WIA CP144-1 Operator'S Manual Download | Manualshive

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From serial numbers C1442A*/C1452A*

MIG &

Multi-Process

Welders

OPERATORS MANUAL

CP144-1, CP145-1

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Summary of Contents for CP144-1

Page 1: ...WELDING COM AU From serial numbers C1442A C1452A MIG Multi Process Welders OPERATORS MANUAL CP144 1 CP145 1 ...

Page 2: ...of ITW Australia Pty Ltd ABN 63 004 235 063 1300 300 884 Email info welding com au welding com au WELDWELL NEW ZEALAND A Division of ITW New Zealand NZBN 9 429 039 833 129 GST NO 080177186 0800 9353 9355 Email info weldwell co nz weldwell co nz ...

Page 3: ...ding Sequence 14 7 Basic Welding Information 14 8 General Maintenance 20 9 External Trouble Shooting 21 10 Trouble Shooting Chart 22 11 Service Information 25 11 1 Circuit Diagram 26 12 Assembly Parts Lists 12 1 Power Source 27 12 2 Welding Torch 350 29 12 3 Welding Torch 500 30 13 Australian Warranty Information 32 14 New Zealand Warranty Information 34 ...

Page 4: ...e handles for 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 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 Auth...

Page 5: ...th 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 Vapours from chlorinated solvents can be decomposed by the heat of the arc or flame to form phosg...

Page 6: ...ling just below working level 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 whose body becomes a con...

Page 7: ...ely Flux cored consumable wires are available in both gas shielded and gasless 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 soft and flux cored wires for the GMAW process A compact motor with integral gear box is coupled to a two roll drive assembly f...

Page 8: ...ich an AC machine is required 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 Weldmatic 350 package contains CP144 2 Weldmatic 350 power source Argon gas regulator Gas Hose Welding torch 300 AMP fitted with Bernard 0 9 centre fire tip Work lead...

Page 9: ... 387Amp 35 5V 100 Duty TIG 350Amp 24V 60 Duty 500Amp 30V 60 Duty 271Amp 20 8V 100 Duty 387Amp 25 5V 100 Duty Spool Size ES6 5kg 15kg ES6 5kg 15kg Supply Plug 32A 32A Supply Cable 2 5mm2 3 Core E Heavy Duty PVC 4 0mm2 3 Core E Heavy Duty PVC Mains Circuit Breaker Rating 25A 32A Wire Speed Range 2 22 Metre min 2 22 Metre min Wire Size 0 9 1 2 1 6 mm Solid Wire 0 9 1 6 mm Cored Wire 0 9 1 2 1 6 mm So...

Page 10: ...utput and wait until machine has cooled down before welding output can commence 8 Digital Display Amps If Weld Mode is stick MMA Mode or TIG mode the display will indicate the selected welding Amps when adjusted with knob item 9 During welding in any mode the display will show actual welding Amps At the end of welding the display will hold the actual weld amps for 10 seconds 4 CONTROLS PANTONE 432...

Page 11: ...Sensing VS the knob will adjust the weld volts setting 11 3 MIG Arc Control When in MIG GMAW mode the harshness of the arc can be adjusted For example aluminium welding would require a different setting to steel welding The display 10 will indicate the MIG Arc Control value 0 10 12 Process Selection Button Pressing the button will cycle through each of the four welding processes as indicated by th...

Page 12: ...f 20 Amps The machine needs to be fitted with a plug capacity 20A or greater and a supply capacity 25A or greater The minimum recommended supply circuit breaker rating for a Weldmatic 350 is 25 Amps 500 The Weldmatic 500 is factory fitted with a 3 metre 3 core earth 4 0mm2 Heavy Duty PVC mains power supply cable The power cable is fitted with a 32 amp 3 phase plug Maximum rated output To achieve t...

Page 13: ...olarity Positive 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 into the output terminal on the power source and the wirefeeder weld cable into the output terminal Negative Wire Some self shielded flux cored gasless consumable wires are operated with...

Page 14: ... 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 When welding aluminium particular care must be taken with all aspects of shielding gas delivery and work piece preparation in order to avoid weld porosity 6 NORMAL WELDING SEQUENCE Weld Start Closing the welding gun switch initiates th...

