WIA CP147-2 MIG Welder User Manual
- June 13, 2024
- WIA
Table of Contents
CP147-2 MIG Welder
Product Information
Product Name: MIG Welder
Model Numbers: CP147-1, CP148-1
Manufacturer: Welding Industries Australia
Distributor (Australia): ITW Australia Pty Ltd
Distributor (New Zealand): ITW New Zealand
Product Usage Instructions
-
Introduction: Familiarize yourself with the
contents of this manual to properly maintain and operate the MIG
Welder. -
Receiving: Upon receiving the product, ensure
all components are present and in good condition. -
Specifications: Refer to page 7 for detailed
specifications of the MIG Welder. -
Controls: Understand the functions and
operation of the controls. Refer to page 8 for more
information. -
Installation: Follow the instructions on page
10 to install the MIG Welder properly. -
Normal Welding Sequence: Learn the correct
sequence for welding using the MIG Welder. Refer to page 12 for
guidance. -
Basic Welding Information: Acquire essential
knowledge about welding techniques. See page 12 for details. -
General Maintenance: Perform regular
maintenance procedures to ensure optimal performance. Page 14
provides maintenance guidelines. -
External Trouble Shooting: Troubleshoot
external issues that may arise. Refer to page 15 for
troubleshooting tips. -
Trouble Shooting Chart: Utilize the
troubleshooting chart on page 16 to identify and resolve common
problems. -
Circuit Diagram: Understand the circuit
diagram of the MIG Welder. Details can be found on page 18. -
Assembly & Parts Lists: Find assembly
instructions and parts lists on page 19. -
Australian Warranty Information: Learn about
the warranty coverage for Australian customers on page 23. -
New Zealand Warranty Information: Find
warranty information for New Zealand customers on page 25.
Safety Instructions
-
Eye Protection: Always wear a helmet with
safety goggles or glasses with side shields and appropriate filter
lenses to protect your eyes from radiant energy and flying
metal. -
Burn Protection: Wear protective clothing such
as leather or heat-resistant gloves, hat, safety-toe boots, and
buttoned shirt collar and pocket flaps. Avoid wearing oily or
greasy clothing.
Note: This is just a partial extract from the user manual.
Please refer to the complete manual for comprehensive product
information and detailed usage instructions.
MIG Welder
OPERATORS MANUAL | CP147-1, CP148-1
From serial numbers C1472A, C1482A
WELDING.COM.AU
WELDING INDUSTRIES AUSTRALIA
A Division of ITW Australia Pty Ltd ABN: 63 004 235 063 1300 300 884 Email:
[email protected] 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: [email protected] weldwell.co.nz
2
CONTENTS
Section General Information
Safe Practices
1
Introduction
2
Receiving
3
Specifications
4
Controls
Page 4 7 7 8 9
5
Installation
10
6
Normal Welding Sequence 12
7
Basic Welding Information 12
8
General Maintenance
14
9
External Trouble Shooting
15
10
Trouble Shooting Chart
16
11
Circuit Diagram
18
12
Assembly & Parts Lists
19
13
Australian Warranty
Information
23
14
New Zealand Warranty
Information
25
3
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
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 356 and 396 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
200300
13 11
12-13 12-13
300400
14 12
13 14
400500
— 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-
toe 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 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
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.
If the supply cable is damaged it must be replaced by the manufacturer, their
service agent or a similarly qualified person.
6
1 INTRODUCTION
Gas Metal Arc Welding (G.M.A.W.) 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 Fabricator has been designed to be used with consumable wires in
the range from 0.6mm to 1.6mm 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 G.M.A.W. 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 G.M.A.W. using the correct
consumable wire and shielding gas.
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 356 package contains;
Weldmatic 356 Power Source CP147-2 W64-1 Wire Feeder with 10m
interconnection cable. 35mm2 weld cable. 10m Work Lead with Clamp Welding
Torch 300 A 3.6m with Centre Fire Consumables. Gas Regulator Gas Hose
(This) Operating Manual
The Weldmatic 396 package contains;
Weldmatic 396 Power Source CP148-2 W64-1 Wire Feeder with 10m
interconnection cable. 50mm2 weld cable. 10m Work Lead with Heavy Duty G
Clamp Welding Torch 300 A 3.6m with Centre Fire Consumables. Gas Regulator
Gas Hose (This) Operating Manual
7
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
3 SPECIFICATIONS
WELDMATIC 356 Manufactured to Standards AS60974-1.
Rated Input Voltage
415 Vac, 50 Hz
Rated Primary Current
15 Amps
Maximum Primary Current 23 Amps
Recommended Generator kVA
16.5 kVA
Rated Output @ 40oC
355 A , 31.8 V, 40% duty 225 A, 25.3 V, 100% duty
Welding Current
30 – 355 Amps
Open Circuit Voltage
16 – 44 V
Shipping weight Includes wirefeeder & leads
163 kg
Mains Circuit Breaker Rating 20 Amps
Supply plug
Min. 20 Amp (415 V 3 phase) 32 Amp fitted
Fitted Supply Cable
47/0.20 Four Core, Heavy Duty PVC
Cooling Insulation
Fan on demand, fan operates only as required to cool internal components
Class H, 140°C Rise.
