CP44-3 Weldmatic 335 Internal Feeder Manual
Contents
1. 2 6 nee Drs oss ds CPI des jc 44 41 RE PT 4 40 poe TO curate end 42 7 RR P4299 rover 42 34 gt MENDA 42 39 7i CEPR n MEER e P I ERREUR CP101 0 18 rc m MMC MEIST PA E CP2T UI TS CPT2 0 2 e EE RE 43 0 8 V ee ERE 43 0 3 W11 0 16 5 NEED 5 10 19 CV PINE Kok dicii to LM aes AMT Includes OE b d et 133 3 WT TSTS CE Lp Mr 42 0 3 CABACATHD HOSSR 1 SIO P 3 DIZS DIE C secca uda nus MINOS WELDMATIC 335 MANUAL DESCRIPTION Printed Circuit Board Reiay 24v 2 Front Panel Back Panel Cenire Panel Base Assembly Castor Wheel 2 Baffle Panel Side Cover Fixed Side Cover Fixed Lower side Cover Opening Top Cover PCB Cover Rectifier Mounting Bracket 2 Wel2. 4 Power Source 5 Installation uuo totes P 6 Normal Welding P 9 UP A Basic Welding Information P 9 DEC RN General Maintenance 12 9 Trouble Shooting P 12 10 Service 14 11 Parts LISS 2 16 50612 Safe Practices 20 FIGURES gi M RR Power Source Controls 5 ap Connection of Supply Cable P 6 PAS m Positive Wire Connection P 8 0 4 Negative Wire Connection P 8 occ PEE 11 PIG Bad WEld 11 G n POSIBOT 11 Circuit Diagram 44 3 14 FIO ERN Wirefeed Control Board 42 12 P 15 PIG NO NEN Power Source Assembly P 17 FIOTT oeiee Gun Cable Assembly P 18 ial Wir
3. It is important to check that the deposited weld provides sufficient strength to suit the application WELDMATIC 335 MANUAL Page 11 A good weld will have the characteristics illustrated in Figure 5 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 6 The weld has not penetrated the joint root and there is poor side wall fusion This lack of fusion would normally be corrected by increasing the arc voltage or by increasing both wirefeed rate and arc voltage to achieve a higher current weld setting bo FIGURE 5 GOOD WELD FIGURE 6 BAD WELD GUN POSITION For down hand fillet welding the gun is normally positioned as shown in Figure 7 below with the nozzle end pointing in the direction of travel FIGURE 7 GUN POSITION 12 WELDMATIC 335 MANUAL 8 GENERAL MAINTENANCE 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 machine covers be removed and any accumulated dust be removed by the use of dry low pressure compressed air or a vacuum cleaner WIREFEED In order to obtain the most satisfactory welding results from the G M A W process the wirefeed must be smooth and constant It is therefore important to observe the following po
4. Spacer large W217 Axle Clip WV 20 011 Inlet Guide 2 0mm 419 Pressure Screw complete Includes 10 1 WT 1 12 Thumbscrew oce Spring TOS ENTM 27 1 14 Base W2T 1115 seien eeu Pressure Link Pressure Screw Axle jc Spring jc W27 1 18 ierra in We External Circlip 4mm ID pio PETENTEM DEN External Circlip 5mm iD ALTERNATIVE PARTS PAESE TERUEL 262 o eb Feed Roll 0 8 1 0mm W26 2 8 Feed Roll 1 0 1 2mm W26 3 8 cod aa ies Feed Roll 1 0 1 2mm Alum NN W26 4 8 Feed Roll 1 2 1 6mm Feed Roll 0 9 1 2mm 26 6 8 Feed Roll 1 2 1 6mm Knurled Inlet Guide 3mm W272 1S usitas Inlet Guide 2 4mm TROU W2T 2I 1 SN ios inlet Guide 2 4mm Nylon FIGURE 12 W27 2 TWO ROLL DRIVE ASSEMBLY 20 WELDMATIC 335 MANUAL 12 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 Standard
5. and is dynamically braked to a stop After a short pre set period known as the burn back time the Power source contactor function is released This period ensures that the consumable wire does not freeze in the weld pool To adjust the burn back time refer to Figure 9 At the completion of any post gas time set the gas valve is de energised and the flow of shielding gas ceases To adjust the pre and post gas times refer to Figure 9 7 BASIC WELDING INFORMATION CHOICE OF SHIELDING GAS The choice of shielding gas is largely determined by the consumable wire to be used Many proprietary shielding gas mixtures are available The recommended shielding gases for use with the WELDMATIC 335 are Mild Argon 5 to 25 Carbon Dioxide Aluminium Argon W Stainless Steel Argon 1 to 296 Oxygen Consult your gas supplier if more specific information is required 10 WELDMATIC 335 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 the weld deposit becomes honeycombed in appearance an effect which is described as weld porosity In draft free conditions the gas flow rate required to give adequate protection is typically 10 litres min In situations where drafts canno