Page 15: ...c will be long with metal transfer occurring as a series of large droplets The weld setting should be chosen to suit the application and the thickness of the metal to be welded It is important to check that the deposited weld provides sufficient strength to suit the application A good weld will have the characteristics illustrated in Figure 2 The weld has penetrated into the parent metal fusing th...

Page 16: ...s normally positioned as shown in Figure 4a below with the nozzle end pointing in the direction of travel For down hand fillet welding with gasless flux cored wires the gun is normally positioned as shown in Figure 4b with the nozzle end pointing away from the direction of travel referred to as dragging the weld Gasless flux cored wires should be operated with approximately 10 15mm of wire stick o...

Page 17: ...the work piece as if striking a match As the arc initiates lift the electrode slightly away aiming to establish an arc length of approximately 3 mm As the electrode end is consumed feed the electrode into the arc in order to maintain arc length As a general rule the arc should be held as short as possible while still giving stable burn off and good weld appearance An arc which is too long cause an...

Page 18: ...e tip For welding currents less than 20 amps the included angle of the point should be 30o for currents greater than 20 amps the recommended angle is 60o When set in the torch the tungsten should protrude 6 mm from the ceramic gas nozzle TIG Welding Operation Connect the Work Clamp to the work piece Turn on the power switch located on the rear panel Wait approximately 5 seconds as the unit goes th...

Page 19: ... output current for each 10 min period over 4 hours The Weldmatic 350 is rated at 350 Amps and the 500 at 500 Amps 60 duty cycle If the machine is operated at a reduced welding current a higher duty cycle is available The diagram below illustrates the appropriate duty cycle rating for the range of welding currents available and so allows the maximum welding time per 10 minute period to be determin...

Page 20: ... groove is not worn 2 Gun cable liner is clear of dust and swarf build up When replacement becomes necessary fit only the correct liner 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 replaced 3 Welding tip is free of obstructions such as spatter build up Ream out the tip bore with a suitable si...

Page 21: ...quipment should be returned to a WIA Service agent Phone 1300 300 884 for details of your nearest service agent If you are in New Zealand and the following checks do not identify the fault condition the equipment should be returned to the original place of purchase with proof of purchase or contact Weldwell on 06 8341 600 ...

Page 22: ...nergized with the fan running until the machine has cooled sufficiently The duty cycle should be observed and understood No welding current display on The connections may not be made securely Ensure all connections are in position and securely made Machine gives poor quality weld The polarity of the electrode return cables is incorrect The return lead contacts or workbench surface requires cleanin...

Page 23: ... x seconds Pre gas selection should be wound off below 0 seconds The arc starts normally but then stops x seconds Spot time is selected to x seconds Spot time selection should be wound off below 0 seconds The arc does not stop after trigger is released Latch mode is selected Latch mode should be switched off Motor continues to run once arc is extinguished Latch mode is selected Latch mode should b...

Page 24: ...lectrode return cables is incorrect Gas not turned on Gas flow too low Not enough Pregas time Polarity should be confirmed for the process wire type in use Review gas set up The weld has small black lumps or dots appearing in the pool Cleaning is poor Old or dirty filler rods can often be the cause of dirty TIG welding operations Switching filler rods to another type or batch may solve this issue ...

Page 25: ... and electronic components It is not intended that persons without suitable training and knowledge attempt to perform service tasks on the components of this welder If the welding machine requires service or repair take the machine to an authorised service agent Australian service agents can be located on the welding com au website Alternatively call customer service Australian 1300 300 884 New Ze...

Page 26: ...CN303 AC27V 1 2 3 CN901 A5 3 A5 1 A5 2 A5 6 A5 4 A5 5 A5 9 A5 7 A5 8 A3 A2 1 2 CN102 NTC RV15K NB Ew 1 2 3 4 CN202 1 2 CN207 1 2 3 4 CN2 1 2 CN3 1 2 3 4 CN1 1 2 3 4 5 6 7 8 CN304 1 2 CN902 1 2 7CN1 0 22 3 0V 3 3 0V 3 T1 NB EW GND Uo 15V 15V HE1 500A 4V A5 3 A5 1 A5 2 A5 6 A5 4 A5 5 A5 8 A5 7 A5 9 1 2 3 4 5 6 7 CN101 1 2 3 4 5 6 7 8CN1 1 2 8CN2 X1 X1 X3 9R3 200R 9R2 NC A5 14 A5 16 A5 15 A5 13 A5 12...

