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Operators Manual

Quality

 

 

Reliability

 

 

Performance

Safe Practices When Using 
Welding Equipment

These notes are provided in the interests 
of improving operator safety. They should 
be considered only as a basic guide to Safe 
Working Habits. A full list of Standards 
pertaining to industry is available from 
the Standards Association of Australia, 
also various State Electricity Authorities, 
Departments of Labour and Industry or 
Mines Department and other Local Health 
or Safety Inspection Authorities may have 
additional requirements. Australian Standard 
AS1674.2 provides a comprehensive guide to 
safe practices in welding.

Eye Protection

NEVER LOOK AT AN ARC WITHOUT 
PROTECTION. 

Wear a helmet with 

safety goggles or glasses with side shields 
underneath, with appropriate filter lenses 
protected by clear cover lens. This is a MUST 
for welding, cutting, and chipping to protect 
the eyes from radiant energy and flying 
metal. Replace the cover lens when broken, 
pitted, or spattered.

Recommended Shade Filter Lens

Amps

TIG

MMAW

MIG

Pulsed 

MIG

0-100

10

9

10

12-13

100-150

11

10

10

12-13

150-200

12

10-11

11-12

12-13

200-300

13

11

12-13

12-13

300-400

14

12

13

14

400-500

13

14

14

500 +

14

14

Read first

The information contained in this 
manual is set out to enable you to 
properly maintain your new equipment 
and ensure that you obtain maximum 
operating efficiency. 

Please ensure that this information is 
kept in a safe place for ready reference 
when required at any future time.

When ordering spare parts, please 
quote the model and serial number of 
the wirefeeder and part number of the 
item required. All relevant numbers are 
shown in lists contained in this manual. 
Failure to supply this information 
may result in unnecessary delays in 
supplying the correct parts.

Safety

Before this equipment is put into 
operation, please read the Safe 
Practices section of this manual. 
This will help to avoid possible 
injury due to misuse or improper 
welding applications.

Handle on Power Source

Please note that the handle fitted to 
the Weldmatic 270C

 

power source 

is intended for manoeuvring the 
equipment by hand only.

DO NOT

 use this handle for 

suspending or mounting the power 
source in any other manner.

Summary of Contents for WELDMATIC 270C

Page 1: ...CP136 40 Rev B Weldmatic 270C compact internal wirefeeder Operators Manual Weldmatic 270C MIG welder Model No CP136 2 Iss A 0812...

Page 2: ...Welding Industries of Australia An ITW Company Telephone 1300 300 884 Facsimile 1300 301 884 Email Info welding com au www welding com au...

Page 3: ...fe Practices 2 1 Introduction 5 2 Receiving 5 3 Specifications 6 4 Controls 7 5 Installation 9 6 Normal Welding Sequence 12 7 Basic Welding Information 13 8 General Maintenance 14 9 External Trouble S...

Page 4: ...Filter Lens Amps TIG MMAW MIG Pulsed MIG 0 100 10 9 10 12 13 100 150 11 10 10 12 13 150 200 12 10 11 11 12 12 13 200 300 13 11 12 13 12 13 300 400 14 12 13 14 400 500 13 14 14 500 14 14 Read first Th...

Page 5: ...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 necessar...

Page 6: ...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 b...

Page 7: ...m to 1 2mm diameter The smaller wire sizes are used when welding at lower currents such as sheet metal applications Increasing the wire diameter permits higher welding currents to be selected A common...

Page 8: ...urrent 30 270 Amps Open Circuit Voltage 17 41 V Shipping weight 127 kg Power source weight 85 kg Mains Circuit Breaker Rating 25 Amps Supply plug 15 Amp 240 V for initial commissioning only Fitted Sup...

Page 9: ...o not switch the equipment off as the cooling fan will assist the resetting of the thermostats 4 Controls 3 Arc start This control can be set to modify arc starting conditions For many applications th...

Page 10: ...owed by rapid acceleration so that the arc does not flare up and damage the tip Even if an arc is not established within one second of the gun switch being operated the wire feed accelerates to select...

Page 11: ...fitted with a 3 metre 3 core 2 5 mm2 Heavy Duty PVC mains power supply cable with moulded 3 pin 15 Amp Single Phase plug 15 Amp Supply Limited Output To operate the machine with the 15 Amp plug from...

Page 12: ...Successful Operation Successful operation will depend on a number of factors Variation in circuit breaker thresholds Ambient temperature Number of previous circuit breaker operations Actual weld condi...

Page 13: ...d 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...

Page 14: ...he gas valve is de energised and the flow of shielding gas ceases Compression screw Top roller arms Fig 5 WF042 Four Roll Drive Inlet guide Drive rollers Feeding the Consumable Wire At the wirefeeder...

Page 15: ...excess build up of spatter When welding aluminium particular care must be taken with all aspects of shielding gas delivery and workpiece preparation in order to avoid weld porosity Establishing a Wel...

Page 16: ...ze 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...

Page 17: ...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 Power source has no output and no wirefeed when gun s...

Page 18: ...s required 5 Check the work piece surface and MIG wire for contamination Water oil grease or paint can result in porosity in the weld the equipment off as the cooling fan will assist the resetting of...

Page 19: ...Weldmatic 270C Model No CP136 2 Iss A 08 12 17 10 Circuit Diagram Power Source Fig 9 Power Source Circuit Diagram...

Page 20: ...Reliability Performance 11 1 Assembly and Parts List Weldmatic 270C Power Source Fig 10 Weldmatic 270C Power Source Assembly 9 8 14 12 16 18 5 6 7 3 2 1 17 15 23 19 21 22 28 33 34 30 32 29 27 26 25 2...

Page 21: ...0304 Plastic Front 1 20 L0022 Control Transformer 1 21 E0058 Contactor 1 22 E0041 Gas Valve 24 vdc 1 23 PWA010N Fan On Demand PCB 1 24 FAN008 Fan Assembly 1 25 TFM061 Welding Transformer Assembly Wire...

Page 22: ...WF026 0 6 0 8 mm Solid Wire 2 WF028 1 2 1 6 mm Solid Wire 2 WF029 1 0 1 2 mm Aluminium 2 WF030 1 0 1 2 mm Flux Cored Wire 2 WF031 1 2 1 6 mm Flux Cored Wire 2 3 WF037 Pressure screw complete 1 4 W26...

Page 23: ...ips page 24 Contact Tip 3 BE4335 Gas Diffuser Head 4 BE4323 Cap 5 BEQT2 45 BEQT2 30 Body Tube 2 45o Body Tube 2 30o 6 GUN002 Handle Kit includes both halves screws trigger 7 GUN003 Trigger 8 GUN005 Ri...

Page 24: ...un end compress the liner within the gun cable then cut it 20 mm past the end of the body tube 5 Refit head tip and nozzle Fig 13 Replacing the gun cable liner Wire diameter Short series 25mm 0 6 mm B...

Page 25: ...ded 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 pr...

Page 26: ...24 Operators Manual Quality Reliability Performance Notes...

Page 27: ...Weldmatic 270C Model No CP136 2 Iss A 08 12 25 Notes...

Page 28: ......

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