG& CONTROLS
I, POWER ON/OFF AND
0 -1 COARSE VOLTAGE SWITCH
‘@: FINEVOLTAGESWITCH
COARSE FINE
4
FIGURE 1 - POWER SOURCE CONTROLS
1. POWER ON INDICATOR
This is illuminated when the machtne is energised, that is when electrical mains
power is connected to the welder, and theCoarse Voltage switch is in positions 1,2 or 3.
2. COARSE VOLTAGE CONTROL
ranges, plus a ‘0’ power off position.
This switch provides Coarse adjustment of the Output Welding Voltage over three
3. VOLTAGE CONTROL
This switch providessix steps of Fineadjustment of theOutput Welding voltage.
4. WIRE SPEED CONTROL
clockwise direction increasesthewirefeed speed, increasingthewelding current.
5. SPOT TIME CONTROL
When operating the machine in Spot Weld mode, this control willvary the spot weld
time. Rotatingthe dial clockwise will increase the spot weld time, in the range 0.5 - 2.5
seconds.lf the Spot Weld mode is not requiredthis feature can be turned off by rotating
the controlanti-clackwise until it ‘clicks’ into theminimum position.
The wirefeed speed of the machine is varied with this control; turning the dial in a
6. INTERVAL CONTROL
When operatingthe machine inCycle Arc mode this control sets the periodbetween
welds. The spot time control sets the weldingperiod.Rotating the dialclockwisewill
increase the interval time, in the range 0.5 - 2.5 seconds. if the Cycle Arc mode is not
requiredthis featurecan be turned off by rotating both controls fully anti-clockwise.

WELDMATIC 305 MANUAL Page 7
5. INSTALLATION
CONNECTION TO ELECTRICAL MAINS POWER SUPPLY
The WELDMATIC 305 is supplied with a 5 metre 4 core 30/0.20 Heavy Duty PVC
mainspower supply cable. Thiscableshouldbe correctly connected to a suitable 3
Phase plugtop or fixed connection point.
Therecommended Supply Fuse rating is 10 Amps.Due to peak current
requirements, the Electrical Mains supply to welding machines is best protected by
fuses. Circuit Sreakers may trip frequently if used inthis application.
If it becomesnecessary to replace the mainspower supply cable, use only cable
Access to the machine supply terminals is gained by removing the power-source
side panelopposite tothe wire-spool enclosure.
Pass the cable through the bushfitted to themachine back panel. The three phases
are terminated at the main Contactor as shown in Figure 2. Ensurethat the two internal
control loom wires areterminated, Red to L1 , and Blueto L3.
with anequivalentor higher current rating.
Tighten the cable clamp leavingsufficient slack in the cable such that the
terminatedwires are not intension.
LI L2 L3
SUPPLY
CONTROL
FIGURE 2. CONNECTION OF SUPPLY FLEXIBLE CABLE

Page 8 WELDMATIC 305 MANUAL
_I_
FITTING THE GUN CABLE
The
BERNARD BEBA3lOAE gun eabie is equipped with a ‘Euro’wirefeeder
connector which incorporates all required connection paints to the gun cable for
welding current, shielding gas and gun switch control.
To attach the gun cable to the wirefeeding mechanism, engage the mating parts sf
the male and female Euro connectors, then rotate the locking ring clockwise to firmly
secure the connection.
REMQTE WIREFEEDER
Where fitted, the W324 remotewirefeederis connected Is the WELDMATIC 305
power source using an AM224 extension lead kit. The connection details are shown in
the diagram below.
BLUE
E WHITE
GBN/YEL
r” RED
WELDMATIC
305
POWERSOURCE
DETAIL OF POWER CABLE CONNECTION
FIGURE 3. REMOTE WIREFEEDEW CONNECTiOMS

