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