WIA WELDMATIC 200+ Operator's Manual
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WIA WELDMATIC 200+ Operator's Manual

Mig & multi-process welders
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MIG & Multi-Process Welders
OPERATORS MANUAL | CP142-1, CP143-1
From serial numbers C1422A*, C1432A*
WELDING.COM.AU

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Summary of Contents for WIA WELDMATIC 200+

  • Page 1 MIG & Multi-Process Welders OPERATORS MANUAL | CP142-1, CP143-1 From serial numbers C1422A*, C1432A* WELDING.COM.AU...
  • Page 2 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...

  • Page 3: Table Of Contents

    CONTENTS Section General Information Page Safe Practices Introduction Receiving Specifications Controls - LCD Interface Installation Normal Welding Sequence Basic Welding Information General Maintenance External Trouble Shooting Trouble Shooting Chart Service Information 11.1 Circuit Diagram 200+ 11.2 Circuit Diagram 250 Assembly & Parts Lists 12.1 Power Source 200+ 12.2 Power Source 250 12.3 Wirefeeder 200+...

  • Page 4: Safe Practices

    Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 SAFE PRACTICES WHEN USING WELDING EQUIPMENT READ FIRST 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 equipment and ensure that you...
  • Page 5 Burn Protection Metals coated with or containing materials that emit fumes should not be heated The welding arc is intense and visibly bright. unless coating is removed from the work Its radiation can damage eyes, penetrate surface, the area is well ventilated, or the light-weight clothing, reflect from light- operator wears an air-supplied respirator.
  • Page 6 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Walls touching combustibles on opposite Shock Prevention sides should not be welded on or cut. Exposed conductors or other bare metal Walls, ceilings, and floor near work should in the welding circuit, or ungrounded be protected by heat-resistant covers electrically alive equipment can fatally...

  • Page 7: Introduction

    The Weldmatic has been designed to be WIA supplies a wide range of mild steel and used with consumable wires of different special purpose electrodes which cater diameter. The smaller wire sizes are used...

  • Page 8: Receiving

    4m cable with Due to variation between generators Torch twist-lock connection by different manufacturers, it is and fitted with 2.4mm impossible for WIA to validate collet and thoriated operation from all generators. tungsten Therefore, correct operation of welding Trolley Kit...

  • Page 9: Specifications

    3 SPECIFICATIONS 250 15A PLUG 200+ 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 50/60 Hz Generator Single Phase 13KVA 15KVA 15KVA Capacity...
  • Page 10 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 3 SPECIFICATIONS (CONT) 250 15A PLUG 200+ OPERATION Spool Size ES6 – 1kg & 5kg ES6 – 5kg & 15kg ES6 – 5kg & 15kg Supply Plug 15Amp 15Amp 15Amp commissioning...

  • Page 11: Controls - Lcd Interface

    4 LCD INTERFACE PROCESS MIG Steel RETURN VOLTS SELECT WIN642B ARC CONTROL 1 Front Panel Controls 1.5 Return Button Takes menu selection to the previous 1.1 GAS PURGE setting selection. Press and Hold this button to purge the air 1.6 Volts/Arc Control from gas line when changing gas bottle.
  • Page 12 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 2 MIG Welding Modes 2.1.1.1 Shielding Gas The welding machine has 5 different MIG welding modes. Protective Gas MIG Steel 2.1 Preset MIG Material ~5%CO2, ~2%O2+Ar There are 4 modes that are specific for 10~25%CO2+Ar material type.
  • Page 13 2.1.1.3 Wire Wire Size MIG Steel CO2 + Ar MIG Steel CO2 Rotate SELECT knob to required wire size then press to select. 2.1.1.4 Material Thickness Thickness MIG Steel CO2 + Ar 1.0mm Rotate SELECT knob to required material thickness then press to select. Machine will then turn to the weld screen.
  • Page 14 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 2.1.2 Preset MIG Weld Screen Information Voltage Difference 1: Wire Speed Material from recommended 2: Actual Weld Current Thickness 1: Voltage Setting Wire Speed 200A 20.0V 20.0V 2: Actual Difference Weld Volts from recom-...
  • Page 15 2.3.1.2 Latch 4 STEP 2.3.6 Memory Save The current setup of the machine can be When Latch 4 STEPS mode is selected, the operator needs to close the trigger switch stored for later use. This way different jobs momentarily only to commence welding, can be setup and stored and then retrieved and again momentarily to end welding.
  • Page 16 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 3.2 Electrode Polarity 3.5.3 Arc Force Press the SELECT knob to highlight the Arc The first screen is information about the Force. Rotate the SELECT knob to adjust correct Polarity connection.
  • Page 17 4.2 Electrode Size 5 Settings Rotate SELECT knob to the required From the setting menu, general Electrode size 1.6 OR 2.4 then press to machine parameters can be adjusted Select. by rotating the SELECT knob to highlight the parameter. Then press SELECT to activate the adjustment.

