®
CP121-40 Rev B
Weldmatic 150
[internal wirefeeder]
Operators Manual
Weldmatic 150 MIG welder
Model No. CP121-0, Iss B
07/08
Quality • Reliability • Performance
Welding Industries of Australia
An ITW Company
ABN 18 004 547 111
Telephone: 1300 300 884
Facsimile: 1300 301 884
Email: Info@welding.com.au
www.welding.com.au
Weldmatic 150
Model No CP121, Iss B 07/08 1
Contents
Section General Information Page
Safe Practices 2
1 Introduction 5
2 Receiving 5
3 Specifications 6
4 Controls 7
5 Installation 8
6 Normal Welding Sequence 10
7 Basic Welding Information 10
8 General Maintenance 15
9 External Trouble Shooting 16
10 Service Information 18
10.1 PWA-006 Control Board 18
10.2 Circuit Diagram 19
11 Assembly and Parts Lists
11.1 Power Source 20
11.2 Wirefeed assembly 22
11.3 Gun and Cable Assembly 23
12 Warranty information 25
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Operators Manual
Quality • Reliability • Performance
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 150 power source are
intended for carrying the equipment
by hand only.
DO NOT use these handles for
suspending or mounting the power
source in any other manner.
Safe practices when using
welding equipment
These notes are provided in the interests
of improving operator safety. They should
be considered only as a basic guide to Safe
Working Habits. A full list of Standards
pertaining to industry is available from
the Standards Association of Australia,
also various State Electricity Authorities,
Departments of Labour and Industry or
Mines Department and other Local Health
or Safety Inspection Authorities may have
additional requirements. Australian Standard
AS1674.2 provides a comprehensive guide to
safe practices in welding.
Eye protection
NEVER LOOK AT AN ARC WITHOUT
PROTECTION. Wear a helmet with
safety goggles or glasses with side shields
underneath, with appropriate filter lenses
protected by clear cover lens. This is a MUST
for welding, cutting, and chipping to protect
the eyes from radiant energy and flying
metal. Replace the cover lens when broken,
pitted, or spattered.
Recommended shade filter lens
Amps TIG MMAW MIG
Pulsed
MIG
0-100 10 9 10 12-13
100-150 11 10 10 12-13
150-200 12 10-11 11-12 12-13
200-300 13 11 12-13 12-13
300-400 14 12 13 14
400-500 — 13 14 14
500 + — — 14 14
Weldmatic 150
Model No CP121, Iss B 07/08 3
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 cuffless 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
perchlorethylene 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
percholorethylene.
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.
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.
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Operators Manual
Quality • Reliability • Performance
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(includingbuilding
construction) are within 10 metres.
• Combustiblesarefurtherthan10metres
but can be ignited by sparks.
• Openings(concealedorvisible)inoors
or walls within 10 metres may expose
combustibles to sparks.
• Combustiblesadjacenttowalls,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.
Weldmatic 150
Model No CP121, Iss B 07/08 5
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 150 has been designed to
be used with consumable wires in the range
from 0.6mm to 1.2mm 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.
The Weldmatic 150 wirefeeder has been
designed to feed a range of hard, soft, and
flux-cored wires for the G.M.A.W. process.
A compact motor with integral gear box is
coupled to a two roll drive assembly forming
the basic component of the wirefeeder. The
motor is controlled by an electronic speed
control which provides speed regulation.
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.
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Operators Manual
Quality • Reliability • Performance
3 Specifications
Manufactured to Australian Standard
AS60974.1.
Primary Voltage
240 Vac, 50/60 Hz
Rated Primary Current
12 Amps
Maximum Primary Current
28 Amps
Recommended Generator kVA
6.7 kVA
Rated Output @ 40oC
Duty cycle based on 10 minute cycle time
150 Amp, 21.5 V, 20% duty
67 Amp, 18 V, 100% duty
Welding Current
35 - 150 Amps
Open Circuit Voltage
19 - 40 V
Shipping weight
38 kg
Mains Circuit Breaker Rating
16 Amps
Supply plug
15 Amp
Fitted Supply Cable
30/0.25 Three Core, Heavy Duty PVC
Cooling
Fan cooled, air drawn in through rear grille.
