CP144-1 Weldmatic 350 MIG and Multi Process Welders

MIG & Multi-Process Welders

Product Information

The MIG & Multi-Process Welders are welding machines
manufactured by Welding Industries Australia, a division of ITW
Australia Pty Ltd, and Weldwell New Zealand, a division of ITW New
Zealand. These welders are designed to provide maximum operating
efficiency for various welding applications.

Product Usage Instructions

Section 1: Introduction

• Read the entire operator’s manual to properly understand and
  operate the equipment.

Section 2: Receiving

• Inspect the equipment upon receipt for any damage during
  shipping.

Section 3: Specifications

• Refer to page 7 for detailed specifications of the
  welders.

Section 4: Controls

• Refer to page 8 for information on the controls of the
  welders.

Section 5: Installation

• Follow the instructions on page 9 to properly install the
  welders.

Section 6: Normal Welding Sequence

• Refer to page 14 for the proper welding sequence.

Section 7: Basic Welding Information

• Find general welding information on page 14.

Section 8: General Maintenance

• Refer to page 20 for maintenance guidelines.

Section 9: External Trouble Shooting

• Page 21 provides troubleshooting tips for external issues.

Section 10: Trouble Shooting Chart

• Refer to page 22 for a comprehensive troubleshooting
  chart.

Section 11: Service Information

• Page 25 contains service information for the welders.

Section 11.1: Circuit Diagram

• Page 26 provides the circuit diagram for reference.

Section 12: Assembly & Parts Lists

• Refer to page 27 for the assembly and parts list of the power
  source.

• Page 29 provides the assembly and parts list for Welding Torch

• Page 30 provides the assembly and parts list for Welding Torch

Section 13: Australian Warranty Information

• Page 32 contains warranty information specific to
  Australia.

Section 14: New Zealand Warranty Information

• Page 34 contains warranty information specific to New
  Zealand.

Safety Instructions

Before operating the equipment, please read and follow the
safety instructions below:

Eye Protection

• * NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with  

  safety goggles or glasses with side shields underneath, with
  appropriate filter lenses protected by clear cover lens. This is a
  MUST for welding, cutting, and chipping to protect the eyes from
  radiant energy and flying metal. Replace the cover lens when
  broken, pitted, or spattered.

  • Recommended Shade Filter Lens:

Burn Protection

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

• Avoid oily or greasy clothing. A spark may ignite them. Hot
  metal such as electrode stubs and workpieces 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.

MIG & Multi-Process Welders
OPERATORS MANUAL CP144-1, CP145-1
From serial numbers C1442A/C1452A
WELDING.COM.AU

WELDING INDUSTRIES AUSTRALIA
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: 080177186 0800 9353 9355 Email: info@weldwell.co.nz weldwell.co.nz
2

CONTENTS

Section General Information

Safe Practices

1

Introduction

2

Receiving

3

Specifications

4

Controls

Page 4 7 8 9 10

5

Installation

12

6

Normal Welding Sequence 14

7

Basic Welding Information 14

8

General Maintenance

20

9

External Trouble Shooting

21

10

Trouble Shooting Chart

22

11

Service Information

25

11.1 Circuit Diagram

26

12

Assembly & Parts Lists

12.1 Power Source

27

12.2 Welding Torch 350

29

12.3 Welding Torch 500

30

13

Australian Warranty

Information

32

14

New Zealand Warranty

Information

34

3

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

READ FIRST
The information contained in this manual is set out to enable you to properly maintain your new equipment and ensure that you obtain maximum operating efficiency.
Please ensure that this information is kept in a safe place for ready reference when required at any future time.
When ordering spare parts, please quote the model and serial number of the power source and part number of the item required. All relevant numbers are shown in lists contained in this manual. Failure to supply this information may result in unnecessary delays in supplying the correct parts.
SAFETY
Before this equipment is put into operation, please read the Safe Practices section of this manual. This will help to avoid possible injury due to misuse or improper welding applications.
PLASTIC HANDLES ON POWER SOURCE
Please note that the handles fitted to the Weldmatic power source are intended for carrying the equipment by hand only.
DO 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 Electricity Authorities, Departments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements. Australian Standard AS1674.2 provides a comprehensive guide to safe practices in welding.

Eye Protection
NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or glasses with side shields underneath, with appropriate filter lenses protected by clear cover lens. This is a MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal. Replace the cover lens when broken, pitted, or spattered.

Recommended Shade Filter Lens

Amps

TIG MMAW MIG Pulsed MIG

0-100

10 9

10 12-13

100-150 11 10

10 12-13

150-200 12 10-11 11-12 12-13

200-300 13 11

12-13 12-13

300-400 14 12

13 14

400-500 — 13

14 14

500 + — —

14 14

4

Burn Protection
The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate light-weight clothing, reflect from lightcoloured 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 cuff less 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 perchloroethylene 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 perchloroethylene.
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.