6. 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 1674 1974 the S A A Cutting and Welding Safety Code 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 1974 Water filling just below working leve 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 wh
7. 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 WELDMATIC 335 MANUAL Page 21 Vapours from chlorinated solvents can
8. E PERSON should be consulted FJONVLONGNI 5 lt 1USUuU3nau gt ALLYY10d Lf p vg 9 pd Ld TAON 18918 ux mu PG Ro C FHIL HOVANHNG lt SLNIWLSNCAY TYNHALNI AWIL TYAXad LN TWIL 1048 13445 8 W149 AS NNS HOLIMS NNS Ouni MS T TOULNOY 84848 JAIM Zd 1 2 p oerte fo ea e pur eiie pee oem 955909 24 SPT ET BT 1 i 98 6 3 88 5 Lary re i FH g A x i LUISOHHUZHJI i 899 aM EJ Bp UJIJILOSUI F 9 8 I34243HI1 A QE FIGURE 8 44 3 CIRCUIT DIAGRAM HIHUS 10 SERVICE INFORMATION Page 14 WELDMATIC 335 MANUAL Page 15 WIREFEED CONTROL BOARD CP42 12 wirefeed control board provides the following functions Wirefeed motor on off control in response to the gun switch Speed control of the wirefeed motor Switchable creep standard wirefeed start modes Burn back control Braking of the wirefeed motor at end of weld opot weld timer Interval timer Pre and Post gas control timers Pull gun motor speed calibration where pull gun fitted Local or remote wire speed control Connections to the board and service points are detailed in the drawing below The circuit is factory calibrated for a maximum push motor drive
9. Handle Kit 25 5060 Euro Block 5662 Trigger Assembly 26 BE4421 O Ring 10 BE1880004 Screw Kit 27 BE43110 Liner 0 9mm 1 2mm 14 BE1480012 Cable Assembly To replace liner Disconnect gun cable assembly from the Euro adaptor on the machine case remove nozzle 1 and head 3 Withdraw old liner from the wire feeder end Insert new liner and refit gun cable assembly to Euro adaptor on the machine case At the gun end compress the liner within the gun cable then cut it one contact tip length past ihe end of the body tube 7 Refit head tip and nozzie FIGURE 11 BEXT2 4E310AE 300 AMP GUN CABLE ASSEMBLY WELDMATIC 335 MANUAL Page 19 W27 2 MOTOR amp TWO ROLL DRIVE ASSEMBLY ITEM Z PART DESCRIPTION WZ Motor amp Gearbox WV 26 0 8 ensien Screw M6x12 NE W2T1 0 8 o isse oett Key A Feed Plate W26 S 8 0 9 1 2 la PAUL eR Positioning Screw Axle Pressure Arm complete Includes WA2T DIES eM LA W2 Pressure Arm siot Spacer narrow oerte Pressure Roll 89 APT EST
10. WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ABN 18 004 547 111 Head Office and International Sales 5 Allan Street Melrose Park South Australia 5039 Telephone 08 8276 6494 Facsimile 08 8276 6327 www weldingindustries com au info weldingindustries com au OWNERS MANUAL WELDMATIC 335 INTERNAL WIREFEEDER MODEL NO CP44 3 REV C 11 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE 2 WELDMATIC 335 MANUAL 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 requesting spare parts please quote the model and serial number 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 SAFETY Before this equipment is put into operation the Safe Practices section at the back of the manual must be read completely This will help to avoid possible injury due to misuse or improper welding applications CONTENTS IntrOQ LIC HOD erre etra teu tar toes iun P 3 ee Specifications 4