Insulation
Class H, 140°C Rise
Spool Sizes
1 kg, 5 kg
Wirespeed Range
0 - 160 RPM (0 - 15 Metres per min.)
Wire Size Range
0.6mm - 0.9mm diameter (solid wire)
0.8mm - 1.2mm diameter (cored wire)
If the supply cable is damaged it must
be replaced by the manufacturer, their
service agent or a similarly qualified
person.
Weldmatic 150
Model No CP121, Iss B 07/08 7
Fig 1 Power Source Controls
2
1
1 Wire Speed Control
This control provides adjustment of the
wirefeed speed. Rotating the dial in a
clockwise direction will increase the wirefeed
speed, thereby increasing the welding
current.
Refer to the Weld Setting Chart in Section
7 of this manual for information on setting
these controls to obtain the intended
welding current. This chart is also located
inside the wire-spool enclosure cover
2 Euro Gun/Cable Connector.
3 Coarse Voltage Control
This switch provides Coarse adjustment
of the output welding voltage over three
ranges.
4 Over Temprature Indicator
Lights up if the unit over heats
5 Fine Voltage Control
This switch provides Fine adjustment of the
output welding voltage over three ranges.
Note: Minimum welding voltage is obtained
with Coarse A and Fine 1 selected. Maximum
welding voltage is obtained with Coarse C
and Fine 3 selected.
3
4
6
5
8
7
4 Controls
Do not operate the Voltage Control
switches during welding
6 Standby/Operate Switch
7 Positive Welding Output Terminal
8 Negative Welding Output Terminal
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Quality • Reliability • Performance
Fig 2 Positive Wire
Fig 3 Negative Wire
To work clamp
To gun cable
5 Installation
Connection to Electrical Mains Power
Supply
The Weldmatic 150 is factory fitted with a
3 metre, 3 core 30/0.25 Heavy Duty PVC
mains power supply cable with moulded 3
pin, 15 Amp, Single Phase plug.
A 15 Amp plug and socket is recognisable by
a wide Earth pin. Power Supply authorities
require that equipment fitted with a 15 Amp
plug shall ONLY be connected to a 240 Volt,
15 Amp power point. DO NOT modify the
plug.
The minimum capacity of the mains wiring
and power outlet supplying a welder is
selected according to the effective primary
current of the equipment. The effective
primary current for the Weldmatic 150 is 12
Amps.
The minimum recommended mains circuit
breaker rating for a Weldmatic 150 is 16
Amps.
Note : Due to normal variations of sensitivity,
the tripping time of some 16A circuit
breakers may limit the duty cycle available
from the Weldmatic 150. A higher rated
circuit breaker can be selected, but the mains
wiring capacity must be rated 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.
Output Voltage Polarity
The design of the Weldmatic 150 allows
selection of the output voltage polarity.
To work clamp
To gun cable
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 the ‘WELDING’
lead from the power source into the (+)
socket, as in Figure 2.
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 the
‘WORK’ lead plug into the (+) output socket
on the Power Source, and the ‘WELDING’
lead from the power source into the (-)
socket, as in Figure 3.
Weldmatic 150
Model No CP121, Iss B 07/08 9
The quality of the consumable wire
greatly affects how reliably a gas
metal arc welder will operate. For best
results when welding mild steel, we
recommend quality WIA AUSTMIG ES6.
Dirty, rusty or kinked wire will not feed
smoothly through the gun cable and
will cause erratic welding. Deposits from
the wire will clog the gun cable liner
requiring it to be replaced prematurely.
Fitting the gas cylinder
Place the gas cylinder on the tray at the
rear of the optional welder trolley (if using).
Retain the cylinder with the chain provided.
Fit the gas regulator to the cylinder. DO NOT
apply grease or oil to these joints.
Fit the end of the gas inlet hose from the
back of the power source to the connector
supplied with the gas regulator, and secure
with the clamp also supplied.
