WIA CP150-1 Operator'S Manual Download

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WELDING.COM.AU

From serial numbers C1502A*

MIG & Multi-Process Welder

OPERATORS MANUAL | CP150-1

Summary of Contents for CP150-1

Page 1: ...WELDING COM AU From serial numbers C1502A MIG Multi Process Welder OPERATORS MANUAL CP150 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: ...rmal Welding Sequence 17 7 Basic Welding Information 17 8 General Maintenance 26 9 External Trouble Shooting 27 10 Trouble Shooting Chart 28 11 Service Information 31 11 1 Circuit Diagram 32 12 Assembly Parts Lists 12 1 Power Source 33 12 2 Wirefeeder 35 12 3 Gun Cable 36 13 Australian Warranty Information 38 14 New Zealand Warranty Information 40 ...

Page 4: ...les 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 Authoritie...

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: ...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 explode Never weld o...

Page 7: ...atively 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 assemb...

Page 8: ...h good arc stability and out of position welding characteristics This electrode is ideal for medium carbon steels or steels of unknown analysis Unicord 312 Classification ES312 16 A high tensile 50tsi chromium nickel electrode specially formulated for joining all alloy steels and irons and for tool and die maintenance Equipment options Part TIG Torch 135A complete with valve 4m cable with twist lo...

Page 9: ...Sample wire Austfil T 11 0 9mm Gasless Tips 0 6 0 8 0 9 1 2mm Argon Flow Gauge Regulator REG003 This Operating Manual CP150 40 IMPORTANT NOTICE Warranty may be voided if equipment is powered from an unsuitable engine driven generator Generators used to power this equipment must have the recommended minimum capacity and incorporate output voltage regulation Due to variation between generators by di...

Page 10: ...ator Single Phase Capacity 13KVA Rated Maximum Supply Current Imax 36A Maximum Effective Supply Current Ieff 14A Output No Load Voltage 71V VRD Safe 13 5V Rated Output 40 C 10 Min Cycle Time MIG Gmaw 10 Duty 15 Duty 200Amps 24V 20 Duty 100 Duty 77Amps 17 9V Stick MMA 10 Duty 15 Duty 170Amps 26 8V 20 Duty 100 Duty 66Amps 22 6V TIG 10 Duty 15 Duty 200Amps 18V 20 Duty 100 Duty 77Amps 13 1V ...

Page 11: ...ng 25A Wire Speed Range 2 14 5 Metre min Wire Size Solid 0 6mm 0 9mm Wire Size Cored 0 8 1 2mm Cooling Type Air cooling Efficiency 85 Power Factor 0 62 Insulation H 140 C Rise Protection IP21S Weight 15kg Shipping Weight 25kg Dimension L W H 525 x 260 x 410mm Shipping Dimension L x W x H 705 x 320 x 495mm 3 SPECIFICATIONS CONT ...

Page 12: ... 5 3 1 此图形光面黑色透明稿制作 1图样颜色要求按提供色号为准线裁切刷以电子稿为准寸公差按 GB T1804 m执行 PANTONE 426 C WHITE PANTONE 116 C PANTONE 432 C C WIN699A 1 Control Panel 2 m min Indicator When this light is on the Digital Display 8 is indicating the selected wire speed in metres per minute MIG Mode 3 Amps Indicator When this light is on the Digital Display 8 is indicating the selected Amps Stick or TIG Mode 4 Power On Indicat...

Page 13: ... Force 0 10 will be displayed MIG Mode Weld Volts will be displayed when adjusted with Voltage Adjustment Control 9 11 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 12 Mode Selection Button Press this button to step between modes A mode is selected when the light is on There are three weld...

Page 14: ...ecommended mains circuit breaker rating for a Weldmatic 200 is 20 Amps Supply Cable If it becomes necessary to replace the mains flexible supply cable use only cable with correct current rating The replacement cable must be fitted and retained in the same manner as the original Successful Operation Successful operation will depend on a number of factors Variation in circuit breaker thresholds Ambi...

Page 15: ...to the output terminal as in Figure 2 Negative Wire Some self shielded flux cored gasless consumable wires are operated with the work piece Positive and the consumable wire Negative Refer to the manufacturers data for the particular consumable wire to be used To setup for this condition connect the WORK lead plug into the output terminal on the power source and the Polarity Selection Cable from th...

Page 16: ...oading the wirefeed motor Feeding the Consumable Wire At the wirefeed assembly release the compression screw by swivelling it outwards This allows the top roller arm to spring 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 roll groove is correct for the wire in use The...

Page 17: ... 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 NORMAL WELDING SEQUENCE Weld Start The wire feed has an in built creep function When the trigger is pressed the wire will slowly feed out until the wire touches the work piece then the arc will start wire speed will change to set speed...

Page 18: ...ease 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 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 ...

Page 19: ... Drive Roll Arc Control 1 Material Thickness Wire Size 0 8mm 0 9mm 1 2mm Wirefeed Volts Stick Out Wirefeed Volts Stick Out Wirefeed Volts Stick Out 8mm 5 0 19 0 15mm 5mm 6 0 17 0 10mm 7 0 18 0 12mm 4 5 17 0 15mm 3mm 5 5 16 0 10mm 5 6 17 0 12mm 2 5 15 5 15mm 1 6mm 4 5 14 0 10mm 2 6 14 0 12mm 2 0 14 5 15mm 1 2mm 2 8 13 0 10mm 2 4 13 0 12mm 0 8mm 2 0 13 0 10mm Stick Out ...

