WIA CP147-2 MIG Welder User Manual

June 13, 2024
WIA

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

  1. Introduction: Familiarize yourself with the
    contents of this manual to properly maintain and operate the MIG
    Welder.

  2. Receiving: Upon receiving the product, ensure
    all components are present and in good condition.

  3. Specifications: Refer to page 7 for detailed
    specifications of the MIG Welder.

  4. Controls: Understand the functions and
    operation of the controls. Refer to page 8 for more
    information.

  5. Installation: Follow the instructions on page
    10 to install the MIG Welder properly.

  6. Normal Welding Sequence: Learn the correct
    sequence for welding using the MIG Welder. Refer to page 12 for
    guidance.

  7. Basic Welding Information: Acquire essential
    knowledge about welding techniques. See page 12 for details.

  8. General Maintenance: Perform regular
    maintenance procedures to ensure optimal performance. Page 14
    provides maintenance guidelines.

  9. External Trouble Shooting: Troubleshoot
    external issues that may arise. Refer to page 15 for
    troubleshooting tips.

  10. Trouble Shooting Chart: Utilize the
    troubleshooting chart on page 16 to identify and resolve common
    problems.

  11. Circuit Diagram: Understand the circuit
    diagram of the MIG Welder. Details can be found on page 18.

  12. Assembly & Parts Lists: Find assembly
    instructions and parts lists on page 19.

  13. Australian Warranty Information: Learn about
    the warranty coverage for Australian customers on page 23.

  14. 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: 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 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: info@welding.com.au 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: info@weldwell.co.nz 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: info@welding.com.au 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: info@weldwell.co.nz
weldwell.co.nz

WELDING.COM.AU

References

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