11. ating for a Weldmatic 335 is 20 Amps Note The tripping time of a typical 20A circuit breaker may limit the duty cycle available from the Weldmatic 335 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 machine supply terminals is gained by removing the power source side panel opposite to the wire spool enclosure Pass the cable through the bush fitted to the machine back panel The three phases are terminated at terminal block as shown in Figure 2 Tighten the cable clamp leaving just sufficient slack in the cable such that the terminated wires are not in tension FIGURE 2 CONNECTION OF SUPPLY FLEXIBLE CABLE WELDMATIC 335 MANUAL Page FITTING THE GUN CABLE The BERNARD BEQA310AE gun cable is equipped with a Euro wirefeeder connector which incorporates all required connection points 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 of the male and female Euro connectors then rotate the locking ring clockwise to firmly secure the connection FITTING THE GAS BOTTLE Depending on configuration of the cylinder to be used th
12. 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 trichlorethyiene 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 A person acting as Fire Watcher must
13. ding Transformer Assembly inductance Assembly Rectifier Assembly Output Terminal Insulating Support Positive Busbar Negative Busbar Handle Assembly Motor and Two Roll Drive Assembly Euro Gun Adaptor Gas Valve Hose Barb Coarse Voltage Switch Fine Voltage Switch Potentiometer Knob Large Potentiometer Knob Smail 2 Work Clamp Spool Holder Assembly Insulating Spacer Bush 2 Nylon Insulating Bush 2 Rubber Tyre Wheel 2 Mains Supply Flexible Cable Rubber Grommet Terminal Block 2 WELDMATIC 335 MANUAL Page 17 9 5 _ 2 a X ll O 1 d 66 _ 5 5 U U ul Lay T a E 22 LEFT SIDE VIEW 4 9 FIGURE 10 WELDMATIC 335 POWER SOURCE ASSEMBLY 18 WELDMATIC 335 MANUAL BEXT2 4E310AE GUN ASSEMBLY p NS BE4392 Nozzle 15 BE4E213B End Fitting BE7497 Contact Tip 0 6mm 16 4305 Cone Nut BE7488 Contact 0 8mm 17 2660001 Terminal ee BE7498 Contact Tip 0 9mm 18 BE1520008 Clamp MOTUUM BE7490 Contact Tip 1 2 19 BE2520017 Strain Relief Flexible D unus BE4335 Head 20 BE1470007 Bushing 4 BE4323R Cap 21 BE1880135 Strain Relief Rigid Bis 4780 Nut Insulator 22 BE2280002 Screw Dus BE1370117 Insulator 29 5 H2072 AE Insulated Link umm BE1370116 Body Tube 24 BE4816 Nut 8 BE1780006
14. e Drive P 19 WELDMATIC 335 MANUAL Page 3 1 INTRODUCTION Gas Metal Arc Welding G M A W is a basically simple welding process where consumable wire is fed by motor driven drive rollers 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 sheetmetal to heavy plate and metals ranging from carbon steel to aluminium alloys The WELDMATIC 335 has been designed to be used with consumable wires in the range from 0 6mm 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 such as AUSTMIG ES6 is used with a shielding gas of Carbon Dioxide or Argon mixed with Carbon Dioxide Alternatively Flux cored consumables are available in both gas shielded and gasless self shielding types Stainless steel and Aluminiu
15. e gas flowmeter regulator may be fitted directly to the cylinder or conjunction with an elbow fitting DO NOT apply any grease to these joints and tighten the nuts securely Fit the end of the gas inlet hose from the back panel of the machine to the connector supplied with the flow regulator and secure with the clamp also supplied FITTING THE CONSUMABLE WIRE 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 Place the spool of welding wire onto the spool holder The location pin should mate with a hole provided the wire spool body Fit the spool retaining R clip supplied 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 the Nyloc nut using a 15 16 AF or 24mm socket wrench SELECTION OF START MODE The WELDMATIC 335 offers selection between Creep and Standard arc starting modes in creep mode the electrode wire is fed at a reduced speed when the gun switch is first closed Once the arc is initiated the wire accelerates to full welding speed his mode produces a