WELDMATIC 396 AS60974-1. 415 Vac, 50Hz 15 Amps 27 Amps 20 kVA
395 A, 33.8 V, 40% duty 220 A, 25 V, 100% duty 20 – 395 Amps 16 – 46.5 V 172
kg
25 Amps Min. 20 Amp (415 V 3 phase) 32 Amp fitted 50/0.20 Four Core, Heavy
Duty PVC Fan on demand, fan operates only as required to cool internal
components Class H, 140°C Rise.
Wirefeeder Circuit Breaker Rating
5 Amps
5 Amps
8
4 POWER SOURCE CONTROLS
3
4
1
2
Fig 1 Power Source Controls
1 Ammeter
This meter displays actual welding current during welding operation, and a
stored reading for 30 seconds after welding. Weldmatic 396 Only.
2 Voltmeter
This meter displays actual welding voltage during welding operation, and a
stored reading for 30 seconds after welding. Weldmatic 396 Only.
3 Coarse Voltage, On/Off Control
This switch provides mains power ON/ OFF and Coarse adjustment of the output
welding voltage over three ranges.
4 Fine Voltage Control
This switch provides Fine adjustment of the output welding voltage over ten
steps.
9
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
5 INSTALLATION
Connection to Electrical Mains Power Supply
NOTE. All electrical work shall only be undertaken by a qualified electrician.
The Weldmatic 356 is supplied with a 5 metre 4 core 47/0.20 Heavy Duty PVC
mains power supply cable. The Weldmatic 396 is supplied with a 5 metre 4 core
50/0.25 Heavy Duty PVC mains power supply cable. This cable should be
correctly connected to a suitable 3 Phase plug top or fixed connection point.
The minimum capacity of the mains wiring and power outlet supplying a welder
is selected according to the effective primary current of the machine. The
effective primary current for Weldmatic 356 and Weldmatic 396 are 15 Amps.
The minimum recommended mains circuit breaker rating for a Weldmatic 356 is 20
Amps and Weldmatic 396 is 25 Amps.
Note: Due to normal variations of sensitivity, the tripping time of some
circuit breakers may limit the duty cycle available from the Weldmatic 356 &
396 machines. A higher rated circuit breaker can be selected, but the mains
wiring capacity must be increased to suit.
The current rating of the mains cable depends on cable size and method of
installation. Refer to AS/NZS 3008.1, Table 9.
If it becomes necessary to replace the mains flexible supply cable, use only
cable with correct current rating. Access to the supply terminals is gained by
removing the power source side panels. The replacement cable must be fitted
and retained in the same manner as the original.
10
Output Voltage Polarity
The design of the Weldmatic 356 & 396 allows selection of the output voltage
polarity.
Positive Wire
G.M.A.W. with solid consumable wires 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 socket on the Power Source, and theWELDING’ lead from the wirefeeder into
the (+) socket on the Power Source, as in Figure 2.
Wirefeeder Circuit Breaker
Wirefeeder Control Socket
To Wirefeeder
Gas Connection
To Work Clamp
Fig 2 Positive Wire
Negative Wire
Some self-shielded’ flux cored 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 theWORK’ lead plug into the (+) output
socket on the Power Source, and the `WELDING’ lead from the wirefeeder into
the (-) socket on the Power Source, as in Figure 3.
Fitting the Gas Cylinder
Place the gas cylinder on the tray at the rear of the welder. 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 rear of the machine to the
connector supplied with the gas regulator, and secure with the clamp also
supplied.
Remote Wirefeeder
The remote wirefeeder is connected to the Weldmatic 356 & 396 power source via
the composite cable interconnecting lead. Check all connections are firmly
made to ensure good electrical contact, and to prevent gas leaks.
To Work Clamp To Wirefeeder Fig 3 Negative Wire
11
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
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 and continues for any pregas time set The power source contactor
function is initiated. 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 After a short pre-set period, known as the
burn-back’ time, the Power-source contactor function is released. This period ensures that the consumable wire does notfreeze’ in the weld pool At the
completion of any post-gas time set, the gas valve is de-energised and the
flow of shielding gas ceases.
12
7 BASIC WELDING INFORMATION
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.
The recommended shielding gases for use with the Weldmatic 356 & 396 are:
Mild Steel: Aluminium:
Argon + 5 to 25% Carbon Dioxide; 100% CO
2
Argon;
Stainless Steel: Argon + 1 to 2% Oxygen.
Consult your gas supplier if more specific information is required.
Shielding Gas Flow Rate
In G.M.A. welding, one function of the shielding gas is to protect the molten
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 workpiece 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.
Important: Do not operate the Voltage Control switches during welding.
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 4. 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 5. 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 4 “Good” Weld Fig 5 “Bad” Weld
13
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
Gun Position
For “down hand” fillet welding, the gun is normally positioned as shown in
Figure 6 below with the nozzle end pointing in the direction of travel.
