WELDING INDUSTRIES Weldmatic 200i Operator's Manual
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WELDING INDUSTRIES Weldmatic 200i Operator's Manual

Cp137-2;cp138-2
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Weldmatic 200i + Weldmatic 250i
[Internal Wirefeeder]
Weldmatic 200i MIG,
Arc/TIG welder
Model No. CP137-2
Iss A
Operators Manual
01/16
®
Weldmatic 250i MIG,
Arc/TIG welder
Model No. CP138-2
Iss B
CP137-40 Rev B

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  • Page 1 ® Weldmatic 200i + Weldmatic 250i [Internal Wirefeeder] Weldmatic 200i MIG, Weldmatic 250i MIG, Arc/TIG welder Arc/TIG welder Model No. CP137-2 Model No. CP138-2 Iss A Iss B Operators Manual 01/16 CP137-40 Rev B...
  • Page 2 Welding Industries of Australia A division of ITW Australia Pty Ltd 1300 300 884 Info@welding.com.au welding.com.au...

  • Page 3: Table Of Contents

    Weldmatic 200i + Weldmatic 250i Contents Section General Information Page Safe Practices Introduction Receiving Specifications Controls Installation Normal Welding Sequence Basic Welding Information General Maintenance External Trouble Shooting Service Information 10.1 Circuit Diagram Assembly and Parts Lists 11.1 Power Source 11.2 Wirefeed assembly...

  • Page 4: Safe Practices

    Operators Manual Safe Practices When Using Read First Welding Equipment The information contained in this These notes are provided in the interests manual is set out to enable you of improving operator safety. They should to properly maintain your new be considered only as a basic guide to Safe equipment and ensure that you obtain Working Habits.

  • Page 5: Fire And Explosion Prevention

    Weldmatic 200i + Weldmatic 250i Burn Protection coating is removed from the work surface, the area is well ventilated, or the operator The welding arc is intense and visibly bright. wears an air-supplied respirator. Its radiation can damage eyes, penetrate...
  • Page 6 Operators Manual A person acting as Fire Watcher must be Shock Prevention standing by with suitable fire extinguishing Exposed conductors or other bare metal equipment during and for some time after in the welding circuit, or ungrounded welding or cutting if; electrically alive equipment can fatally shock •...

  • Page 7: Introduction

    The arc and the weld pool are both shielded by gas flow from the gun, or The Weldmatic 200i and 250i has been in the case of “self shielded” wires, by gases designed to be used with 2.0mm, 2.5mm, generated by the wire core.

  • Page 8: Receiving

    If filler metal is required, it is hand fed into the welding arc. IMPORTANT NOTICE: Warranty may The DC current output of the Weldmatic 200i be voided if equipment is powered is suitable for welding most ferrous and...

  • Page 9: Specifications

    Weldmatic 200i + Weldmatic 250i 3 Specifications 250i 15A 200i 250i plug operation Manufactured to AS60974.1 AS60974.1 AS60974.1 Standards IEC60974.10 IEC60974.10 IEC60974.10 Rated Input Voltage 220 – 240V 220 – 240V 220 – 240V Power Frequency 50/60 Hz 50/60 Hz...
  • Page 10 Operators Manual 3 Specifications (cont) 200i 250i 250i 15A plug operation Spool Size ES6 – 1kg & 5kg ES6 – 5kg & 15kg ES6 – 5kg & 15kg Supply Plug 15Amp 15Amp 15Amp commissioning purpose only Supply Cable 2.5mm2 3 Core 2.5mm2 3 Core 2.5mm2 3 Core Heavy Duty PVC...

  • Page 11: Controls

    FORCE CONTROL VOLTS GASLESS 0.8/0.9/1.2 mm Fig 1 Weldmatic 200i Controls (250i uses similar controls) 1 Control Panel 9 Over Temperature Indicator This light is on if the machine overheats 2 Euro Gun/Cable Connector or mains voltage os too high or low – the...

  • Page 12: Arc Control

    Operators Manual 12 Digital Display – Amps or m/min 15 Arc Control During welding actual welding Amps will be When in MIG (GMAW) mode the harshness displayed and then held for 30 seconds after of the arc can be adjusted. the end of the weld.