5

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

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.
A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if;
­ Combustibles (including building construction) are within 10 metres.
­ Combustibles are further than 10 metres but can be ignited by sparks.
­ Openings (concealed or visible) in floors or walls within 10 metres may expose combustibles to sparks.
­ Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.
After work is done, check that area is free of sparks, glowing embers, and flames.
A tank or drum which has contained combustibles can produce flammable vapours when heated. Such a container must never be welded on or cut, unless it has first been cleaned as described in AS.1674-2. 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 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 equipment installed by a qualified electrician. On mobile or portable equipment, regularly inspect condition of trailing power leads and connecting plugs. Repair or replace damaged leads.
Fully insulated electrode holders should be used. Do not use holders with protruding screws. Fully insulated lock-type connectors should be used to join welding cable lengths.
Terminals and other exposed parts of electrical units should have insulated knobs or covers secured before operation.
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 different manufacturers, it is impossible for WIA to validate operation from all generators. Therefore, we recommend that operation of equipment on the generator is received from the manufacturer before purchasing the generator.

6

1 INTRODUCTION

The Weldmatic is a multi-process welding machine capable of Gas Metal Arc Welding (GMAW or MIG), Manual Metal Arc Welding (MMAW or Stick) and Gas Tungsten Arc Welding (GTAW or TIG).
GMAW (MIG Welding)
Gas Metal Arc Welding (GMAW) is an arc welding process where a consumable wire is fed by motor driven feed rolls to a welding gun, and where welding current is supplied from the welding power source. The welding arc is struck between the work piece and the end of the wire, which melts into the weld pool. The arc and the weld pool are both shielded by gas flow from the gun, or in the case of self-shielded wires, by gases generated by the wire core.
The process is very versatile in that by selection of the correct wire composition, diameter and shielding gas, it can be used for applications ranging from sheet-metal to heavy plate, and metals ranging from carbon steel to aluminium alloys.
The Weldmatic has been designed to be used with consumable wires of different diameter. The smaller wire sizes are used when welding at lower currents, such as sheet-metal applications. Increasing the wire diameter permits higher welding currents to be selected.
A common application of GMAW 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 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 assembly forming the basic component of the wirefeeder. The motor is controlled by an electronic speed control which provides speed regulation.
MMAW (Stick Welding)
Manual Metal Arc Welding (MMAW) is a process where an arc is struck between a flux-coated consumable electrode and the work piece. The arc and the weld pool are both shielded by gases generated by the flux coating of the electrode.
The Weldmatic 350/500 has been designed to be used with 2.0mm, 2.5mm, 3.2mm, 4.0mm and 5.0mm diameter electrodes. The smaller electrodes are used when welding at lower currents, such as sheet metal applications. Increasing the electrode diameter permits higher welding currents to be selected.
WIA supplies a wide range of mild steel and special purpose electrodes which cater for home workshop, rural, and industrial requirements. Some popular AUSTARC electrodes are listed below. The correctly selected AUSTARC electrode will influence the quality of the weld, and the stability of the arc.
Austarc 12P, Classification E4313-A
A popular general purpose electrode used with ease in all positions, vertical up or down. The smooth forceful arc makes it an ideal electrode for all general mild steel applications.

7

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

2 RECEIVING

Austarc 13S, Classification E4313-A A smooth running electrode with a soft arc, particularly suited to light sheet metal and smooth mitre fillet welds.
Austarc 16TC, Classification E4916-A A low hydrogen electrode with 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.
GTAW (TIG Welding) Gas Tungsten Arc Welding (GTAW) is a welding process where the arc is struck between a non-consumable tungsten electrode and the work piece. A ceramic nozzle surrounds the tungsten electrode and directs a flow of inert gas, usually Argon, over the electrode and the weld zone. If filler metal is required, it is hand fed into the welding arc. The DC current output of the Weldmatic is suitable for welding most ferrous and non-ferrous metals, but is not suitable for welding Aluminium for which an AC machine is required.
8

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 350 package contains: ­ CP144-2 Weldmatic 350 power source. ­ Argon gas regulator. ­ Gas Hose ­ Welding torch ­ 300 AMP fitted with
Bernard 0.9 centre fire tip ­ Work lead and spring clamp – 10m
x 35mm2 cable with large twist lock connector. ­ W67-0 wire feeder with 4 roll drive. ­ Feed roller V0.9/1.2mm with V groove quantity 2 fitted ­ Feed roller V0.9/1.2mm with teeth (knurled) quantity 2 spare ­ Composite lead 35mm2 10m ­ AM358 trolley with drawers ­ Owners Manual CP145-40
The Weldmatic 500 package contains: ­ CP145-2 Weldmatic 500 power source. ­ Argon gas regulator ­ Gas Hose ­ Welding torch – 400amp fitted with
0.9mm Bernard centre fire tip ­ Work lead and clamp – 10m x 50mm2
cable terminated with G clamp ­ W67-0 wire feeder with heavy duty
4 roll drive ­ Feed roller V0.9/1.2mm with V groove
quantity 2 fitted ­ Feed roller V0.9/1.2mm with teeth
(knurled) quantity 2 spare ­ COMPOSITE LEAD 50mm2 10m ­ AM358 Trolley with drawers ­ Owners Manual CP145-40
Optionally available
­ TIG Torch Complete TIG002, 4m cable with twist-lock connection and fitted with 2.4mm collet. Manual Gas valve on hand piece