8 GENERAL MAINTENANCE
Before removing the power source covers, 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.
Fig 6 Gun Position
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 G.M.A.W.
process, the wirefeed must be smooth and constant. Most causes of erratic
wirefeed can be cured by basic maintenance. Check the General Maintenance
section of the Wirefeeder Operators Manual for more details.
14
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.
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; 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 on the machine.
C1472A……………………
C1482A……………………
If you are in South East Asia 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 ITW Welding Singapore Pte Ltd on +65 6552 1223.
15
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
10 TROUBLE SHOOTING CHART
Problem All Transformer Models No welding current, no display.
Mains Circuit breaker nuisance tripping during welding.
Machine continually cuts out on thermal overload
No welding current, but display on. Machine gives poor quality weld.
Likely Reason
Outcome
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 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.
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.
The connections may not be Ensure all connections are in
made securely.
position and securely made.
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.
16
Problem GMAW/MIG Models The machine feeds slowly and then speeds up after 3-5
seconds.
Nothing happens for first x seconds after trigger is pulled. The arc starts
normally but then stops x seconds. The arc does not stop after trigger is
released. Motor continues to run once arc is extinguished. Weld is
contaminated with small bubbles (presence of porosity).
Likely Reason
Creep mode is selected, or machine has a permanent creep mode function.
Pre gas is selected to x seconds.
Spot time is selected to x seconds. Latch mode is selected.
Latch mode is selected.
Air in the gas hose. The torch gas hose has not been purged sufficiently.
Outcome
Some models have a creep mode function that cannot be adjusted. Other models
have a push button selection for creep mode on/off. Allow for Pre Gas time, or
adjust time.
Spot time selection should be adjusted to 0 seconds. Latch mode should be
switched off. Latch mode should be switched off. 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
Wire feed stutters and arc Torch consumables are is erratic. Also, motor turns
blocked/partially blocked. correctly under no load.
Remove nozzle, check O ring on torch head, check condition of insulator in
nozzle
Liners and contact tips are consumable and wear over time.
Presence of porosity at weld 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.
17
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2 11 CIRCUIT
DIAGRAMS – POWER SOURCE
Fig 7 Power Source Circuit Diagram 18
12 ASSEMBLY AND PARTS LIST WELDMATIC 356 & 396 POWER SOURCE
22 5
3
2
1
20
18 19
6 7 8 9 10 13
4 12 11
7 14 8 21 15
17
16
Fig 8 Weldmatic 356 & 396 Power Source Assembly 19
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
WELDMATIC 356 & 396 PARTS LIST
Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17
18
19 20 21 22
Not Shown
Part # WHL002 PAN094 WHL003 E0053 MZ231554 MZ231553 E0077 CP43-0/3 TC265 TC266 CX58 E0024 MZ230304 PWA010 L0023 D0032 E0056 IND030 E0057 TFM062 TFM063 FAN009 E0060 PWA100 PAN097 PAN101 R0028
Description
Qty
Wheel, Rubber, Castor
2
Base Panel
1
Wheel, Rubber, Fixed
2
Control Socket
1
Handle Left
1
Handle Right
1
Switch, Coarse, Off/1/2/3
1
Switch, Fine, 10 Position
1
5/8″ UNF Nipple
1
5/8″ UNF Nut
1
Socket, Dinse
2
Circuit Breaker, 5 Amp
1
Plastic Front
1
Fan on Demand PCB
1
Control Transformer
1
Rectifier
1
Thermostat
1
Inductance Assembly
1
Thermal Overload
1
Welding Transformer Assembly, Wired 356
1
Welding Transformer Assembly, Wired 396
1
Fan Assembly
1
Contactor
1
Digital Meter Assembly (Weldmatic 396 Only) 1
Side Panel CP147
1
Side Panel CP148
1
Fan on Demand Thermistor
2
20
12.1 ASSEMBLY AND PARTS LIST – QTB 350 TORCH
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 22) seeTips’ (page 22) 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
21
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
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 10 Replacing the Gun Cable Liner
22
13 AUSTRALIAN WARRANTY INFORMATION
WIA Weldmatic MIG 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.
23
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2
For products purchased in Australia 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: [email protected] Web:
www.welding.com.au
24
14 NEW ZEALAND WARRANTY INFORMATION
WIA Weldmatic MIG Equipment 3 Year Gold Shield Warranty Statement Effective
1st January 2022 WIA Weldmatic MIG Equipment purchased in New Zealand have
identical 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: [email protected] Web:
www.weldwell.co.nz
25
Weldmatic 356 & 396 | Operator Manual | Model No CP147-2, CP148-2 NOTES:
26
NOTES: 27
WELDING INDUSTRIES AUSTRALIA
A Division of ITW Australia Pty Ltd ABN: 63 004 235 063 1300 300 884 Email:
[email protected] welding.com.au
CP148-40 RevB
WELDWELL NEW ZEALAND
A Division of ITW New Zealand NZBN: 9 429 039 833 129 GST NO: 080 177 186
0800 9353 9355 Email: [email protected]
weldwell.co.nz
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