16. he range 0 5 2 5 seconds If the Spot Weld mode is not required this feature can be turned off by rotating the control anti clockwise until it clicks into the minimum position 6 INTERVAL CONTROL When operating the machine in Cycle Arc mode this control sets the period between welds The spot time control sets the welding period Rotating the dial clockwise will increase the interval time in the range 0 5 2 5 seconds If the Cycle Arc mode is not required this feature can be turned off by rotating both controls fully anti clockwise 7 PRE AND POST GAS CONTROLS Adjustable timers for pre weld and post weld shielding gas flow are available on the CP42 12 Wirefeed control board Refer to Figure 9 for adjustment details 6 WELDMATIC 335 MANUAL Adjustable timers for pre weld and post weld shielding gas flow are available on the CP42 12 Wirefeed control board Refer to Figure 9 for adjustment details 5 INSTALLATION CONNECTION TO ELECTRICAL MAINS POWER SUPPLY The WELDMATIC 335 is supplied with a 5 metre 4 core 47 0 20 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 s selected according to the effective primary current of the machine The effective primary current for a Weldmatic 335 is 14 Amps The minimum recommended circuit breaker r
17. in use Contamination of the work piece surface by water oil grease galvanising paint or oxide layers can severely disturb the welding arc and result in a poor weld The contaminating material should be removed before welding WELDMATIC 335 MANUAL Page 13 WIREFEED ARC VOLTAGE RELATIONSHIP If the consumabie wire is stubbing into the work piece 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 situation either increase arc voltage or decrease the wire speed the arc length is too long the arc voltage is too high to suit the wire speed To correct this increase wire speed or decrease arc voltage NO WELDING CURRENT Check that Mains Supply is available at the WELDMATIC 335 Power Source i e that the fan is running and the indicator light is illuminated Check continuity of the welding current circuit i e work lead work clamp and gun cable connections The WELDMATIC 335 welding power source incorporates an in built over temperature thermostat which will trip if the welding load exceeds the operating duty 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 the cooling fan will assist the resetting of the thermostat If the forgoing checks have been made and have not revealed the fault condition a QUALIFIED SERVIC
18. ints Keep the gun cable liner clear of dust and swarf buiid up When replacement becomes necessary fit only the correct liner to suit the gun cable model See Section 11 The build up of dust in a cable liner 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 Replace the welding tip as it becomes worn E Keep the wire drive mechanism clean Periodically check the drive rollers for wear and for free rotation Check that the consumable wire spool holder rotates smoothly and that the braking action is not excessive This also may be conveniently done each time the wire is replenished 9 TROUBLE SHOOTING UNSATISFACTORY RESULTS WIREFEED Frratic wirefeed is the MOST LIKELY cause of failure in all Gas Metal Arc Welding lt should therefore be the first point checked when problems occur Refer to the section above Check for correct gas flow rate at the welding torch nozzle and ensure there are no gas leaks The gun nozzle must be free from spatter and firmly attached to the welding gun to ensure that air is not drawn into the shielded area Check that the shielding gas selected is correct for the consumable wire in use WELDING CIRCUIT Ensure that the work clamp is securely tightened onto the work piece so that good electrical contact is achieved Check also that the output polarity selected is appropriate for the consumable