3 SPECIFICATIONS

350

Manufactured to Standards

AS60974.1 IEC60974.10

Rated Input Voltage

380 ­ 415V 3 Phase

Power Frequency

50/60 Hz

Generator Three Phase Capacity 32KVA

Rated Maximum

26A

Supply Current Imax

Maximum Effective

20A

Supply Current Ieff

Output No Load Voltage

66V

VRD Safe

7.5V

MIG GMAW

350Amp @ 31.5V 60% Duty

271Amp @ 27.6V 100% Duty

Stick MMA

350Amp @ 34V 60% Duty

271Amp @ 30.8V 100% Duty

TIG

350Amp @ 24V 60% Duty

271Amp @ 20.8V 100% Duty

Spool Size

ES6 ­ 5kg & 15kg

Supply Plug

32A

Supply Cable

2.5mm2 3 Core + E Heavy Duty PVC

Mains Circuit Breaker Rating 25A

Wire Speed Range

2-22 Metre/min

Wire Size

0.9, 1.2, 1.6 mm Solid Wire 0.9 – 1.6 mm Cored Wire

Cooling Type

Fan on Demand

Efficiency

85%

Power Factor

0.92

Insulation

H 140°C Rise

Protection

IP21S

Weight

97kg

Shipping Weight

143kg

Dimension L × W × H

940 x 485 x 880mm

Shipping Dimension L × W × H 1080 x 500 x 980mm

500 AS60974.1 IEC60974.10 380 ­ 415V 3 Phase 50/60 Hz 47KVA 42A
32.5A
75V 7.5V
500Amp @ 39V 60% Duty 387Amp @ 33.4V 100% Duty
500Amp @ 40V 60% Duty 387Amp @ 35.5V 100% Duty
500Amp @ 30V 60% Duty 387Amp @ 25.5V 100% Duty ES6 ­ 5kg & 15kg 32A 4.0mm2 3 Core + E Heavy Duty PVC 32A 2-22 Metre/min 0.9, 1.2, 1.6 mm Solid Wire 0.9 – 1.6 mm Cored Wire Fan On Demand 85% 0.92 H 140°C Rise IP21S 105kg 148kg 940 x 485 x 880mm 1080 x 500 x 980mm

9

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2 4 CONTROLS

8

10 9

11

WIN649A
VOLTS

AMPS

56 7
ON VRD
STICK ARC FORCE MIG ARC CONTROL

PROCESS

MIG STICK TIG MIG VS (Hold 3 Sec.)

WIRE

0.9
1.2
1.6
CORED WIRE – Self/Gas Shielded – All Sizes

3 24

1

12

13

Fig 1 Weldmatic 350 + 500 Controls

1 Control Panel
2 Remote Connector Connect the wire feeder control cable to this connection.
3 Positive Welding Output Terminal
4 Negative Welding Output Terminal
5 Power On Indicator
6 VRD Safe Light VRD safe light is on when the open circuit output voltage is reduced to a safe level.

7 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.
8 Digital Display Amps
If Weld Mode is stick MMA Mode or TIG mode the display will indicate the selected welding Amps when adjusted with knob, item (9).
During welding in any mode, the display will show actual welding Amps. At the end of welding, the display will hold the actual weld amps for 10 seconds.

10

9 Weld Current Adjustment
Weld Current Adjustment Knob for Stick MMA or TIG Mode.
10 Digital Display Volts
MIG Mode (GMAW): The display will indicate Actual weld volts as measured at output terminals. At the end of welding, the display will hold the actual weld volts for 10 seconds. The display will indicate the MIG Arc Control 0-10 setting by knob (11).
Stick Mode (MMA): The display will indicate the amount of Arc Force 0-10 set by Knob (11). During welding, the display will show actual weld volts. At the end of welding, the display will hold the actual weld volts for 10 seconds.
Voltage Sensing (VS): The display will indicate the weld volts setting set by Knob (9). During welding, the display will show actual weld volts. At the end of welding, the display will hold the actual weld volts for 10 seconds.
TIG Mode (GTAW): During welding, the display will show actual weld volts. At the end of welding, the display will hold the actual weld volts for 10 seconds.
11 Voltage Adjustment Knob
11.1 Stick Mode
When in Stick MMA Mode the knob will adjust Arc force 0-10.
When the welding machine detects a sudden drop in the weld arc voltage, the machine will compensate momentarily by increasing the weld current and weld voltage.
A higher arc force might be useful for difficult electrodes such as Cellulose.
11.2 Voltage Sensing
If Weld Mode is Voltage Sensing VS the knob will adjust the weld volts setting