WELDMATIC 305 MANUAL Page 9
FlmlNG THE GAS BOTTLE
Depending on configurationof the cylinderto be used, the gas flowmeter / regulator
may be fitted directly to the cylinder, or in conjunction with an elbow fitting. DO NOT
apply any greasetothesejoints, and tighten thenutssecurely.
Fit the end ofthe gas inlet hose fromthe back panel of the machine tothe
connector suppliedwith theflow regulator, and securewiththe clamp also supplied.
FllTlNG THE CONSUMABLE WIRE
The quality of the consumable wire greatlyaffects how reliably a gas metal arc
welder will operate. For bestresultswhen welding mildsteel, we recommend quality WIA
AUSTMIG ES4 or ES6. Dirty, rusty or kinkedwire will notfeed smoothly through the gun
cable and will cause erratic welding. Deposits fromthe wire will clog the gun cable liner
requiringit to be replaced prematurely.
Placethe spool of welding wire onto the spool holder. The location pin should mate
with a hole provided on the wire spool body. Fit the-spool retaining 'R'clip supplied.
Check theadjustment of the spool brake, which should be set to prevent over-run of
the wire spool at theend of a weld, without unduly loadingthe wirefeed motor.The
braking can beadjusted by the Nyioc nut using a 15/16" AF or 24mm socket wrench.
FEEDING THE CONSUMABLE WIRE
Open the two roll drive mechanism by lifting the pressure lever upwards, which lifts
the upper roller away from the driven roller. The end of the welding wire can now be
passed through the inlet guide, over the bottom driven roller, and into the output wire
guide tube.
Check that the drive roller groove is correctfor the wire in use. Theappropriate size
is stamped on the visible side of theinstalled roiler. Check also thatthecorrect size
contact tipis fitted at the gun end. Refer to section 11 for gun partnumbers.
Return the top roller to the dosed positionand, with the machine turned on, close
the gun switch to feed wire through the gun cable. Adjust the compressionscrew to
provide sufficient clamping of the drive rolls drive to achieve constant wirefeed. Do not
overtighten.

Page 10 WELDMATIC 305 MANUAL
OUTPUT VOLTAGE POLARITY.
The design of the WELDMATIC 305 allows selection of the outputvoltage polarity
POSITIVE WlRE
Most G.M.A.W. is carriedoutwith the workpiece Negativeand thewelding
consumable wire Positive. To set the machine for this condition, bolt the ’WORK’
lead onto the (-) output stud, and the ’GUN CABLE’ lead to the (+) stud, as in
figure 4. below.
NEGATIVE WIRE
Some ‘self-shielded’flux cored consumables are intended to be operated with
the workpiece Positive andthe consumable wire Negative.Refer to the
manufacturersdatafor the particular consumabie to be used.
To set the machine forthiscondition,boltthe ’WORK’ lead ontothe (+)
output stud, and the ’GUN CABLE’ onto the (-) stud, as infigure 5. below.
WORK LEAD
0 0
I
U
FIGURE 4.POSITIVE WIRE
II \
GUN CABLE LEAD WORK LEAD
LEAD
FIGURE 5. NEGATIVE WlRE

WELDMATIC 305 MANUAL Page 11
6. NORMAL WELDING SEQUENCE
WELD START
Closingthe welding gun switch initiates this sequence of events:
m Thegasvalve is energisedand gas flow commences;
m The Power Source contactor is initiated. Wetding voltage is applied between the
a The wire drive motor is energised,wirefeed commences and the arc is
work-pieceand the consumable wire.
established.
WELD END
Releasingthe gun switch initiatesthis sequence of events:
a The wire drive motor is de-energised,and is dynamicallybraked toa stop;
P After ashort pre-setperiod, known as the ‘burn-back’time, the Power-source
contactor function is released.This periodensures that the consumable wire
does not ‘freeze’ in the weld pool. To adjust the ‘burn-back’ time, refer to
Section IO.
P The gas valve is de-energised and the flow of shielding gas ceases.
7. BASK WELDlNG 1NFORMAPION
CHOICE OF SHIELDING GAS
The choice of shieldin gas is largely determined by the consurnable wire to be
The recommendedshielding gases for use with the WELDMATIC 205s are :
used. Manyproprietaryshie 9 ding gas mixturesare available.
B MildSteel ............................ Argon + 5 to 25% Carbon Dioxide;
a Aluminium ...........................
Argon;
B Stainless Steel .................... Argon + 1 to 2% Oxygen.
Consult your gas supplier if more specific information is required.

Page 12 WELDMATIC 305 MANUAL
SHIELDING GAS FLOW RATE
In G.M.A. welding, one of the functions of the shielding gas is to protect the molten
weld pool from the effects of oxygen in the atmosphere. Without this protection theweld
deposit becomes'honeycombed' in appearance, an effect which is described as weld
porosity.
In draft-free conditions the gas flowraterequired to give adequate protection is
typically IO litres/min. Insituations where drafts cannot beavoided, itmay be necessary
to increasethis rate and/or to provide screening of the work area.
Weld porosity can alsobe caused by air entering thegas streamthrough a damaged
hose, loose gas connection, or from restriction in the nozzle,such as from excess build-
up of spatter.
ESTABLISHING A WELD SE-r"ING
two variablesthat are adjusted inorder toobtain a stable arcare;
Once the consumable wire type, wire size and shieldinggas have been chosen, the
Wirefeedspeed,
= Weldingarc voltage.
The wirefeed rate determinesthe welding current; increasingthe feed rate increases
the current, and decreasing it decreases current. The selected wirefeed rate must be
matched with sufficient arc voltage; an increase of wirefeed rate requires an increase of
arc voltage.
If the voltage is too low the wire will stub and stutter, and there will not be a steady
arc. If the voltage is too high the arc will be long with the metal transfer within the arc
occurring as a series of large droplets.
The welding current should be chosen to suit the thickness of the metal to be
welded. It is important to check that the deposited weld provides sufficient strength to
suit the application.
- ..