Page 20: ...eld Settings Chart Wire Type 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 22 5 9 5 22 5 3mm 13 0 22 0 7 0 20 0 5 5 19 5 1 6mm 7 5 18 5 4 0 17 5 3 5 16 5 1 2mm 5 0 17 0 3 5 16 5 2 8 15 5 0 8mm 4 0 16 0 3 0 16 0 ...

Page 21: ...re 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 23 5 5mm 10 5 24 0 9 0 22 0 3mm 9 5 21 0 6 5 20 0 5 5 19 5 1 6mm 7 0 18 5 4 5 17 5 3 7 17 0 1 2mm 5 0 17 0 3 5 16 5 3 0 16 0 0 8mm 4 0 16 5 2 8 16 0 ...

Page 22: ...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 7c Wire Stickout for Gasless Welding Stick Welding MMAW Connection for Stick Welding It is important to select the electrode polarity in accordance with the manufacturers recommendations for that elec...

Page 23: ...ly 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 will narrow the weld deposit Always fill the crater which tends to form at the end of a weld deposit by pausing momentarily before withdrawing the electrode to break the arc Unfilled craters are a point of weakness and ...

Page 24: ...ng procedure 1 Turn on the torch gas valve Gas will start to flow on torch 2 Touch the electrode lightly against the work piece A small current will pass through the electrode 3 While still holding the electrode against the work piece roll the hand piece over until the cup rests on the work piece 4 Use the cup as a pivot point to roll the hand piece over allowing the electrode to lift of the work ...

Page 25: ...cycle rating for the range of welding currents available from the 200 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 operated in excess of its current and duty cycle rating If this occurs the fan will continue to run but the machine will not deliver weldi...

Page 26: ...ot worn 2 Gun cable liner is clear of dust and swarf build up When replacement becomes necessary 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 replaced 3 Welding tip is free of obstructions such as spatter build up Ream out the tip bore with a suitable si...

Page 27: ...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 9 EXTERNAL TROUBLE SHOOTING ...

Page 28: ...d 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 cleaning Polar...

Page 29: ... 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 30: ...de 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 Weld i...

Page 31: ...al 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 ...

Page 32: ...V IFB GND PMH200E 14 12AE12 MAIN01 PMH200 F27MB PMH250 PMH250 F27ZKB G1 G2 G3 E1 QF QF1 1 2 3 4 5 6 7 8 CN304 SW1 M M1 B1 1 2 1CN1 1 2 CN302 1 2 3 4 CN102 MOTOR MOTOR 1 2 3 4 CN303 1 2 CN201 1 2 CN301 CN305 20PIN CN201 20PIN FAN FAN 24V IFB ERR PWM REF GND 15V 15V 1 2 3 4 5 6 7 8 1CN4 2 1 3 4 RL1 PTC1 C70 C3 C4 C5 C2 C8 C1 C9 E1 C7 G1 R1 R4 G2 C6 C11 G4 G3 G5 G6 G4 G5 G6 E2 E2 D1 24V 1 2 1CN5 VCC ...

Page 33: ...33 Fig 12 Weldmatic 200 Assembly and Parts List 12 1 ASSEMBLY AND PARTS LIST WELDMATIC 200 POWER SOURCE 17 16 2 4 5 3 6 7 1 10 9 11 12 13 15 14 18 8 ...

Page 34: ...A113 Wirefeeder Control PCB 1 9 M0138 Front Panel 1 10 SA140 0 2 Dinse Socket 2 11 PWA114 Front Panel Control PCB 1 12 WIN540 Front Panel Sticker 1 13 M0104 Knob 3 14 WF055 Wire Drive Assembly 1 15 WF056 Euro Adaptor 1 16 PAN199 Side Door 1 17 M0049 Latch 1 18 M0082 Wire Spool Holder Assembly 1 19 REG003 Argon Regulator 1 20 CLA002 Work Clamp 1 21 62513 Blue Oxy Single Gas Hose 5 mm 1 Not shown CP...

Page 35: ...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 12 2 ASSEMBLY AND PARTS LIST WIREFEEDER 200 ...

Page 36: ...er Head 4 BE4323 Cap 5 BEQT2 45 BEQT2 30 Body Tube 2 45 supplied Body Tube 2 30 6 GUN002 Handle Kit includes both halves screws trigger 7 GUN003 Trigger 8 GUN005 Rigid Casing 9 BEL3B 15 BE43115X Steel Liner 0 9 1 2mm Nylon Liner 0 9 1 2mm Fig 14 GUN001 200 amp Gun and Cable Assembly 12 3 ASSEMBLY AND PARTS LIST GUN AND CABLE ASSEMBLY 1 2 3 4 5 6 7 8 9 ...

Page 37: ... 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 tube 5 Refit head tip and nozzle Wire diameter Short series 25mm 0 6mm BE7497 0 8mm BE7488 0 9mm BE7489 1 0mm BE7496 1 2mm BE7490 Tips Cut Here Compress Liner Fig 15 Replacing the gun cable liner 20mm ...

Page 38: ... Warranty Term The repair of 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 t...

Page 39: ...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 40: ...nt 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 New Zealand 64 Thames Street Napier 4110 New Zeala...

Page 41: ...41 NOTES ...

Page 42: ...Weldmatic 200 Operator Manual Model No CP150 1 42 NOTES ...

Page 43: ...43 NOTES ...

Page 44: ... 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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