19. m 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 CP44 3 package contains WELDMATIC 335 Power source Internal wirefeeder BEXT2 4E310AE BERNARD Gun cable 3 metre Euro connector m WGAC24 Regulator and Flowgauge Argon This Owners Manual 4 3 SPECIFICATIONS WELDMATIC 335 MANUAL Manufactured to Australian standard AS1966 1 1985 PRIMARY 415 Vac 3 Phase VOLTAGE 50 60 Hz EFFECTIVE 14 Amps PRI CURRENT MAXIMUM 22 Amps 16 kVA PRI CURRENT OPEN CIRCUIT 18 to 44 Volts VOLTAGE in 30 steps WELDING 35 335 AMPS CURRENT RANGE RATED OUTPUT 190 Amps 25 Volts 100 Duty Cycle 260 Amps 30 Volts 55 Duty cycle 335 Amps 34 Volts 3296 Duty cycle CIRCUIT BREAKER RATING 20 Amps 400 Vac 3 phase 50 60 Hz 14 Amps 20 Amps 14 kVA 17 to 43 Volts in 30 steps 35 335 AMPS 190 Amps 24 Volts 100 Duty Cycle 260 Amps 26 5 Volts 55 Duty cycle 335 Amps 31 Volts 32 Duty Cycle 380 Vac 3 Phase 50 60 Hz 14 Amps 19 Amps 13 16 to 41 Volts in 30 steps 35 320 AMPS 190 Amps 24 Volts 100 Duty Cycle 260 Amps 26 5 Volts 5596 Duty cycle 320 Amps 30 Volts 35 Duty c
20. ose body becomes a conductor Ensure that the machine is correctly connected and earthed If unsure have machine 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
21. put voltage polarity POSITIVE WIRE Most G M A W is carried out with the work piece Negative and the welding consumable wire Positive To set the machine for this condition boit the WORK iead onto the output stud and the CABLE lead to the stud as in Figure 3 below NEGATIVE WIRE Some seif shielded flux cored consumables are intended to be operated with the work piece Positive and the consumable wire Negative Refer to the manufacturers data for the particular consumable to be used To set the machine for this condition the WORK lead onto the output stud and the GUN CABLE onto the stud as in Figure 4 below WORK LEAD GUN CABLE LEAD GUN CABLE LEAD WORK LEAD FIGURE 4 NEGATIVE WIRE WELDMATIC 335 MANUAL Page 9 6 NORMAL WELDING SEQUENCE WELD START Closing the welding gun switch initiates this sequence of events The gas valve is energised gas flow commences and continues for any pre gas time set The power source contactor is initiated Welding voltage is applied between the work piece and the consumable wire The wire drive motor is energised If creep start mode is selected wirefeed commences at reduced speed The wire touches the work piece and the arc is established If creep start mode is selected wirefeed rate increases to full welding speed WELD END Releasing the gun switch initiates this sequence of events a The wire drive motor is de energised
22. roller speed of 160 rpm PULL MOTOR VE PULL MOTOR VE REMOTE SPEED POT 1K 25 REMOTE SPEED 1 EMITTER REMOTE A COLLECTOR r LOCAL PULL MOTOR FUSE ee LL 8 1 16A STD ACT CUT LINK T 1 LEDI LOCAL REMOTE H INDUCTANCE zi E SWITC WELDING be INDUCTANCE 4 a TSA 222 START MODE SWITCH POT 1 NS CP34 36 2 UP CREEP START DOWN STANDARD 47 798 POT 3 POT 2 27 11 26 27 11 26 MAX PUSH PUSH Ho Pa CALIBRATION amen 6 S PULL GUN BURN BACK a CALIBRATION TIMER PRE GAS TIMER Q ruse O P3 feo lt STD ACT 1 4 tA 1 NEREZE 8 GUN SWITCH 30 VAC SUPPLY GUN SWITCH 0 VAC SUPPLY 30 VAC SUPPLY PUSH MOTOR VE PUSH MOTOR VE CONTACTOR CONTROL CONTACTOR CONTROL FIGURE 9 WIREFEED CONTROL BOARD 16 11 PARTS LISTS WELDMATIC 335 POWER SOURCE ITEM PART 2 includes 2 200 GPA222 booths 42 23 MER P EE RERUM OP44 23 includes 42 24 6 CPA2 42 26 2 2 ae 42 2
23. s pertaining to industry is available from the Standards Association of Australia also various State Electricity Authorities Depariments of Labour and Industry or Mines Department and other Local Heaith or Safety Inspection Authorities may have additional requirements WTIA Technical Note TN7 98 also 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 ciear cover lens This is 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 fens Amps MMAW MiG Puised MiG 0 100 S II NE 12 13 100 150 TU Soins 12 13 150 200 12 codi 10 11 nne 12 13 200 300 dO uut s T2513 o 12 13 300 400 Id iode ciet pom oT 14 400 500 js rt pL ten 14 500 14 BURN PROTECTION The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light coloured surfaces and burn the skin and eyes Burns resuiting from gas shielded arcs resemble acute sunburn but can be more severe and painful Wear protective clothing leather