11.3 MIG 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. The display (10) will indicate the MIG Arc Control value 0-10.
12 Process Selection Button Pressing the button will cycle through each of the four welding processes as indicated by the four lights. The Four Processes are:
12.1 GMAW MIG using remote wire feeder: The weld voltage is controlled from the wire feeder and the set value is displayed on (10). The output voltage is only active when signaled from the wire feeder.
12.2 Stick electrode welding MMA, with LOCAL control: Knob (9) will adjust the weld current which is displayed on (8). Knob (11) will adjust arc force displayed on (10).
12.3 TIG GTAW welding, LOCAL control: Lift arc start, using TIG welding torch with separate gas supply. Knob (9) will adjust the weld current which is displayed on (8).
12.4 MIG Process Voltage Sensing VS: The Knob (11) will adjust the weld volts setting, which is displayed on (10). The output terminals are at full OCV. This process requires a special wire feeder that is capable of operating from output live terminals. Note: Process selection switch must be pressed for 3 seconds, to lock into VS Process.
13 Wire select Button and Indicator Use this button to select the wire size being used. For 350, sizes 0.9, 1.2, 1.6mm can be used. For 500, sizes 0.9, 1.2, 1.6mm can be used. When wire setting is set to Gasless then there is no need to select wire size.
11

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

5 INSTALLATION
Connection to Electrical Mains Power Supply
Note: All electrical work shall only be undertaken by a qualified electrician.
350
The Weldmatic 350 is factory fitted with a 3 metre, 3 core+ earth 2.5mm2 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 350A 60% the machine requires maximum primary current Imax 26A and Effective primary current Ieff 20 Amps.
The machine needs to be fitted with a plug capacity 20A or greater, and a supply capacity 25A or greater.
The minimum recommended supply circuit breaker rating for a Weldmatic 350 is 25 Amps.

500
The Weldmatic 500 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 42A and Effective primary current Ieff 32.5 Amps.
The machine needs to be fitted with a plug capacity 32A or greater, and a supply capacity 31A or greater.
The minimum recommended supply circuit breaker rating for a Weldmatic 500 is 32 Amps.

12

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 can result in
repeated in-rush currents raising circuit breaker threshold.
Repeated circuit breaker operation at weld start can sometimes be overcome by using a “D” curve circuit breaker.
To reduce nuisance tripping, a higher rated circuit breaker can be selected, but the supply circuit wiring capacity must be increased to suit.
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.
Output Voltage Polarity
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 Someself-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 wirefeeder weld cable into the (-) output terminal.
Fitting the Gas Cylinder
Place the gas cylinder on the tray at the rear of the optional welder trolley (if using). Retain the cylinder with the chain provided.
Fit the gas regulator to the cylinder. DO NOT apply grease or oil to these joints.
Fit the end of the gas inlet hose from the back of the power source to the connector supplied with the gas regulator, and secure with the clamp also supplied.

13

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

6 NORMAL WELDING SEQUENCE
Weld Start Closing the welding gun switch initiates this sequence of events: ­ The gas valve is energised and gas
flow commences; ­ Welding voltage is applied between
the work piece and the consumable wire. ­ The wire drive motor is energised. ­ The wire touches the work piece, and the arc is established.
Weld End Releasing the gun switch initiates this sequence of events: ­ The wire drive motor is de-energised,
and is dynamically braked to a stop; ­ The welding current stops. ­ The gas valve is de-energised and the
flow of shielding gas ceases.
The quality of the consumable wire greatly affects how reliably a gas metal arc welder will operate. For best results when welding mild steel, we recommend quality WIA AUSTMIG ES6. Dirty, rusty or kinked wire will not feed smoothly through the gun cable and will cause erratic welding. Deposits from the wire will clog the gun cable liner requiring it to be replaced prematurely.
14

7 BASIC WELDING INFORMATION

MIG Welding (GMAW)

Choice of Shielding Gas

The choice of shielding gas is largely determined by the consumable wire to be used. Many proprietary shielding gas mixtures are available.

Some recommended shielding gases are:

­ Mild Steel:

Argon + 18% Oxygen;

Argon + 2% Oxygen + 5% Carbon dioxide;

­ Aluminium: Argon;

­ Stainless Steel: Argon + 1 to 2% Oxygen.

Argon + Helium

Consult your gas supplier if more specific information is required.

Shielding Gas Flow Rate
In GMAW, one function of the shielding gas is to protect the moulten weld pool from the effects of oxygen in the atmosphere. Without this protection the weld deposit becomes `honeycombed’ in appearance, an effect which is described as weld porosity.
In draft-free conditions the gas flow rate required to give adequate protection is typically 10-12 litres/min. In situations where 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 gas delivery and work piece preparation in order to avoid weld porosity.

Establishing a Weld Setting
Once the consumable wire type, wire size and shielding gas have been chosen, the two variables that are adjusted in order to obtain a the desired weld setting are;
­ Wirefeed speed,
­ Welding arc voltage.
The wirefeed speed determines the welding current; increasing the speed increases the current, and decreasing it decreases current.
The selected wirefeed speed must be matched with sufficient arc voltage; a speed increase requires an increase 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 to suit the application.