WELDMATIC 305 MANUAL Page 13
A "good" weld will have the characteristicsillustrated in figure 6. The weld has
penetrated into the parent metal, fusing the root of the joint where the two plates meet,
and the weld blends smoothly into the side walls.
A "bad"weld is shown in figure 7. The weld has not penetrated the joint root, and
there is poorside wall fusion. This lack of fusion would normally becorrected by
increasing the arc voltage, or by increasing both wirefeed rate and arc voltage to
achieve a higher current weld setting.
b
L
FIGURE 6. 'GOOD" WELD FIGURE 7. 'BAD' WELD
GUN POSITION
belowwith the nozzle end pointingin the direction of travel.
For "down hand" fillet welding, the gun is normally positioned as shown in figure 8
FIGURE 8. GUN POSITION

1
Page 14 WELDMATIC 305 MANUAL.
8. GENERAL MAINTENANCE
DUST
Care should be taken to prevent excessive build-up of dust and dirtwithinthe
welding powersource. It is recommended that at reguiar intervals, according tothe
prevailing conditions, the machine covers be removed and any accumulated dust be
removed bythe use of dry, low pressurecompressed air, or a vacuum cleaner.
WIREFEED
The G.M.A. welding process, in order to obtainthe most satisfactory welding results,
requires the wirefeed to be smooth andconstant. It is therefore important to observe
the followingpoints;
m Keep the gun cable liner clear of dust andswarf build-up. When replacement
becomes necessary,fit only the correctliner tosuit the gun cable model. See
Section 11. The build-upof dust ina cable linercan be minimized by regular
purging of the linerwith drycompressed air.This may beconveniently done
each time the wire spool is replaced.
I Replacethe welding tip as itbecomes worn.
I Keepthe wire drive mechanism clean. Periodicallycheck the drive rollers for
wear and for freerotation.
Check that the consumable wire spool holder rotates smoothly andthat the
brakingaction is not excessive.This also may be conveniently done each time
the wire is replenished.
9. TROUBLE SHOOTING
UNSATISFACTORY RESULTS
WIREFEED
= Erraticwirefeed is the MOST LIKELY cause of failure in all Gas Metal Arc
Welding. It should therefore be thefirst pointchecked when problems occur
Refer to the section above.
m Check for correct gas flow rateat the welding torch nozzle and ensure there are
no gas leaks. Thegun nozzle must befree from spatter and firmly attached to
the weldinggun toensure that air is not drawn into theshielded area.
a Check that the shielding gas selected is correctfor the consumable wire in use.
3
WELDING ClRCUIY
I Ensurethat the work clamp is securely tightened onto the work-pieceso that
good electricalcontact isachieved.Check also that theoutput polarity selected
isappropriatefor the consumable in use.
Contaminationof the work-piece surface by water, oil, grease, galvanizing,
paint,or oxidelayerscan severelydisturb the welding arc and result ina poor
weld. Thecontaminating materialshould beremoved beforewelding.

WELDMATIC 305 MANUAL Page 15
WIREFEED / ARC VOLTAGE RELATIONSHIP
If the consumable wire is stubbing into the workpiece, and a steady arc cannot be
obtained, it is likely that the arc voltage is set too low to suit the wire speed. To correct
this situationeither increase arc voltage, or decreasethe wire speed.
If thearc length is too long, the arc voltage is too high to suit the wire speed. To
correct this, increasewire speed or decreasearc voltage.
NO WELDING CURRENT
the fan isrunning and the indicator light isilluminated.
Check that Mains Supply is available at theWELDMATIC 305 Power Source, i.e.that
Check continuity of the welding current circuit, i.e., work lead, work clamp and gun
cable connections.
The WELDMATIC 305 welding power source incorporates an inbuilt Over
temperaturethermostat which will trip if the welding load exceeds theoperating duw
cycle.
In this event the machine will not deliver welding current until the machine has
cooled sufficiently. The thermostat will reset automatically - do not switch the machine
off as thecooling fan will assist the resettingof the thermostat.
If the forgoing checks have been made and have not revealedthe fault condition, a
QUALIFIED SERVICE person should be consulted.
10. SERVICE INFORMATION.
Themain electrical components of the WELDMATIC 305 are listed below, with
= Welding RectifierAssembly, Item f. This comprises six high-currentrectifier
m Welding Transformer, Iteme.
m Wirefeed control Board, Item m. (See following description.)
m Control Transformer, Item h.
Power ON/OFF and Coarse Voltage Switch, Itemd.
e Fine Voltage switch,Item e.
= Gas valve, Item j.
referenceto the following circuitdiagram.
diodes mounted on an aluminium heatsink, with transient protectioncapacitors.
1

