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Weldmatic 350i + Weldmatic 500i

Model No CP139, CP140   

3

Burn Protection

The welding arc is intense and visibly bright. 
Its radiation can damage eyes, penetrate 
light-weight clothing, reflect from light-
coloured surfaces, and burn the skin and 
eyes. Burns resulting from gas-shielded arcs 
resemble acute sunburn, but can be more 
severe and painful.

Wear protective clothing – leather or heat 
resistant gloves, hat, and safety-toed boots. 
Button shirt collar and pocket flaps, and 
wear cuffless trousers to avoid entry of 
sparks and slag.

Avoid oily or greasy clothing. A spark may 
ignite them. Hot metal such as electrode 
stubs and work pieces should never be 
handled without gloves.

Ear plugs should be worn when welding in 
overhead positions or in a confined space. 
A hard hat should be worn when others are 
working overhead.

Flammable hair preparations should not be 
used by persons intending to weld or cut.

Toxic Fumes

Adequate ventilation with air is essential. 
Severe discomfort, illness or death can 
result from fumes, vapours, heat, or oxygen 
depletion that welding or cutting may 
produce. 

NEVER

 ventilate with oxygen.

Lead, cadmium, zinc, mercury, and beryllium 
bearing and similar materials when welded 
or cut may produce harmful concentrations 
of toxic fumes. Adequate local exhaust 
ventilation must be used, or each person in 
the area as well as the operator must wear 
an air-supplied respirator. For beryllium, both 
must be used.

Metals coated with 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 phosgene, a highly toxic 
gas, and lung and eye irritating products. 
The ultra-violet (radiant) energy of the arc 
can also decompose trichlorethylene and 
perchlorethylene vapours to form phosgene. 
Do not weld or cut where solvent vapours 
can be drawn into the welding or cutting 
atmosphere or where the radiant energy 
can penetrate to atmospheres containing 
even minute amounts of trichlorethylene or 
percholorethylene.

Fire and Explosion Prevention

Be aware that flying sparks or falling slag can 
pass through cracks, along pipes, through 
windows or doors, and through wall or floor 
openings, out of sight of the operator. Sparks 
and slag can travel up to 10 metres from the arc.

Keep equipment clean and operable, free of 
oil, grease, and (in electrical parts) of metallic 
particles that can cause short circuits.

If combustibles are present in the work 
area, do NOT weld or cut. Move the work if 
practicable, to an area free of combustibles. 
Avoid paint spray rooms, dip tanks, storage 
areas, ventilators. If the work can not be 
moved, move combustibles at least 10 metres 
away out of reach of sparks and heat; or 
protect against ignition with suitable and 
snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite 
sides should not be welded on or cut. Walls, 
ceilings, and floor near work should be 
protected by heat-resistant covers or shields.

Содержание weldmatic 350i CP139-2

Страница 1: ... CP139 40 Rev A Weldmatic 350i Weldmatic 500i Weldmatic 350i Multiprocess welder Model No CP139 2 Iss A Operators Manual 01 16 Weldmatic 500i Multiprocess welder Model No CP140 2 Iss A ...

Страница 2: ...Welding Industries of Australia A division of ITW Australia Pty Ltd 1300 300 884 Info welding com au welding com au ...

Страница 3: ...es 2 1 Introduction 5 2 Receiving 6 3 Specifications 7 4 Controls 8 5 Installation 10 6 Normal Welding Sequence 12 7 Basic Welding Information 12 8 General Maintenance 18 9 External Trouble Shooting 19 10 Service Information 20 10 1 Circuit Diagram 21 11 Assembly and Parts Lists 22 12 Warranty information 24 ...

Страница 4: ...or 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 Authorities Dep...

Страница 5: ...eated 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 product...

Страница 6: ... 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 conductor Ensure that the equipment is correctly connected and earthed If unsure have the equipmen...

Страница 7: ...ble 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 forming the basic component of the wirefeed...

Страница 8: ...ing Aluminium 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 350i package contains CP139 2 Weldmatic 350i power source Argon gas regulator Gas hose Welding torch 350 AMP fitted with Bernard 0 9 cen...

Страница 9: ...0 Duty 271Amp 30 8V 100 Duty 380Amp 35 2V 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 0 15 Metre sec 0 20 Metre sec Wire Size 0 8 0 9 1 2 mm Solid Wire 0 8 1 2 mm ...

Страница 10: ...as Connection 6 Power On Indicator 7 VRD Safe Light VRD safe light is on when the machine is in stick mode and the open circuit output voltage is reduced to a safe level 8 Over Temperature Warning If an over temperature condition is reached the machine will prevent weld output and wait until machine has cooled down before welding output can commence 9 Digital Display Amps If Weld Mode is stick MMA...