A “good” weld will have the characteristics illustrated in Figure 2. The weld has penetrated into the parent metal, fusing the root of the joint where the two plates meet, and the weld blends smoothly into the side walls. A “bad” weld is shown in Figure 3. The weld has not penetrated the joint root, and there is poor side wall fusion. This lack of fusion would normally be corrected by increasing the arc voltage, or by increasing both wirefeed speed and arc voltage to achieve a higher current weld setting.
Fig 2 “Good” Weld

Fig 3 “Bad” Weld 15

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

Gun Position
For “down hand” fillet welding with gas shielded solid wires, the gun is normally positioned as shown in Figure 4a below, with the nozzle end pointing in the direction of travel.
For “down hand” 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 wirestick-out’ from the welding contact tip
as shown in Figure 4c.

10Fig 4a Wire Stickout for Gasless Welding

Fig 4b Gas Shielded Solid Wires

Fig 4c Gasless Flux Cored Wires 16

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 electrodes, including cellulose types, are operated with the electrode at positive polarity.
Stick Welding Operation
Be certain that you are wearing suitable protective clothing, gloves etc and that you are working in a non-hazardous area. If necessary, refer again to Section 1 – Safe Practices in this manual.
Connect the work clamp to the work piece. Place the desired electrode in the electrode holder (electrode holder optional extra).
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 Process button until the Stick Process light is on.
Select an appropriate welding current for the electrode diameter by setting the knob on the machine front panel. WIA Austarc electrodes will give the best results.
To strike the arc, drag the end of the electrode along the work piece as if striking a match. As the 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 appearance and reduced penetration.
An arc too short leads to a narrow weld deposit and “stuttery” arc characteristics, and the electrode is liable to freeze onto the work piece.
As the solidified weld deposit forms, move the end 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 point of weakness, and can lead to weld cracking.

Current Range for General Purpose Electrodes

Diameter (mm) Current (Amps)

2.0

40 – 60

2.5

60 – 85

3.2

90 – 130

4.0

130 – 180

17

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

TIG Welding (GTAW)
Connection for TIG Welding
For TIG welding, the torch is connected to the negative terminal. Welding grade Argon is the shielding gas most commonly used for DC GTAW welding. The machine does not have an internal gas valve. The gas is connected directly to the torch.
Before first use of the welding torch, allow gas to purge the torch and hoses for 1 minutes at approximately 10 litres/min. For welding purposes, the gas flow rate should be set in the range 2-5 litres/min.
Tungsten electrodes for DC GTAW should be 1-2% Thoriated. This type will provide the best arc initiation, arc stability and tip shape retention characteristics. Thoriated electrodes can be recognised by a red coded end. The tungsten electrode is ground to a point, with the grinding marks pointing towards the tip. For welding currents less than 20 amps, the included angle of the point should be 30o, 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 Process button until the TIG Process light is on. The Weldmatic keeps the last process used in memory, so this step is only necessary when using a different process to that used last.
Select an appropriate welding current for the job by setting the knob on the machine front panel.
Use of a copper striking plate can be used to avoid electrode contamination. The electrode can also be contaminated by contact with the filler rod. A contaminated electrode produces an unstable arc. If this occurs regrind the electrode tip.
When in TIG the output is turned on and the LIFT-ARC voltage is present at the electrode.

18

LIFT TIG Operation
LIFT TIG arc start can be achieved with the following procedure.

1

2

3

4

Fig 5 Lift TIG Operation Procedure

1 Turn on the shielding gas.

2 Touch the electrode lightly against the work piece.
3 While still holding the electrode against the work piece, roll the hand piece over until the cup rests on the work piece.
Use the cup as a pivot point to roll the hand piece over allowing the electrode to lift of the work piece.
The arc will ignite.

4 Immediately lift the cup of the work piece, the current will rise to the welding level.

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 350 is rated at 350 Amps, and the 500 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 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 temperature warning indicator will be on, the fan will continue to run, but the machine will not deliver welding current until the unit has cooled sufficiently.
Maximum welding time per 10 min
150 200 250 300 350 400 450 500

Fig 6 Duty Cycle Rating

19

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

8 GENERAL MAINTENANCE
Before removing the equipment cover, ENSURE that the equipment is disconnected from the mains power supply. When the equipment is energised LETHAL VOLTAGES are present on the electrical components enclosed.
Dust
Care should be taken to prevent excessive build-up of dust and dirt within the welding power source. It is recommended that at regular intervals, according to the prevailing conditions, the equipment covers be removed and any accumulated dust be removed by the use of a dry, low pressure compressed air, or a vacuum cleaner. The machine should be blown out with compressed air at least every 12 months as grinding dust can settle on PCB componentry causing failure. Failure to maintain machines may void warranty.
Wirefeed
In order to obtain the most satisfactory welding results from the GMAW process, the wirefeed must be smooth and constant. Most causes of erratic wirefeed can be cured by basic maintenance. Check that the:
1 Feed rolls are the correct size and type for the wire in use. Check also that the drive groove is aligned with the wire, and that the groove is not worn;
2 Gun cable liner is clear of dust and swarf build-up. When replacement becomes necessary, 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;
20

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 pressure should be just sufficient to feed the wire evenly. Excessive pressure will deform the electrode wire and make feeding more difficult;
5 Consumable wire spool holder rotates smoothly and that the braking action is not excessive. The spool should only have sufficient braking to prevent over run when the motor stops. This also may be conveniently checked each time the wire is replenished;
7 Welding wire is straight and free of buckles or `waviness’. To check, remove 2 or 3 metres of wire from the spool. Clamp one end in a vice or similar, then holding the other end pull the wire out straight. Look down the length of the wire, any buckles will be obvious. Buckled wire is extremely difficult to feed reliably and should be replaced;
8 Welding wire is free of surface rust. Replace if rust is evident.

