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WIA CP137-2, Operator'S Manual

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WIA CP137-2 Operator'S Manual Download Page 18

16 

Operators Manual

Trusted by the best

Weldmatic Settings Chart

Fig 6a

 Weld Settings Chart

Suggested Settings for Fillet Weld Mild Steel – Gasless Wire

Wire type

•  Gasless / Flux Cored
•  Negative Polarity
•  Knurled Drive Roll
•  Arc Control 1

Material 

Thickness

Wire Size

0.8mm

0.9mm

1.2mm

Wirefeed

Volts

Wirefeed

Volts

Wirefeed

Volts

8mm

5.5

25.0

5mm

5.9

20.0

7.4

24.0

5.0

25.0

3mm

5.6

18.5

5.6

21.0

5.6

18.4

1.6mm

4.0

14.0

2.6

14.0

2.0

14.5

1.2mm

3.0

13.5

2.4

13.0

0.8mm

2.0

13.0

Summary of Contents for CP137-2

Page 1: ...CP137 40 Rev F Weldmatic 200i Weldmatic 250i Internal Wirefeeder Weldmatic 200i MIG Arc TIG welder Model No CP137 2 Iss B Operators Manual 02 19 Weldmatic 250i MIG Arc TIG welder Model No CP138 2 Iss...

Page 2: ...lia An ITW Company Telephone 1300 300 884 Facsimile 1300 301 884 Email Info welding com au www welding com au Weldwell New Zealand A Division of ITW New Zealand Telephone 06 8341 600 Email info weldwe...

Page 3: ...ls 9 5 Installation 11 6 Normal Welding Sequence 14 7 Basic Welding Information 14 8 General Maintenance 23 9 External Trouble Shooting 24 10 Service Information 26 10 1 Circuit Diagram 27 11 Assembly...

Page 4: ...r suspending or mounting the power source in any other manner Safe Practices When Using Welding Equipment These notes are provided in the interests of improving operator safety They should be consider...

Page 5: ...ated 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 nece...

Page 6: ...tible 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...

Page 7: ...asless self shielding types Stainless steel and Aluminium can be welded with GMAW using the correct consumable wire and shielding gas The Weldmatic wirefeeder has been designed to feed a range of hard...

Page 8: ...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 Weldmatic 200i 250i package...

Page 9: ...Maximum Supply Current Imax 36A 45A 45A Maximum Effective Supply Current Ieff 14A 20 2A 14 2A Output No Load Voltage 71V 71V 71V VRD Safe 13 5V 13V 13V Rated Output 40 C 10 Min Cycle Time MIG GMAW 10...

Page 10: ...c 0 20 Meter sec 0 20 Meter sec Wire Size Solid 0 6mm 0 9mm 0 8 1 2mm 0 8 1 2mm Wire Size Cored 0 8 1 2mm 0 8 1 2mm 0 8 1 2mm Cooling Type Air cooling Air cooling Air cooling Efficiency 85 85 85 Power...

Page 11: ...is indicating the selected Amps Stick or TIG Mode 8 Power On Indicator 9 Over Temperature Indicator This light is on if the machine overheats or mains voltage is too high or low the machine will prev...

Page 12: ...Arc Force 0 10 will be displayed MIG Mode Weld Volts will be displayed when adjusted with Voltage Adjustment Control 13 15 Arc Control When in MIG GMAW mode the harshness of the arc can be adjusted Fo...

Page 13: ...machine needs to be limited so as not to exceed primary current Ieff 15A Check the output amps on the digital display at end of weld If output is higher than 200A the voltage and wire speed should be...

Page 14: ...Wire MIG welding GMAW with solid consumable wires and gas shielding is carried out with the work piece Negative and the welding wire Positive To setup for this condition connect the WORK lead plug int...

Page 15: ...ol rotation tension Adjust spool holder hex head screw to prevent over run of the wire spool at the end of a weld without unduly loading the wirefeed motor Feeding the Consumable Wire At the wirefeed...

Page 16: ...such as from 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 6 Norm...

Page 17: ...crease 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 metal transfer occurring as a ser...

Page 18: ...el Gasless Wire Wire type Gasless Flux Cored Negative Polarity Knurled Drive Roll Arc Control 1 Material Thickness Wire Size 0 8mm 0 9mm 1 2mm Wirefeed Volts Wirefeed Volts Wirefeed Volts 8mm 5 5 25 0...

Page 19: ...pe Carbon Steel ES6 Positive Polarity Gas Ar 5 CO2 2 O2 Arc Control 5 Material Thickness Wire Size 0 6mm 0 8mm 0 9mm Wirefeed Volts Wirefeed Volts Wirefeed Volts 8mm 10 5 24 5 5mm 11 5 24 0 9 0 22 5 3...