  • Page 18: Installation

    Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 5 INSTALLATION With the output limited to 200A, and the Connection to Electrical Mains input to 34.5A. (Based on conventional Power Supply load). Then operation at 10% duty cycle (i.e. 1 minute on, 9 minutes off) will maintain an 200+ effective input current Ieff of 15A.
  • Page 19 Supply Cable Negative Wire If it becomes necessary to replace the Some ‘self-shielded’ flux cored gasless mains flexible supply cable, use only cable consumable wires are operated with the work with correct current rating. piece Positive and the consumable wire Negative.
  • Page 20 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Fitting the Gas Cylinder Feeding the Consumable Wire Place the gas cylinder on the tray at the At the wirefeed assembly, release the rear of the optional welder trolley (if using). compression screw by swivelling it outwards.

  • Page 21: Normal Welding Sequence

    Weld porosity can also be caused by best results when welding mild air entering the gas stream through a steel, we recommend quality WIA damaged hose, loose gas connection, or AUSTMIG ES6. Dirty, rusty or kinked from restriction in the nozzle, such as from wire will not feed smoothly through excess build-up of spatter.
  • Page 22 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Establishing a Weld Setting A “good” weld will have the characteristics illustrated in Figure 4. The weld has Once the consumable wire type, wire size penetrated into the parent metal, fusing and shielding gas have been chosen, the the root of the joint where the two plates two variables that are adjusted in order to...
  • Page 23 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 gasless flux cored wires, the gun is normally Fig 5c Wire Stickout for Gasless Welding positioned as shown in Figure 7b, with the...
  • Page 24 Connection for TIG Welding the electrode diameter by setting the knob For TIG welding, the torch is connected to on the machine front panel. WIA AUSTARC the negative terminal. Figure 9 illustrates electrodes will give the best results. the correct connection of the welding torch To strike the arc, drag the end of the and gas supply.
  • Page 25 TIG Welding Operation LIFT TIG Operation When the Welding mode is set to LIFT TIG Connect the Work Clamp to the work piece. then the arc start can be achieved with the Turn on the power switch located on the following procedure.
  • Page 26 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Duty Cycle The power source is protected by in built over temperature protection devices. These The term duty cycle indicates the percentage will operate if the machine is operated in welding time available at the rated output excess of its current and duty cycle rating.

  • Page 27: General Maintenance

    8 GENERAL MAINTENANCE Welding tip is free of obstructions Before removing the equipment such as spatter build-up. Ream out cover, ENSURE that the equipment the tip bore with a suitable size oxy-tip is disconnected from the mains cleaner. Replace the welding tip as it power supply.

  • Page 28: 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...

  • Page 29: Trouble Shooting Chart

    10 TROUBLE SHOOTING CHART Problem Likely Reason Outcome All Inverter Multi-Process Models No welding current, no The machine is not turned on If confirmed that the machine display. at both the mains supply and is switched on correctly, the machine power switch. test the same outlet using a known serviceable appliance.
  • Page 30 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Problem Likely Reason Outcome MMA/STICK Models In MMAW (Stick), the arc is The technique required The technique to strike should difficult to strike. for VRD enabled welding be reviewed, not as a ‘strike’ machines is not the same as but more as ‘touch, twist, lift’...
  • Page 31 Problem Likely Reason Outcome GMAW/MIG Models (continued) Wire feed stutters and arc Torch consumables are Liners and contact tips are is erratic. Also, motor turns blocked/partially blocked. consumable and wear over correctly under no load. time. Rusty MIG Wire. Replace the torch liner and reduce wire feed tension.