9 EXTERNAL TROUBLE SHOOTING If you are in Australia and the following checks do not identify the fault condition, the equipment 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.
21

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

10 TROUBLE SHOOTING CHART

Problem

Likely Reason

Outcome

All Inverter Multi-Process Models

No welding current, no display.

The machine is not turned on at both the mains supply and the machine power switch.

If confirmed that the machine is switched on correctly, test the same outlet using a known serviceable appliance.

Mains Circuit breaker nuisance tripping during welding.

Mains Circuit breaker inadequately rated, or duty cycle exceeded.

The circuit breaker may be rated for Ieff (effective current). If Weld output is greater than the 100% rating the machine will require mains current higher than Ieff. The duty cycle should be observed and understood

Machine continually cuts out on thermal overload

The machine duty cycle has been exceeded.

Leave the machine energized, 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 Ensure all connections are in

made securely.

position and securely made.

Machine gives poor quality weld.

The polarity of the electrode/ Polarity should be confirmed

return cables is incorrect.

for the process/wire type

in use.

The return lead contacts, or workbench surface requires cleaning.

Machine works fine on mains power but does not work when connected to a generator.

Generator cannot provide high peak cycle currents for inverter

The return lead contacts and connections should be inspected and cleaned, and the workbench cleared of waste materials.
Use larger kVA generator or sometimes a different band generator will work.

Machine works fine on mains power but does not work when connected with extension lead.

Extension leads creating additional resistance, and voltage drop

Use larger cable size, and keep extension lead as short as possible.

22

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 Spot time is selected to

then stops x seconds.

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

Latch mode is selected.

once arc is extinguished.

Latch mode should be switched off.

Weld is contaminated with Air in the gas hose. The

small bubbles (presence torch gas hose has not

of porosity).

been purged sufficiently.

Purge the system and confirm sufficient gas flow through the regulator.

The gas hose is not securely connected at the machine or at the regulator.

Ensure the gas connections from regulator through to the torch connection are sufficiently tightened.

Air is being drawn into arc through torch nozzle

Remove nozzle, check O ring on torch head, check condition of insulator in nozzle

23

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

Problem

Likely Reason

GMAW/MIG Models (cont.)

Wire feed stutters and arc Torch consumables are is erratic. Also, motor turns blocked/partially blocked. correctly under no load.

Outcome
Liners and contact tips are consumable and wear over time.

Presence of porosity at weld start.
GTAW/TIG Models Tungsten burns up on arc start.

Rusty MIG Wire.
The torch gas hose has not been purged sufficiently.

Replace the torch liner and reduce wire feed tension.
Purge the system and confirm sufficient gas flow through the regulator.

The polarity of the electrode/ Polarity should be confirmed

return cables is incorrect.

for the process/wire type

in use.

The weld has small black lumps’ ordots’ appearing in the pool. Cleaning is poor. Weld is contaminated with small bubbles (presence of porosity).
Presence of porosity at weld start.

Gas not turned on. Gas flow too low. Not enough Pregas time. Old or dirty filler rods can often be the cause of `dirty’ TIG welding operations.
The gas hose is not securely connected at the machine or at the regulator.
The torch gas hose has not been purged sufficiently.

Review gas set up.
Switching filler rods to another type or batch may solve this issue.
Ensure the gas connections from regulator through to the torch connection are sufficiently tightened. Purge the system and confirm sufficient gas flow through the regulator.

24

11 SERVICE INFORMATION
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.
Before removing the equipment cover, ENSURE that the equipment is disconnected from the mains power supply. When the equipment is energised LETHAL VOLTAGES are present on the electrical components enclosed.
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 Zealand 0800 9353 9355. When contacting a service agent please have an accurate description of the fault, and the machine serial number located on the base of the machine. C1442A……………. C1452A…………….
25