  • Page 13: Installation

    Then operation at 10% duty cycle (i.e. 1 200i minute on, 9 minutes off) will maintain an effective input current Ieff of 15A. The Weldmatic 200i is factory fitted with a 3 metre, 3 core 2.5mm Heavy Duty PVC Maximum rated output mains power supply cable with moulded 3 pin, 15 Amp, Single Phase plug.
  • Page 14 Operators Manual Supply Cable Negative Wire If it becomes necessary to replace the mains Some ‘self-shielded’ flux cored gasless flexible supply cable, use only cable with consumable wires are operated with the correct current rating. work piece Positive and the consumable wire Negative.
  • Page 15 Weldmatic 200i + Weldmatic 250i Fitting the Gas Cylinder Fitting the Consumable Wire Place the gas cylinder on the tray at the Remove the spool holder knob, spring and rear of the optional welder trolley (if using). flange. Fit the spool of welding wire. Refit Retain the cylinder with the chain provided.

  • Page 16: Normal Welding Sequence

    • Welding voltage is applied between the work piece and the consumable wire. The recommended shielding gases for use with the Weldmatic 200i and 250i are: • The wire drive motor is energised. • Mild Steel Argon + 18% Oxygen ;...
  • Page 17 Weldmatic 200i + Weldmatic 250i Establishing a Weld Setting A “good” weld will have the characteristics illustrated in Figure 4. The weld has penetrated Once the consumable wire type, wire size into the parent metal, fusing the root of the...
  • Page 18 Operators Manual Weldmatic Settings Chart Suggested Settings for Fillet Weld Mild Steel – Gasless Wire Wire type • Gasless / Flux Cored • Negative Polarity • Knurled Drive Roll • Arc Control 1 Wire Size Material 0.8mm 0.9mm 1.2mm Thickness Wirefeed Volts Wirefeed...
  • Page 19 Weldmatic 200i + Weldmatic 250i Weldmatic Settings Chart (cont) Suggested Settings for Fillet Weld Mild Steel – Solid Wire Wire type • Carbon Steel ES6 • Positive Polarity • Gas: Ar + 5% CO + 2% O • Arc Control 5...
  • Page 20 Operators Manual Weldmatic Settings Chart (cont) Suggested Settings for Fillet Weld Mild Steel – Solid Wire Wire type • Carbon Steel ES6 • Positive Polarity • Gas: Ar + 18% CO • Arc Control 5 Wire Size Material 0.6mm 0.8mm 0.9mm Thickness Wirefeed...
  • Page 21 Weldmatic 200i + Weldmatic 250i Gun Position For “down hand” fillet welding with gas shielded solid wires, the gun is normally positioned as shown in Figure 7a below, with the nozzle end pointing in the direction of travel. For “down hand” fillet welding with...
  • Page 22 Operators Manual Stick Welding Operation Always fill the crater which tends to form at the end of a weld deposit, by pausing Be certain that you are wearing suitable momentarily before withdrawing the electrode protective clothing, gloves etc and that you to break the arc.
  • Page 23 Weldmatic 200i + Weldmatic 250i TIG Welding Operation LIFT TIG Operation Connect the Work Clamp to the work piece. When the Welding mode is set to LIFT TIG then the arc start can be achieved with the Turn on the power switch located on the rear following procedure.

  • Page 24: 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 200i is rated 200 Amps, 15% duty cycle. The Weldmatic 250i is rated 250 Amps, 20% duty cycle. If the machine is operated at a reduced welding current, a higher duty cycle is available.

  • Page 25: General Maintenance

    Weldmatic 200i + Weldmatic 250i 8 General Maintenance 3 Welding tip is free of obstructions such Before removing the equipment as spatter build-up. Ream out the tip cover, ENSURE that the equipment bore with a suitable size oxy-tip cleaner. is disconnected from the mains Replace the welding tip as it becomes power supply.

  • Page 26: External Trouble Shooting

    Operators Manual 9 External Trouble Shooting Power source has low weld output If the following checks do not identify 1 Check all electrical connections in the the fault condition, the equipment welding current circuit, including weld should be returned to a WIA Service agent.
  • Page 27 Weldmatic 200i + Weldmatic 250i Constant poor arc characteristics Check that the: 1 Correct polarity has been selected for work and weld cables (refer page 10) 2 Shielding gas is correct for the consumable wire in use (refer page 12) 3 Welding circuit is making good electrical connection.