Страница 11: ... is controlled from the wire feeder and the set value is displayed on 11 The output voltage is only active when signaled from the wire feeder 13 4 TIG GTAW welding LOCAL control Lift arc start using TIG welding torch with separate gas supply Knob 10 will adjust the weld current which is displayed on 9 13 5 TIG GTAW welding REMOTE control Lift arc start using TIG welding torch with separate gas sup...

Страница 12: ...capacity 25A or greater The minimum recommended supply circuit breaker rating for a Weldmatic 350i is 25 Amps 500i The Weldmatic 500i 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 the rated output of 500A 60 the machine requires maximum primary current Imax 37A and Ef...

Страница 13: ... The design of the Weldmatic allows selection of the output voltage polarity 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 Som...

Страница 14: ...used 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 workpiece preparation in order to avoid weld porosity 6 Normal Welding Sequence Weld Start Closing the welding gun switch initiates this sequence ...

Страница 15: ...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 A good weld will have the characteristics illustrated in Figure 2 The weld has penetrated into ...

Страница 16: ... 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 out from the welding contact tip as shown in Figure 4c 10 Fig 4a Gas Shielded Solid Wires Fig 4b Gasless Flux Cored Wire...

Страница 17: ...e 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 unwieldy flow of metal with a rough weld a...

Страница 18: ...o 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 through its initiation sequence Press the Weld Mode button until the TIG Mode light is on T...

Страница 19: ...vel Duty Cycle The term duty cycle indicates the percentage welding time available at the rated output current for each 10 min period over 4 hours The Weldmatic 350i is rated at 350 Amps and the 500i 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 weld...

Страница 20: ...ry 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 size oxy tip cleaner Replace the welding tip as it becomes worn 4 Feed roll pressure is not excessive The pr...

Страница 21: ...rating duty cycle The OVERLOAD light will be illuminated The thermostat will reset automatically do not switch the equipment off as the cooling fan will assist the resetting of the thermostat 9 External Trouble Shooting If problem persists after the cool down period call your WIA service agent Power source has low weld output 1 Check all electrical connections in the welding current circuit includ...

Страница 22: ...ld Porosity in weld caused by lack of shielding gas 1 Check that the correct gas flow rate has been set 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 gun to ensure that no air is being drawn into the shi...

Страница 23: ...30 6 ST60N30 6 PM500 FR ZX7 400 QDB R1 C1 R2 C2 ZX7 400 FZB T 3 FUSE 2 X 60 375 FUSE 3 X 60 375 FUSE 1 2A 1 2 3 CN3 1 2 CN1 7 8 7 8 1 2 3 4 5 6 CN901 PM500 PWM 1 2 3 4 CN2 1 2 3 4 CN102 1 2 3 4 5 6 CN001 1 2 1 2 CN503 1 2 1 2 3 4 5 6 7 8 CN401 1 2 O 3 G 4 HE1 500A 4V 3 4 5 6 9 10 6 5 4 3 9 10 1 2 CN103 14PIN CN002 PTAP500 CTRL WeldMatic MB 1 2 CN401 14PIN CN301 19 0 19 AC380V 0 36V 1 2 3 4 5 6 7 8...

Страница 24: ...DM ATIC VS 350i WE LD AM PS WE LD VO LTS 350 271 31 5 60 100 27 6 LOC AL COR ED WIR E Self Shie lded Gas Shie lded All Size s REM OTE He Fig 8 Weldmatic 350i 500i Assembly 11 1 Assembly and Parts List Weldmatic 350i 500i 2 1 11 14 3 4 5 6 7 8 9 10 12 13 27 26 25 24 23 22 21 15 16 17 18 19 20 ...

Страница 25: ...onnection 1 14 PWA034 Output Snubber 1 15 E0086 Current Shunt 1 16 M0076 Front Panel Plastic 1 17 CX58 Weld Terminal Panel Mount Dinse Socket 2 18 E0082 Socket 7 PIN 1 19 TC265 5 8 UNF Nipple 1 20 TC266 5 8 UNF Nut 1 21 M0047 Knob 3 22 WIN571 Front Sticker 350i 1 22 WIN573 Front Sticker 500i 1 23 PWA031 PCB Assy Front Panel 350i 1 23 PWA032 PCB Assy Front Panel 500i 1 24 L0029 Toroid Output 350i 5...

Страница 26: ...riginal 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 purchase of the Product and the purchase price paid for the Product The relevant defect in materials or workmanship The Product not having been altered tampered with or otherwise dealt with by any ...

Страница 27: ...Weldmatic 350i Weldmatic 500i Model No CP139 CP140 25 ...

Страница 28: ...k 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 Lightweight headgear Four independent arc sensors Suits MIG Stick Flux Cored and Pulse TIG rating 5 Amps 3 year warranty Auto Darkening lens only For more information call 1300 300 884 or visit welding c...

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