WIA Weldmatic 150 Operator'S Manual Download

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CP121-40 Rev B

Weldmatic 150

[internal wirefeeder]

Operators Manual

Weldmatic 150 MIG welder
Model No. CP121-0, Iss B

07/08

Summary of Contents for Weldmatic 150

Page 1: ... CP121 40 Rev B Weldmatic 150 internal wirefeeder Operators Manual Weldmatic 150 MIG welder Model No CP121 0 Iss B 07 08 ...

Page 2: ...Quality Reliability Performance Welding Industries of Australia An ITW Company ABN 18 004 547 111 Telephone 1300 300 884 Facsimile 1300 301 884 Email Info welding com au www welding com au ...

Page 3: ...Controls 7 5 Installation 8 6 Normal Welding Sequence 10 7 Basic Welding Information 10 8 General Maintenance 15 9 External Trouble Shooting 16 10 Service Information 18 10 1 PWA 006 Control Board 18 10 2 Circuit Diagram 19 11 Assembly and Parts Lists 11 1 Power Source 20 11 2 Wirefeed assembly 22 11 3 Gun and Cable Assembly 23 12 Warranty information 25 ...

Page 4: ... NOT use these 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 Ele...

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 necessary while wearing air supplied respirator Vapours from chlorinated solvents can be decomposed by the heat of the arc or flame to form phosgene a highly toxic gas and lung and eye irritating products The ...

Page 6: ... 2 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 2 Water filling just below working level may substitute for inerting Hollow castings or containers must be vented before welding or cutting They can exp...

Page 7: ...ing 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 wire such as AUSTMIG ES6 is used with a shielding gas of Carbon Dioxide or Argon mixed with Carbon Dioxide Alternatively Flux cored consumable wires are availabl...

Page 8: ...7 Amp 18 V 100 duty Welding Current 35 150 Amps Open Circuit Voltage 19 40 V Shipping weight 38 kg Mains Circuit Breaker Rating 16 Amps Supply plug 15 Amp Fitted Supply Cable 30 0 25 Three Core Heavy Duty PVC Cooling Fan cooled air drawn in through rear grille Insulation Class H 140 C Rise Spool Sizes 1 kg 5 kg Wirespeed Range 0 160 RPM 0 15 Metres per min Wire Size Range 0 6mm 0 9mm diameter soli...

Page 9: ...spool enclosure cover 2 Euro Gun Cable Connector 3 Coarse Voltage Control This switch provides Coarse adjustment of the output welding voltage over three ranges 4 Over Temprature Indicator Lights up if the unit over heats 5 Fine Voltage Control This switch provides Fine adjustment of the output welding voltage over three ranges Note Minimum welding voltage is obtained with Coarse A and Fine 1 sele...

Page 10: ...cted but the mains wiring capacity must be rated 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 supply terminals is gained by removing the power source side panels The replacement cable must be fit...

Page 11: ...ol adjuster which should be set to prevent over run of the wire spool at the end of a weld without unduly loading the wirefeed motor 1 kg Spools Remove the adjustor knob spring washer and 5 kg spool holder Leave the 5 kg spool holder in a safe place ie inside the welder Fit the 1kg wire spool directly onto the spool axle Fit the washer spring and adjustor knob and tighten the adjustor knob fully C...

Page 12: ...ere drafts cannot be avoided it may be necessary to increase this rate up to 20 litres min 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 When welding aluminium particular care must be taken with all aspects of shielding...

Page 13: ...Weldmatic 150 Model No CP121 Iss B 07 08 11 Weldmatic 150 Settings Chart Fig 4 Weld Setting Charts ...

Page 14: ...12 Operators Manual Quality Reliability Performance Quality Reliability Performance Weldmatic 150 Settings Chart cont Fig 4 Weld Setting Charts ...

Page 15: ...hes during welding 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 5 The weld has penetrated into the parent metal fusing the root of the joint where the two plates meet and the we...

Page 16: ...e 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 from the 150 and so allows the maximum welding time per 10 minute period to be determined The power source is protected by in built over temperature protection devices These will operate if the machine is ope...

Page 17: ...essary fit only the correct liner see page 24 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 size oxy tip cleaner Replace the welding tip as it becomes worn 4 Feed roll pressure is not ...

Page 18: ... resetting of the thermostat If problem persists after the cool down period call your WIA service agent 9 External Trouble Shooting Power source has low weld output 1 Check all electrical connections in the welding current circuit including weld cable work clamp and gun cable assembly Circuit breaker trips during welding 1 Check the rating of the mains supply circuit breaker The Weldmatic 150 shou...

Page 19: ...e welding arc and result in a poor weld Porosity in weld caused by lack of shielding gas 1 Check that the correct gas flow rate has been set refer page 10 2 Check for leaks in the gas hose Replace if leaking 3 Check for leaks in gun cable assembly eg fractured gas hose broken or missing O rings Replace as required 4 Check the gun nozzle is free from spatter and is firmly attached to the welding gu...

Page 20: ...are present on the electrical components enclosed 10 1 PWA006 Control Board The following information is intended for use by qualified service personnel When the unit is energised LETHAL VOLTAGES are present on the electrical 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 10 Service...

Page 21: ...Weldmatic 150 Model No CP121 Iss B 07 08 19 10 2 Circuit Diagram Fig 10 Weldmatic 150 Circuit Diagram ...

Page 22: ...Reliability Performance Quality Reliability Performance 13 24 23 26 25 22 19 10 15 17 11 8 16 27 21 20 12 Fig 11 Weldmatic 150 Power Source Assembly 9 1 6 14 5 4 7 28 18 2 3 11 1 Assembly and Parts List Weldmatic 150 Power Source ...

Page 23: ...Large 2 14 E0042 On Off Switch 1 15 AM321 1 5 kg Spool Holder Assembly 1 16 AM133 3 Rclip included in AM321 1 17 WF023 Wirefeed Assembly 1 18 SUB021 Snubber 2 19 PWA006N Wirefeed Control PCB Assembly 1 20 CP104 0 2 Rectifier 1 CP3 9 8 Thermostat included in rectifier 1 21 62513 Blue Oxy Single Gas Hose 5 metre 1 22 E0041 Gas valve 24 vdc 1 23 E0044 Relay 1 24 FAN006 Fan Assembly 1 25 CP101 0 17 Fa...

Page 24: ...Item Part Description 2 W26 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 Qty 1 W27 0 9 Retaining Screw 1 Feed Rolls 1 2 11 2 Assembly and Parts List Wirefeeder ...

Page 25: ...rass Tapered 2 see Tips page 24 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 BE43115 BE43115X Steel Liner 0 9 1 2mm Nylon Liner 0 9 1 2mm 1 2 3 4 5 6 7 11 3 Assembly and Parts List Gun and Cable Assembly ...

Page 26: ... 3 Withdraw 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 one contact tip length past the end of the body tube 5 Refit head tip and nozzle Fig 6 Replacing the gun cable liner Wire diameter Short series 25mm 0 6mm BE7497 0 8mm BE7488 0 9mm BE7489 1 0mm BE7496 1 2mm BE7490 Tips 20mm...

Page 27: ...hall honour warranty claims on warranted equipment in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or 18 months after the equipment date of manufacture whichever is the earlier Parts and workmanship on Weldarc and Weldmatic equipment are covered for a period of 3 years exce...

Page 28: ...ion costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL WIA BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTEE OR REPRESENT...

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