Page 20: ...eel Solid Wire Wire type Carbon Steel ES6 Positive Polarity Gas Ar 18 CO2 Arc Control 5 Material Thickness Wire Size 0 6mm 0 8mm 0 9mm Wirefeed Volts Wirefeed Volts Wirefeed Volts 8mm 10 0 24 0 5mm 10...

Page 21: ...x cored wires should be operated with approximately 10 15mm of wire stick out from the welding contact tip as shown in Figure 7c 10 Fig 7a Gas Shielded Solid Wires Fig 7b Gasless Flux Cored Wires Fig...

Page 22: ...he electrode slowly along the weld path aiming to maintain a pool of moulten weld metal behind the arc Decreasing this rate of travel will result in a wider weld deposit and similarly increasing it wi...

Page 23: ...TIG Operation When the Welding mode is set to LIFT TIG then the arc start can be achieved with the following procedure 1 Turn on the torch gas valve Gas will start to flow on torch 2 Touch the electro...

Page 24: ...iagram below illustrates the appropriate duty cycle rating for the range of welding currents available from the 200i and 250i and so allows the maximum welding time per 10 minute period to be determin...

Page 25: ...ry fit only the correct liner see page 35 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 replac...

Page 26: ...appliance ON indicator light is illuminated 1 The gun switch circuit may be incomplete Check the gun switch for continuity with an ohm meter when the switch is pressed Replace if faulty Check the 2 p...

Page 27: ...hat the 1 Correct polarity has been selected for work and weld cables refer page 10 2 Shielding gas is correct for the consumable wire in use refer page 14 3 Welding circuit is making good electrical...

Page 28: ...energised LETHAL VOLTAGES are present on the electrical components enclosed The following information is intended for use by qualified service personnel When the unit is energised LETHAL VOLTAGES are...

Page 29: ...2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 VCC SGND G C E G C E G C E G C E G1 E1 G2 E2 NTC 1 5K AC 1 AC 2 3 4 2 1 3 4 NTC 2 5K AC 1 AC 2 3 4 1 2 3 FAN FAN1 24V PWA021 G1 E1 G2 E2 QF QF1 DC24V 2 2 1 2 3 4 5 6 7...

Page 30: ...1 1 Assembly and Parts List Weldmatic 200i Power Source 28 Operators Manual Trusted by the best Fig 13 Weldmatic 200i Power Source Assembly 11 1 Assembly and Parts List Weldmatic 200i Power Source 2 1...

Page 31: ...WA020 Wirefeeder Control PCB 1 9 M0063 Front Panel 1 10 SA140 0 2 Dinse Socket 2 11 PWA021 Front Panel Control PCB 1 12 WIN540 Front Panel Sticker 1 13 M0058 Knob 3 14 WF055 Wire Drive Assembly 1 15 W...

Page 32: ...E AR C CO NT RO L GAS LES S 0 8 0 9 1 2 mm 30 Operators Manual Trusted by the best Fig 14 Weldmatic 250i Power Source Assembly 11 1 Assembly and Parts List Weldmatic 250i Power Source 1 12 14 15 17 18...

Page 33: ...CX58 Dinse Socket 2 9 PWA041 Front Panel Control PCB 1 10 WF067 Euro Adaptor 1 11 WF042 Wire Drive Assembly 1 WF068 Guide Tube suit WF067 1 12 PAN163 Side Door 1 13 M0041 Hinge 2 14 M0062 Latch 3 15...

Page 34: ...26 0 8 0 6 0 8mm Solid Wire 2 W26 8 8 0 8 0 9mm Solid Wire 2 W26 7 8 1 0 1 2mm Flux Cored Wire knurled 2 W26 9 8 0 9 1 2mm Flux Cored Wire knurled 2 W26 3 8 1 0 1 2mm Aluminium Item Part Description Q...

Page 35: ...id Wire fitted 2 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 c...

Page 36: ...Tips page 28 Contact Tip 3 BE4335 Gas Diffuser Head 4 BE4323 Cap 5 BEQT2 45 BEQT2 30 Body Tube 2 45o supplied Body Tube 2 30o 6 GUN002 Handle Kit includes both halves screws trigger 7 GUN003 Trigger...

Page 37: ...draw 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 20mm past the end of the body...

Page 38: ...al 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 pu...

Page 39: ...onditions the customer should return the Product to the original place of purchase with proof of purchase or contact Weldwell on 06 8341600 The warranty shall not apply to parts that fail due to norma...

Page 40: ...Lens and helmet comply with Australian Standards AS NZS 1338 1 Auto Darkening and AS NZS 1337 1 B High Impact Lightweight at only 510g Improved digital controls Battery powered with solar assist Ligh...

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