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Weldmatic 180 | Operator Manual | Model No CP141-1

Problem

Likely Reason

Outcome

MMA/STICK Models
In MMAW (Stick), the arc is

difficult to strike.

The technique required

for VRD enabled welding

machines is not the same as

earlier stick welding units

The technique to strike

should be reviewed, not as

a ‘strike’ but more as ‘touch,

twist, lift’ motion.

If VRD is not a site

requirement, VRD can be

disabled by service agent .

GMAW/MIG Models
The machine feeds slowly

and then speeds up after

3-5 seconds.

Creep mode is selected, or

machine has a permanent

creep mode function.

Some models have a creep

mode function that cannot be

adjusted. Other models have

a push button selection for

creep mode on/off.

Nothing happens for first

x seconds after trigger is

pulled.

Pre gas is selected to

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 be

switched off.

Weld is contaminated with

small bubbles (presence

of porosity).

Air in the gas hose. The

torch gas hose has not been

purged sufficiently.

The gas hose is not securely

connected at the machine or

at the regulator.

Air is being drawn into arc

through torch nozzle

Purge the system and confirm

sufficient gas flow through

the regulator.

Ensure the gas connections

from regulator through to the

torch connection are suffi-

ciently tightened.

Remove nozzle, check O ring

on torch head, check condi-

tion of insulator in nozzle

Содержание CP141-1

Страница 1: ...WELDING COM AU From serial numbers C1412A MIG Multi Process Welder OPERATORS MANUAL CP141 1 ...

Страница 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 ...

Страница 3: ...rmal Welding Sequence 16 7 Basic Welding Information 16 8 General Maintenance 25 9 External Trouble Shooting 26 10 Trouble Shooting Chart 27 11 Service Information 30 11 1 Circuit Diagram 31 12 Assembly Parts Lists 12 1 Power Source 32 12 2 Wirefeeder 34 12 3 Gun Cable 36 13 Australian Warranty Information 37 14 New Zealand Warranty Information 39 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...inium for which 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 180 package contains Weldmatic 180 Power Source Euro MIG Gun and Cable Assembly Gas Hose Twist lock Electrode Holder Work Clamp 3m Drive Roll 0 ...

Страница 9: ...aximum Supply Current Imax 31A Maximum Effective Supply Current Ieff 10A Output No Load Voltage 70V VRD Safe 13 5V Rated Output 40 C 10 Min Cycle Time MIG Gmaw 10 Duty 180 Amps 23 V 60 Duty 73 Amps 17 6 V 100 Duty 57 Amps 16 9 V Stick MMA 10 Duty 150 Amps 26 V 60 Duty 61 Amps 22 4 V 100 Duty 47 Amps 21 9 V TIG 10 Duty 180 Amps 17 2 V 60 Duty 73 Amps 12 9 V 100 Duty 57 Amps 12 3 V ...

Страница 10: ...avy Duty PVC Mains Circuit Breaker Rating 20 A Wire Speed Range 2 11 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 IP23S Weight 11kg Shipping Weight 20kg Dimension L W H 490mm x 220mm x 380mm Shipping Dimension L x W x H 690mm x 320mm x 440mm 3 SPECIFICATIONS CONT ...

Страница 11: ... Display 12 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 prevent weld output until the machine has cooled down or mains voltage returns to normal Welding output can then recommence 10 VRD Safe Indicator This light is on when the machine is in Stick M...

Страница 12: ...ntarily by increasing the weld current and weld voltage MIG Mode Adjusts weld volts Purge Press to open the gas solenoid valve without energising the welding power source 14 Digital Display Volts During welding actual welding Volts will be displayed and then held for 30 seconds after the end of the weld Stick Mode The amount of Arc Force 0 10 will be displayed MIG Mode Weld Volts will be displayed...

Страница 13: ...ble 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 Ambient temperature Number of previous circuit breaker operations Actual weld conditions resulting in higher weld currents Repeated starts...

Страница 14: ... 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 Polarity Selection Cable from the power source into 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 dat...

Страница 15: ...r 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 appropriate size is sta...

Страница 16: ...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 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 w...

Страница 17: ...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 to suit the application...

