WIA weldmatic 350i CP139-2, Operator'S Manual

Page 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 ...

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

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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 ...

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

Page 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...