Fitting The Gun and Cable Assembly
The supplied gun/cable assembly is equipped
with a ‘Euro’ wirefeeder connector which
incorporates all required connection points
for welding current, shielding gas and gun
switch control.
To attach the gun/cable assembly to
the wirefeeder mechanism, engage the
mating parts of the male and female Euro
connectors, then rotate the locking ring
clockwise to firmly secure the connection.
Fitting the Consumable Wire
the adjustment of the spool adjuster, which
should be set to prevent over run of the wire
spool at the end of a weld, without unduly
loading the wirefeed motor.
1 kg Spools
Remove the adjustor knob, spring, washer
and 5 kg spool holder. Leave the 5 kg spool
holder in a safe place (ie inside the welder).
Fit the 1kg wire spool directly onto the spool
axle. Fit the washer, spring and adjustor knob
and tighten the adjustor knob fully.
Compression screw
Top roller arm
Groove size
Feeding the Consumable Wire
At the wirefeed assembly, release the
compression screw by swivelling it outwards.
This allows the top roller arm to spring to the
open position. The end of the welding wire
can now be passed through the inlet guide,
over the bottom driven roller, and into the
output wire guide tube. Check that the drive
roll groove is correct for the wire in use. The
appropriate size is stamped on the visible
side of the installed roller. Check also that
the correct size contact tip is fitted at the gun
end. Feed roller and tip details are shown in
Section 11 of this manual.
Return the top roller arm to the closed
position and adjust the compression screw to
provide sufficient clamping of the drive roll
to achieve constant wirefeed. Do not over
tighten.
With the equipment energised, operate the
gun switch to feed wire through the gun
cable.
5 kg Spools
Place the spool of welding wire onto the
spool holder. The location pin should mate
with a hole provided on the wire spool body.
Fit the spool retaining ‘R’ clip supplied. Check
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Operators Manual
Quality • Reliability • Performance
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 150 are:
• MildSteel Argon+
5 to 25% Carbon
Dioxide;
• Aluminium Argon;
• StainlessSteel Argon+1to2%
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.
6 Normal Welding Sequence
Weld Start
Closing the welding gun switch initiates this
sequence of events:
• Thegasvalveisenergisedandgasow
commences;
• Thepowersourcecontactorisinitiated.
Welding voltage is applied between the
work piece and the consumable wire.
• Thewiredrivemotorisenergised.
• Thewiretouchestheworkpiece,andthe
arc is established.
Weld End
Releasing the gun switch initiates this
sequence of events:
• Thewiredrivemotorisde-energised,and
is dynamically braked to a stop;
• Theweldingtransformorisde-energised
and welding current stops.
• Thegasvalveisde-energisedandthe
flow of shielding gas ceases.
Weldmatic 150
Model No CP121, Iss B 07/08 11
Weldmatic 150
Settings Chart
Fig 4 Weld Setting Charts
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Operators Manual
Quality • Reliability • Performance
Weldmatic 150
Settings Chart (cont)
Fig 4 Weld Setting Charts
Weldmatic 150
Model No CP121, Iss B 07/08 13
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;
• Wirefeedspeed,
• Weldingarcvoltage.
The Weld Setting Charts in Figure 4 can be
used to preset the machine for an approximate
welding current. For each of the combinations
of voltage control switch settings, there is a
range of valid wirespeed settings.
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 5. 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 6. 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 5 “Good” Weld
Fig 6 “Bad” Weld
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
positioned as shown in Figure 7b below,
with the nozzle end pointing away from the
direction of travel, referred to as ‘dragging’
the weld. Gasless flux cored wires should be
14
Operators Manual
Quality • Reliability • Performance
operated with approximately 15mm of wire
‘stick-out’ from the welding contact tip as
shown in Figure 7c.
Fig 7a Gas Shielded Solid Wires
Fig 7b Gasless Flux Cored Wires
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 150 is rated 150 Amps, 20%
duty cycle. If the machine is operated at a
reduced welding current, a higher duty cycle
is available. The diagram below illustrates the
appropriate duty cycle rating for the range of
welding currents available from the 150, and
so allows the maximum welding time per 10
minute period to be determined.