Page 27: ...27 Fig 8 Weldmatic 350 500 Assembly 12 ASSEMBLY WELDMATIC 350 500 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 21 ...

Page 28: ...14 WIN649 Front Panel Sticker 350 1 WIN652 Front Panel Sticker 500 1 15 M0103 Knob 2 16 M0105 Silicon Button 2 17 CX58 Weld Terminal Panel Mount Dinse Socket 2 18 E0101 14 PIN Socket Panel 1 19 PWA066 Output Filter 350 500 1 20 L0029 Current Sensor 500A 1 21 BBA048 BUSBAR 350 500 1 22 D0048 Output Diode 350 500 2 23 PWA072 PCB Assy Output Snubber 350 500 2 24 FAN026 Fan 350 1 FAN026 Fan 500 1 25 E...

Page 29: ...dy Tube 3 x 45 6 GUN002 Handle Kit includes both halves screws trigger 7 GUN003 Trigger Switch 8 GUN006 Rigid Casing 9 BE9165 Small O ring on gas nipple 10 BE4421 Large O ring on gas nipple 11 BEL3B 15 BE4154503N Steel Liner 0 9 1 2mm 300 amp Nylon Liner 0 9 1 2mm BEL3A 15 Steel Liner 0 9 1 2mm 400 amp GUN004 350A Gun Cable Assembly Fig 9 350 Amp Gun and Cable Assembly 1 2 3 4 5 6 7 8 10 9 11 ...

Page 30: ...ct Tip 3 BED 1 Gas Diffuser Large 4 BE10012 Insulator 5 BEQT3 45 Body Tube 3 x 45 6 GUN002 Handle Kit includes both halves screws trigger 7 GUN003 Trigger Switch 8 GUN006 Rigid Casing 9 BE9165 Small O ring on gas nipple 10 BE4421 Large O ring on gas nipple 11 BEL3B 15 BE4154503N Steel Liner 0 9 1 2mm 300 amp Nylon Liner 0 9 1 2mm BEL3A 15 Steel Liner 0 9 1 2mm 400 amp GUN008 400A Gun Cable Assembl...

Page 31: ...read nozzle onto gas diffuser tip and tighten firmly by hand Part Description BEN 3400C Nozzle copper 3 4 I D flush BEN 3414B Nozzle brass 1 4 I D recess BEN 3414C Nozzle copper 3 4 I D 1 4 recess BEN 3418B Nozzle brass 3 4 I D 1 8 recess BEN 5800C Nozzle copper 5 8 I D flush BEN 5814B Nozzle brass 5 8 I D 1 4 recess BEN 5814C Nozzle copper 5 8 I D 1 4 recess BEN 5818B Nozzle brass 5 8 I D 1 8 rec...

Page 32: ... your products may result in the loss of any user generated data Please ensure that you have made a copy of any data saved on your product Any handling and transportation costs and other expenses incurred in claiming under this warranty are not covered by this warranty and will not be borne by Welding Industries of Australia Welding Industries of Australia will return the replacement product if or...

Page 33: ...s fail to be of acceptable quality and the failure does not amount to a major failure The benefits given by this warranty are in addition to other rights and remedies which may be available to the customer under any law in relation to goods and services to which this warranty relates Warranty provided by Welding Industries of Australia ABN 63 004 235 063 A Division of ITW Australia Pty Ltd 5 Allan...

Page 34: ...as Australia with the below conditions In the event of defects listed in the Australian warranty conditions the customer should return the Product to the original place of purchase with proof of purchase or contact Weldwell on 0800 9353 9355 The warranty shall not apply to parts that fail due to normal wear For customers located in New Zealand you can contact Weldwell New Zealand Division of ITW N...

Page 35: ...35 NOTES ...

Page 36: ... A Division of ITW Australia Pty Ltd ABN 63 004 235 063 1300 300 884 Email info welding com au welding com au WELDWELL NEW ZEALAND A Division of ITW New Zealand NZBN 9 429 039 833 129 GST NO 080 177 186 0800 9353 9355 Email info weldwell co nz weldwell co nz ...

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