Страница 18: ...eel Gasless Wire Wire Type Gasless Flux Cored Negative Polarity Knurled Drive Roll Arc Control 1 Material Thickness Wire Size 0 8mm 0 9mm Wirefeed Volts Stick Out Wirefeed Volts Stick Out 5mm 8 0 17 5 8mm 6 5 17 0 8mm 3mm 4 0 15 5 8mm 4 6 15 5 8mm 1 6mm 3 5 14 0 15mm 2 5 13 0 12mm 1 2mm 3 0 13 0 15mm 2 5 12 5 15mm 0 8mm 2 5 12 0 15mm Stick Out ...

Страница 19: ...ire Fig 6b Weld 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 Wirefeed Volts Wirefeed Volts 5mm 11 0 22 0 3mm 11 0 21 0 8 4 19 8 1 6mm 6 7 18 0 4 0 16 7 1 2mm 5 2 17 0 3 6 16 2 0 8mm 4 2 15 8 2 8 15 0 ...

Страница 20: ...Suggested Settings for Fillet Weld Mild Steel Solid Wire Wire Type Carbon Steel ES6 Positive Polarity Gas Ar 5 CO2 Arc Control 5 Material Thickness Wire Size 0 6mm 0 8mm Wirefeed Volts Wirefeed Volts 5mm 10 8 21 5 3mm 10 0 20 0 6 6 19 5 1 6mm 7 6 18 5 4 5 17 3 1 2mm 5 2 17 0 3 4 16 5 0 8mm 4 0 16 5 3 0 16 2 ...

Страница 21: ... 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 electrode Most common elect...

Страница 22: ...d of the 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 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...

Страница 23: ...lding 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 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 pi...

Страница 24: ...ustrates 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 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 ...

Страница 25: ...r is clear of dust and swarf build up When replacement becomes necessary fit only the correct liner see page 33 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 Repla...

Страница 26: ...ent 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 9 EXTERNAL TROUBLE SHOOTING ...

Страница 27: ...ed 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 Polarity should be confirmed for the process wire type...

Страница 28: ...Pre gas is selected to 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 select...

Страница 29: ...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 is contaminated with small bubbles ...

Страница 30: ...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 If the welding machine requires service or repair take the machine to an authorized service agent Australian service agents can be located on the welding com au website Alternatively call customer service Austr...

Страница 31: ...E12 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 SGND 1 2 CN301 T2 ZX7 40...

Страница 32: ...Weldmatic 180 Operator Manual Model No CP141 1 32 12 1 ASSEMBLY AND PARTS LIST WELDMATIC 180 POWER SOURCE 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 12 ...

Страница 33: ...ker 1 10 M0104 Knob 3 11 M0105 Button 2 12 AM364 Polarity conversion cable 1 13 SA140 0 2 Dinse Socket 2 14 WF056 Euro Adaptor 1 15 WF041 Wire Drive Assembly 1 16 PWA074 Main Control PCB 1 17 FAN011 Fan 1 18 M0130 Back Panel Plastic 1 19 E0078 Main Switch 1 20 E0041 Gas Valve 1 21 M0082 Wire holder Assembly 1 22 M0062 Latch 1 23 REG003 Argon Regulator 1 24 CLA200 Work Clamp 1 25 62513 Blue Oxy Sin...

Страница 34: ...on 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 12 2 ASSEMBLY AND PARTS LIST WIREFEEDER 180 ...

Страница 35: ...irefeeder 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 tube 5 Refit head tip and nozzle Fig 16 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 ...

Страница 36: ...2 2 BE7488 Contact Tip 0 030 0 8mm BE7489 Contact Tip 0 035 0 9mm 3 BE4335 Gas Diffuse 4 BE7126 O Ring 12 5x1 8 5 BE4323 Rubber Cap 6 GUN016 Swan Neck 45O 7 GUN017 Trigger PMS116C 8 GUN018 Front Cable Support 9 GUN019 Back Cable Support Spring 10 GUN020 Back Handle 11 GUN021 Gun Plug Nut 12 GUN022 Bernard Euro Gun Plug 13 BE4907 O Ring 4x1 14 BEL3B 15 Liner 0 030 0 040x10ft 15 BE4421 O Ring 5 28x1...

Страница 37: ...ir 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 the replacement product ...

Страница 38: ...or replaced if the goods 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 Au...

Страница 39: ...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 Zealand 0800 9353 9355 Email ...

Страница 40: ... 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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