1
Fig 7 Weldmatic 350 + 500 Circuit Diagram 26

KK1 63A/400V A
B
C
Socket
C2 C1
C3 103/1600V
FAN TG22580H3BL
CR1 2u/630V~

IGBT Filter Board IGBT Module

IGBT Module

Main Transformer

D1 100A/1200V

1~

+4

C4 100uF
C5 100uF

2~

3~

-5

1R9 300K
1C1 475/630V
1C2 475/630V
1C3 475/630V
1C4 475/630V
1R10 300K

FUSE1 2A

RY1 5KA820V
2 2

A1

A3

6 5 4 3 2 1
2CN2

G1 E1
MK1 100A

G2 E2

2

2

2

2

1R1 1R2 33R 33R
1C6 102
1R3 1R4 33R 33R
1C7 102

A2

G3

E3

6

5

4 3 2

MK2 100A

1

3CN2

G4

E4

2

2

2

1R7 1R8 33R 33R
1C5 102/1.2kV

T1 NB-EW 3T

0V

0

3T

KD1 300A/400V

Secondary Filter
Absorber
+ HE1 500A/4V

GND Uo -15V +15V

Current Sensor

2

1R5 1R6 33R 33R

22 T A7

102/1.2kV

1

2

7L1 200Z
7R1 33R
2

KD2 3T 300A/400V 0V 3T
Secondary Filter Voltage Feedback

A5-13 A5-16 A5-15 A5-14

NB

7

A5-12

6

5

4

3

2

1

8CN1

X3

A9
C11 103 C12 103

2

1

7CN1

G3

E3

G4

E4

G2 E2 G1 E1

1 2
7

4CN1

4CN2

IGBT Gate

7 6 5 4 3 2 1

6

5

4

3

2

1

Current

L4

–

IGBT Gate

Output Reactor

Driver Board

NB-U

A4

T1

4CN3

CH1

0V

380V 1

2

380V 1 2 415V
CH2 415V
0V

19V/0.5A

19V A5-1

0V A5-2

19V A5-3 19V A5-4

0V A5-5

19V A5-6

27V/3A A5-7

0A

A5-9

27V/3A A5-8

ZK-T1

Control Transformer

A5-1

1

A5-2

2 CN001

A5-3

3 AC20V

A5-4

1

A5-5

2 CN302

A5-6

3 AC20V

1

A5-7

2

3 CN303

A5-8

4 AC27V

5

A5-9

6

RV15K

1 CN102 2 NTC

3 2 1

1

2

Drive Transformer
CN901
Drive Signal

2

1

CN902
Primary Sampling

3

4

NB-Ew Main Board

Control Line 1
CN202

Control Line 2
CN207

1

2

7 6 5 4 3 2 1 CN101
Current and Voltage Feedback

Wire Feeder Control Line

CN204 1 2 4 3 5
CN304

A5-11 A5-12
A5-13 A5-14 A5-15 A5-16

1 2 3 4 ISO3080 TR

CN3

TL THRL RH

CN4

A5-11

1

2

X1+

X1-

R5 20W/400R
9R2 NC 9R1 9R3 200R 200R 8CN2
Welding Gun

8 7 6 5 4 3 2 1
TXRX 4 3 2 1
To Wire Feeder Control Cable

Panel

1

2

3

4

CN2
Control Line 1
NB-Ew

1

2

CN3
Control Line 2

4 3 2 1

Program Input
CN1

E

F

D

G

M

CL

NH

K

B

I

A

J

14 Pin

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2 11.1 CIRCUIT DIAGRAM – POWER SOURCE

12 ASSEMBLY – WELDMATIC 350/500

31 30
25

29
27 28 3 1
26

24

23 22

20 21 19 Fig 8 Weldmatic 350 + 500 Assembly

2
4 5
6
7
8 9 10
11
12 13 14 15
16 17 18
27

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2 12.1 PARTS LIST – WELDMATIC 350/500

Item # 1 2
3 4 5
6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 Not Shown Not Shown Not Shown

Part # M0111 PAN179 PAN189 L0036 PWA069 PWA068 PWA089 E0107 L0037 L0038 D0047 PWA070 D0049 L0039 M0112 PWA067 WIN649 WIN652 M0103 M0105 CX58 E0101 PWA066 L0029 BBA048 D0048 PWA072 FAN026 FAN026 E0081 PWA065 PWA090 PWA071 M0084 WHL002 WHL005 REG003 CP145-40 62513

Description

Qty

Handle

1

Enclosure 350

1

Enclosure 500

1

Control Transformer

1

IGBT Driver 350 500

1

PCB Assy Main Control 350

1

PCB Assy Main Control 500

1

EMI Filter

1

Weld Transformer 350

1

Weld Transformer 500

1

Rectifier 3 PH 350 500

1

IGBT Snubber 350 500

1

IGBT CP145 500

2

Output Inductance

1

Front Plastic Panel

1

PCB Assy Front Panel 350 500

1

Front Panel Sticker 350

1

Front Panel Sticker 500

1

Knob

2

Silicon Button

2

Weld Terminal Panel Mount Dinse Socket

2

14 PIN Socket Panel

1

Output Filter 350 500

1

Current Sensor 500A

1

BUSBAR 350/500

1

Output Diode 350 500

2

PCB Assy Output Snubber 350 500

2

Fan 350

1

Fan 500

1

Switch On/Off

1

Primary Current Sensor Board

1

Fan Control Board

1

Control Cable Interface 350 500

1

Swivel Post Wirefeeder 350 500

1

Wheel Castor

2

Wheel Fixed

2

Argon Regulator

1

Operating Manual

1

Gas Hose

1

28

12.2 ASSEMBLY AND PARTS LIST – TORCH WELDMATIC 350

4 3 2 1
11 9 10

5
6 7
8

Item # 1 2 3 4 5 6 7 8 9 10 11

Fig 9 350 Amp Gun and Cable Assembly

Part # see Nozzles’ (page 31) seeTips’ (page 31) BED-1 BE10012 BEQT3-45 GUN002 GUN003 GUN006 BE9165 BE4421 BEL3B-15 BE4154503N BEL3A-15 GUN004