The power source is protected by in built
over temperature protection devices. These
will operate if the machine is operated in
excess of its current and duty cycle rating. If
this occurs, the fan will continue to run, but
the machine will not deliver welding current
until the unit has cooled sufficiently.
Fig 8 Duty Cycle Rating
Fig 7c Wire Stickout for Gasless Welding
Weldmatic 150
Model No CP121, Iss B 07/08 15
Before removing the equipment
cover, ENSURE that the equipment
is disconnected from the mains
power supply. When the equipment
is energised LETHAL VOLTAGES are
present on the electrical components
enclosed.
Dust
Care should be taken to prevent excessive
build-up of dust and dirt within the welding
power source. It is recommended that at
regular intervals, according to the prevailing
conditions, the equipment covers be removed
and any accumulated dust be removed by the
use of dry, low pressure compressed air, or a
vacuum cleaner.
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 that the:
1 Feed rolls are the correct size and type for
the wire in use. Check also that the drive
groove is aligned with the wire (refer
page 9), and that the groove is not worn;
2 Gun cable liner is clear of dust and swarf
build-up. When replacement becomes
necessary, fit only the correct liner (see
page 24). The build-up of dust can be
minimised by regular purging of the liner
with dry compressed air. This may be
conveniently done each time the wire
spool is replaced;
3 Welding tip is free of obstructions such
as spatter build-up. Ream out the tip
bore with a suitable size oxy-tip cleaner.
Replace the welding tip as it becomes
worn;
4 Feed roll pressure is not excessive. The
pressure should be just sufficient to feed
the wire evenly. Excessive pressure will
deform the electrode wire and make
feeding more difficult;
5 Consumable wire spool holder rotates
smoothly and that the braking action is
not excessive. The spool should only have
sufficient braking to prevent over run
when the motor stops. This also may be
conveniently checked each time the wire
is replenished;
7 Welding wire is straight and free of
buckles or ‘waviness’. To check, remove
2 or 3 metres of wire from the spool.
Clamp one end in a vice or similar, then
holding the other end pull the wire out
straight. Look down the length of the
wire, any buckles will be obvious. Buckled
wire is extremely difficult to feed reliably
and should be replaced;
8 Welding wire is free of surface rust.
Replace if rust is evident.
8 General Maintenance
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Operators Manual
Quality • Reliability • Performance
If 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.
9 External Trouble Shooting
Power source has no output and no
wirefeed when gun switch is closed :
‘OPERATE’ switch is not illuminated
1 Check equipment is connected to a
functional mains power outlet. Test outlet
using a known working appliance.
‘OPERATE’ switch is illuminated
1 The gun switch circuit may be incomplete.
• Checkthegunswitchforcontinuity
with an ohm meter when the switch
is pressed. Replace if faulty
• Checkthe2pinreceptaclesinEuro
adaptor are making contact with the
mating pins from the gun Euro end.
2 Power source may have overheated.
• TheWeldmatic150weldingpower
source incorporates an in-built
over-temperature thermostat which
will trip if the welding load exceeds
the operating duty cycle. The
‘OVERLOAD’ light will be illuminated
when the gun switch is on. The
thermostat will reset automatically
- do not switch the equipment off
as the cooling fan will assist the
resetting of the thermostat
• Ifproblempersistsafterthecooldown
period, call your WIA service agent.
9 External Trouble Shooting
Power source has low weld output
1 Check all electrical connections in the
welding current circuit, including weld
cable, work clamp and gun/cable assembly.
Circuit breaker trips during welding
1 Check the rating of the mains supply
circuit breaker. The Weldmatic 150
should be supplied from a 16 Amp or
larger circuit breaker.
Unsatisfactory Welding Performance
and Results
Erratic arc characteristics caused by poor
wirefeed
Erratic wirefeed is the MOST LIKELY cause of
failure in all Gas Metal Arc Welding. It should
therefore be the first point checked when
problems occur.
1 Refer to the points in ‘Wirefeed’ in
Section 8
2 Check if the consumable wire is slipping
in the drive rolls. Replace the feed roll if
it is the incorrect size or is worn
3 Check that gun cable liner is not too
short and is fitted correctly. Refer to
page 24 for fitting instructions.