  • Page 28: Service Information

    Operators Manual 10 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.

  • Page 29: Circuit Diagram

    Weldmatic 200i + Weldmatic 250i 10.1 Circuit Diagrams – Power Source Fig 12 Weldmatic 200i Circuit Diagram Model No CP137, CP138...

  • Page 30: Power Source

    Operators Manual 11.1 Assembly and Parts List - Weldmatic 200i Power Source Fig 13 Weldmatic 200i Power Source Assembly Trusted by the best...
  • Page 31 Weldmatic 200i + Weldmatic 250i Item # Part # Description PAN154 Outer Cover M0059 Handle M0060 Rear Panel E0041 Gas Valve E0078 Main Switch FAN011 PWA019 Main Control Panel PCB PWA020 Wirefeeder Control PCB M0063 Front Panel SA140-0/2 Dinse Socket...
  • Page 32 Operators Manual 11.1 Assembly and Parts List - Weldmatic 250i Power Source Fig 14 Weldmatic 250i Power Source Assembly Trusted by the best...
  • Page 33 Weldmatic 200i + Weldmatic 250i Item # Part # Description PAN162 Outer Cover PWA020 Wirefeeder Control PCB PWA019 Main Control Panel PCB M0071 Handle M0073 Front Panel M0058 Knob WIN569 Front Panel Sticker CX58 Dinse Socket PWA021 Front Panel Control PCB...

  • Page 34: Wirefeed Assembly

    Operators Manual 11.2 Assembly and Parts List - Wirefeeder 200i Fig 15 Wirefeed Assembly Item # Part # Description W27-0/9 Retaining Screw Feed Rolls Item # Part # Description W26-0/8 0.6 + 0.8mm, Solid Wire W26-8/8 0.8 + 0.9mm, Solid Wire W26-7/8 1.0//1.2mm, Flux Cored Wire (knurled) W26-9/8...
  • Page 35 Weldmatic 200i + Weldmatic 250i 11.2 Assembly and Parts List - WF042 Wirefeed Assembly Fig 16 Wirefeed Assembly Item # Part # Description WF045 Roller Retaining Screw Feed rolls WF027 0.9 + 1.2 mm, Solid Wire (fitted) WF026 0.6 + 0.8 mm, Solid Wire WF028 1.2 + 1.6 mm, Solid Wire...

  • Page 36: Gun And Cable Assembly

    Operators Manual 11.3 Assembly and Parts List - Gun and Cable Assembly Fig 17 GUN001 (200 amp) Gun and Cable Assembly Item # Part # Description BE4392 Nozzle, Brass, Tapered see ‘Tips’ page 28 Contact Tip BE4335 Gas Diffuser (Head) BE4323 BEQT2-45 Body Tube, 2”, 45...
  • Page 37 Weldmatic 200i + Weldmatic 250i Tips Wire diameter Short series (25mm) 0.6mm BE7497 0.8mm BE7488 0.9mm BE7489 1.0mm BE7496 1.2mm BE7490 To replace liner: Disconnect gun/cable assembly at the Euro adaptor. Remove nozzle (1) and head (3). Withdraw old liner from the wirefeeder end. Insert new liner and refit gun/cable assembly to the wirefeeder.

  • Page 38: Warranty Information

    You are also or contact Welding Industries of Australia on entitled to have the goods repaired or 1300 300 884 to locate an authorised service replaced if the goods fail to be of acceptable agent.
  • Page 39 Weldmatic 200i + Weldmatic 250i Model No CP137, CP138...
  • Page 40 Miller Digital Elite Series ™ AUTO-DARKENING HELMETS Inferno P/N - 257217 Joker P/N - 257218 Lucky’s Speed Shop P/N - 257214 Black P/N - 257213 FOUR MODES – WELD, CUT, GRIND & X-MODE Black Lucky’s Speed Shop Joker Inferno • Lens and helmet comply with •...

This manual is also suitable for:

Weldmatic 250i

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