Description Nozzle Contact Tip Gas Diffuser, Large Insulator Body Tube 3″x 45° Handle Kit (includes both halves, screws & trigger Trigger Switch Rigid Casing Small “O” ring on gas nipple Large “O” ring on gas nipple Steel Liner 0.9-1.2mm, 300 amp Nylon Liner 0.9-1.2mm Steel Liner 0.9-1.2mm, 400 amp 350A Gun & Cable Assembly

29

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

12.3 ASSEMBLY AND PARTS LIST – TORCH WELDMATIC 500

4 3 2
1

5
6 7

11 9 10

8

Fig 10 400 Amp Gun and Cable Assembly

Item # 1 2 3 4 5 6 7 8 9 10 11

Part # see Nozzles’ (page 31) seeTips’ (page 31) BED-1 BE10012 BEQT3-45 GUN002 GUN003 GUN006 BE9165 BE4421 BEL3B-15 BE4154503N BEL3A-15 GUN008

Description Nozzle Contact Tip Gas Diffuser, Large Insulator Body Tube 3″x 45° Handle Kit (includes both halves, screws & trigger Trigger Switch Rigid Casing Small “O” ring on gas nipple Large “O” ring on gas nipple Steel Liner 0.9-1.2mm, 300 amp Nylon Liner 0.9-1.2mm Steel Liner 0.9-1.2mm, 400 amp 400A Gun & Cable Assembly

30

Nozzles Part # BEN-3400C BEN-3414B BEN-3414C BEN-3418B BEN-5800C BEN-5814B BEN-5814C BEN-5818B BEN-5818C

Description
Nozzle, copper, 3/4″ I.D, flush
Nozzle, brass, 1/4″ I.D, recess
Nozzle, copper, 3/4″ I.D, 1/4″, recess
Nozzle, brass 3/4″ I.D, 1/8″, recess
Nozzle, copper, 5/8″ I.D, flush
Nozzle, brass, 5/8″ I.D, 1/4″ recess
Nozzle, copper, 5/8″ I.D, 1/4″ recess
Nozzle, brass, 5/8″ I.D, 1/8″ recess
Nozzle, copper, 5/8″ I.D, 1/8″ recess

Tips

Wire diameter 0.8mm 0.9mm 1.0mm 1.2mm 1.4mm 1.6mm 2.0mm

Part # BET-030 BEST-035 BET-039 BET-045 BET-052 BET-062 BET-078

To replace liner: Disconnect gun/cable assembly at the Euro adaptor. Remove nozzle (1) gas diffuser (3) and insulator (4). 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 approx 20mm past the end of the body tube/neck (5). Refit insulator and screw gas diffuser on firmly with a wrench. Insert tip (2) into gas diffuser then thread nozzle onto gas diffuser/tip and tighten firmly by hand.
Compress Liner
20mm Cut Here
Fig 11 Replacing the Gun Cable Liner

31

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

13

AUSTRALIAN WARRANTY INFORMATION

WIA Weldmatic MIG & Multi-Process Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
Welding Industries of Australia (WIA) warrants to the original retail purchaser that the Weldmatic welding machine purchased (Product) will be free from defects in materials and workmanship for a period of 3 years from the date of purchase of the Product by the customer. If a defect in material or workmanship becomes evident during that period, Welding Industries of Australia will, at its option, either:
­ Repair the Product (or pay for the costs of repair of the Product); or
­ Replace the Product.
In the event of such a defect, the customer should return the Product to the original place of purchase, with proof of purchase, or contact Welding Industries of Australia on 1300 300 884 to locate an authorised service agent.
Products presented for repair may be replaced by refurbished products of the same type rather than being repaired. Refurbished parts may be used to repair the product. Replacement of the product or any part does not extend or restart the 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 the replacement product, if original found to be faulty, freight free to the customer.
This warranty covers the Weldmatic power source and wirefeeder only, and does not extend to the regulator, gun assembly or accessories included in the original 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 person in a manner other than as intended in respect of the relevant Product; and
­ The Product not having been used or applied in a manner that is contrary to customary usage or application for the relevant Product or contrary to any stated instructions or specification of Welding Industries of Australia.

32

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired 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 Australia Pty Ltd 5 Allan Street, Melrose Park South Australia 5039 1300 300 884 Email: info@welding.com.au Web: www.welding.com.au
33

Weldmatic 350 & 500 | Operator Manual | Model No CP144-2/CP145-2

14

NEW ZEALAND WARRANTY INFORMATION

WIA Weldmatic MIG & Multi-Process Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
WIA Weldmatic MIG & Multi-Process Equipment purchased in New Zealand have identical 3 year warranty conditions as Australia, with the below conditions:
In the event 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 Zealand
0800 9353 9355 Email: info@weldwell.co.nz Web: www.weldwell.co.nz

34

NOTES: 35

WELDING INDUSTRIES AUSTRALIA
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

CP145-40 RevB

WELDING.COM.AU

References

• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ
• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ

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