  • Page 32: Service Information

    Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 11 SERVICE INFORMATION The following information is intended for use by qualified service personnel. a 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...

  • Page 33: Circuit Diagram 200

    11.1 CIRCUIT DIAGRAMS – POWER SOURCE 200+ Fig 9 Weldmatic 200+ Circuit Diagram...

  • Page 34: Circuit Diagram 250

    Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 11.2 CIRCUIT DIAGRAMS – POWER SOURCE 250 Fig. 10 Weldmatic 250 Circuit Diagram...

  • Page 35: Power Source 200

    12.1 ASSEMBLY AND PARTS LIST - WELDMATIC 200+ POWER SOURCE Fig. 11 Weldmatic 200+ Power Source...
  • Page 36 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Item # Part # Description M0109 Handle PWA091 Wirefeeder Control Board PWA092 EMC Filter Board E0041 Gas Valve 2.5mm Power Supply Cable E0078 Main Switch M0119 Rear Panel FAN011 PWA093 Main Control Board...

  • Page 37: Power Source 250

    12.2 ASSEMBLY AND PARTS LIST - WELDMATIC 250 POWER SOURCE Fig12 Weldmatic 250 Power Source Assembly...
  • Page 38 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 Item # Part # Description PAN184 Outer Cover PWA080 Wire feeder Control PCB PWA081 Main Control & IGBT Driver PCB PWA088 IGBT SNUBBER PCB D0050 IGBT PWA082 Output Rectifier Board PWA083 Input Rectifier Board PWA084...

  • Page 39: Wirefeeder 200

    12.3 ASSEMBLY AND PARTS LIST - WIREFEEDER 200+ Fig 13 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 0.9//1.2mm, Flux Cored Wire (knurled)

  • Page 40: Wirefeeder 250

    Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 12.4 ASSEMBLY AND PARTS LIST - WIREFEEDER 250 Fig 14 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...

  • Page 41: Gun & Cable

    12.5 ASSEMBLY AND PARTS LIST - GUN AND CABLE ASSEMBLY Fig 15 GUN001 (200 amp) Gun and Cable Assembly Item # Part # Description BE4392 Nozzle, Brass, Tapered see 'TIPS' page 42 Contact Tip BE4335 Gas Diffuser (Head) BE4323 BEQT2-45 Body Tube, 2", 45°...
  • Page 42 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 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.

  • Page 43: Australian Warranty Information

    This warranty covers the Weldmatic power Effective 1st January 2022 source and wirefeeder only, and does not Welding Industries of Australia (WIA) extend to the regulator, gun assembly warrants to the original retail purchaser that or accessories included in the original the Weldmatic welding machine purchased purchase package.
  • Page 44 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 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.

  • Page 45: New Zealand Warranty Information

    WIA Weldmatic MIG & Weldarc MMA Equipment 3 Year Gold Shield Warranty Statement Effective 1st January 2022 WIA Weldmatic MIG & Weldarc Equipment purchased in New Zealand have identical warranty conditions as Australia, with the below conditions: In the event of defects listed in the...
  • Page 46 Weldmatic 200+ & 250 | Operator Manual | Model No CP142-1, CP143-1 NOTES:...
  • Page 47 NOTES:...
  • Page 48 WELDING INDUSTRIES WELDWELL AUSTRALIA NEW ZEALAND A Division of ITW Australia Pty Ltd A Division of ITW New Zealand ABN: 63 004 235 063 NZBN: 9 429 039 833 129 GST NO: 080 177 186 1300 300 884 Email: info@welding.com.au 0800 9353 9355 welding.com.au Email: info@weldwell.co.nz...

This manual is also suitable for:

Weldmatic 250Cp142-1Cp143-1

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