Page 16 WELDMATIC 305 MANUAL
E
-0
FIGURE 9. WELDMATIC 305 CIRCUIT DIAGRAM

I
WELDMATlC 305 MANUAL Page 17
WIREFEED CONTROL BOARD CP27-41
The Wirefeedcontrol board provides the following circuit functions:
Wirefeedmotor ON / OFF control in response to the gun-switch.
Speed control of the wirefeed motor.
‘Burn-back’control.
m 8raking of the wirefeed motor at end of weld.
m Spot-weldtimer.
I Intervaltimer.
m Control of the gas solenoid valve.
Connections to the board, and Service pointsare detailed in thedrawing below.
The circuit is factory adjusted to provide a maximum drive roller speed of 160 rpm.
GUN
SWITCH
PI
CONTACTOR
GAS
VALVE
E
P2
PRESET
RV2
DO NOT ADJUST
RELAY RELAY
P3
RVl
BURN-BACK
CP27-41
FIGURE IO. WIREFEED CONTROL BOARD

Page 18 WELDMATIC 305 MANUAL
11. PARTS LISTS
WELDMATIC 305 POWER SOURCE
ITEM #...... PART# ...................... DESCRIPTION
1 ................ CP27-42 .................... Front Panel
2 ................ CP27-14 ....................
Back panel
4 ................ CP27-16 ....................
Side panel
................ ....................
3 CP27-43 Centre panel
5 ................ cp27-17 ....................
Side cover
6 ................ ~~27-18 .................... Baffle
7 ................ cp27-44 ..................
..Hingedtop and side Panel
. """" ~ ~
8 ................ CP27-20 .................... Base assembly
lncludes CP27-0/14 ................ Castorwheel
CP27-0/13 ................ Fixedwheel
9 ................ CP27-23 .................... Rectifier assembly
Includes CP34-14/19 .............. Diode SKR 130/04
CP34-14/20 ..............
Diode SKN 130/04
CP3-9/8' Thermostat
" -.
....................
10 .............. CP27-71 ....................Transformer assembly (380V)
11 .............. CP27-41 .................... Wirefeed control board
Includes
W1 1-7/16 .................. Relay, 24v (2)
12 .............. TC396-1 ....................
Euro connectorand stem
13 .............. W27-1 ....................... Wirefeed motor and drive ass'y
14 .............. CP101-0/18 .............. Gas valve
15 .............. CP27-0 15 ..............
..Fan
17 .............. CP27-01/17 ..............
Control transformer
18 .............. CP27-0/18 ................
Contactor
19 .............. Wf -41 .......................
Magneticcatch
20 .............. 027-0/20 ................
Coarse switch
23 .............. W5-10/19 ..................
Small knob
26 .............. MC14-0/10 ................
Conduit bush
28 .............. MC1 1-41 /3 ................
Insulating nipple
29 .............. W11-13 ......................
Mounting insulator
32 .............. HOSSR ......................
Gas hose
16 .............. W17-2 / 12 .................. Cliplite clear lens
21 .............. CP27-0 21 ................ Fineswitch
22 .............. W1 1-0 / 16 ..................Wire speedknob
25 .............. LG300 .......................Work clamp
27 .............. AM177 ....................... Spool holder ass'y
31 .............. ..................................Suppl y flex
NOTE
For the CP27-10 remotewirefeeder package (seeFigure 12), items 13 & 27 are deleted,
also see note reitem 12.

WELDMATIC 305 MANUAL Page i 9
FIGURE 1 I. WELDMATIC 305 POWER SOURCE ASSEMBLY

Page 20 WELDMATIC 305 MANUAL
FIGURE 12. WELDMATIC 305 POWER SOURCE (REMOTE WIREFEEDER)