24. softer arc start which is recommended for aluminium welding applications If a faster arc start is required standard mode should be selected The selector switch is located on the wirefeed control board 42 12 as shown Figure 11 Slide the switch upwards to select Creep mode and downwards to select Standard mode FEEDING THE CONSUMABLE WIRE WIRE INCH With reference to Figure 14 release the pressure screw 10 and rotate the pressure arm 8 to the open position 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 correct for the wire in use The appropriate size is stamped on the visible side of the installed roller Check also that the correct size contact tip is fitted at the gun end Drive roller and tip details are available in Section 11 of this manual the pressure arm to the closed position and adjust the compression screw to provide sufficient clamping of the drive rolls drive to achieve constant wirefeed Do not over tighten With the machine energised close the gun switch to feed wire through the gun cable If creep speed is selected the wire will be initially fed at reduced speed however after a short timed period the rate will increase to full welding speed 8 WELDMATIC 335 MANUAL OUTPUT VOLTAGE POLARITY The design of the WELDMATIC 335 allows selection of the out
25. t be avoided it may be necessary to increase this rate and or to provide screening of the work area Weld porosity can also be caused by air entering the gas stream through a damaged hose loose gas connection or from restriction in the nozzle such as from excess build up of spatter Particularly when welding aluminium porosity can occur at the start and end of a weld For this reason it is recommended that some pre and post gas flow time be set This ensures that the welding zone is protected from atmospheric contamination before the arc is established and as the weld pool solidifies at the end of a weld Refer to Figure 11 for adjustment details ESTABLISHING A WELD SETTING Once the consumable wire type wire size and shielding gas have been chosen the two variables that are adjusted in order to obtain a stable arc are Wirefeed speed Welding arc voltage The wirefeed rate determines the welding current increasing the 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
26. ycle FITTED SUPPLY CABLE 47 0 20 Four Core Heavy Duty PVC WIRE SIZE RANGE 0 6mm 1 6mm diameter COOLING Fan cooled air drawn in through top louvre INSULATION Class 140 C Rise DIMEN SIONS L 870mm W 490mm 730mm 112kg Duty cycle is defined in Australian Standard AS1966 1 as the ratio of arcing time to 5 minutes in any 5 minute period expressed as a percentage WELDMATIC 335 MANUAL Page 5 4 POWER SOURCE CONTROLS LIGHT 7 PRE amp POST GAS CONTROLS INTERNAL ADJUSTMENTS FIGURE 1 POWER SOURCE CONTROLS 1 POWER ON INDICATOR This is illuminated when the machine ts energised that is when electrical mains power is connected to the welder and the Coarse Voltage switch is in positions 1 2 or 3 2 COARSE VOLTAGE CONTROL This switch provides Coarse adjustment of the Output Welding Voltage over three ranges plus a power off position 3 VOLTAGE CONTROL This switch provides ten steps of Fine adjustment of the Output Welding voltage 4 WIRE SPEED CONTROL The wirefeed speed of the machine is varied with this control turning the dial in a clockwise direction increases the wirefeed speed increasing the welding current 5 SPOT TIME CONTROL When operating the machine in Spot Weld mode this control will vary the spot weld time Rotating the dial clockwise will increase the spot weld time in t
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