Constant poor arc characteristics
Check that the:
1 Correct polarity has been selected for
work and weld cables (refer page 8)
2 Shielding gas is correct for the
consumable wire in use (refer page 10)
3 Welding circuit is making good electrical
connection. Ensure that the work clamp
is securely tightened onto the work piece
so that good electrical contact is achieved
Weldmatic 150
Model No CP121, Iss B 07/08 17
4 All connections in the external welding
circuit are clean and tight. Problems may
show as hot spots
5 Work piece surface is not contaminated.
Water, oil, grease, galvanising, paint,
or oxide layers can severely disturb the
welding arc and result in a poor weld.
Porosity in weld caused by lack of
shielding gas
1 Check that the correct gas flow rate has
been set (refer page 10)
2 Check for leaks in the gas hose. Replace
if leaking
3 Check for leaks in gun/cable assembly,
eg. fractured gas hose, broken or missing
‘O’ rings. Replace as required
4 Check the gun nozzle is free from spatter
and is firmly attached to the welding gun
to ensure that no air is being drawn into
the shielded area.
18
Operators Manual
Quality • Reliability • Performance
Before removing the equipment
cover, ENSURE that the equipment
is disconnected from the mains
power supply. When the equipment
is energised LETHAL VOLTAGES are
present on the electrical components
enclosed.
10.1 PWA006 Control Board
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.
10 Service Information
Fig 9 PWA006 Control Board
Weldmatic 150
Model No CP121, Iss B 07/08 19
10.2 Circuit Diagram
Fig 10 Weldmatic 150 Circuit Diagram
20
Operators Manual
Quality • Reliability • Performance
13
24
23
26
25
22
19
10
15
17
11
8
16
27
21
20
12
Fig 11 Weldmatic 150 Power Source Assembly
9
1
6
14
5
4
7
28
18
2
3
11.1 Assembly and Parts List - Weldmatic 150 Power Source
Weldmatic 150
Model No CP121, Iss B 07/08 21
Item # Part # Description Qty
1 W29-1/20 Slam Action Catch 1
2 PAN072 Side Door 1
3 WF001-6 Euro Surround, Plastic 1
4 W41-0/1 Hinge Set Left Hand 1
5 W41-0/2 Hinge Set Right Hand 1
6 MZ208015 Handle Assembly 2
7 PAN073 Side/Top Cover 2
8 CP110-10/1N Rotary Switch (including knob and dust cover) 1
9 LST021 Label Set Complete 1
10 SA140-0/2 Socket, Dinse 2
11 WGEC3 Plug, Dinse 1
12 CABW10 Welding Cable 10mm
2
1
13 M0029 Adjusting Knob, Large 2
14 E0042 On/Off Switch 1
15 AM321 1/5 kg Spool Holder Assembly 1
16 AM133-3 Rclip (included in AM321) 1
17 WF023 Wirefeed Assembly 1
18 SUB021 Snubber 2
19 PWA006N Wirefeed Control PCB Assembly 1
20 CP104-0/2 Rectifier 1
CP3-9/8 Thermostat (included in rectifier) 1
21 62513 Blue Oxy Single Gas Hose, 5 metre 1
22 E0041 Gas valve 24 vdc 1
23 E0044 Relay 1
24 FAN006 Fan Assembly 1
25 CP101-0/17 Fan Finger Guard 1
26 HF200-1/15 Plastic Foot 1
27 TFM041N Welding Transformer/Inductance Assembly, Wired 1
CP104-16/2 Thermostat (included in transformer) 1
28 WGWC1 Work Clamp 4
Not shown REG001 Argon Regulator 1
Not shown GUN001 200A Gun/Cable Assembly, 3 metre, Euro Connect 1
22
Operators Manual
Quality • Reliability • Performance
Fig 12 Wirefeed Assembly
Item # Part # Description
2 W26-0/8 0.6 + 0.8mm, Solid Wire
2 W26-8/8 0.8 + 0.9mm, Solid Wire
2 W26-7/8 1.0/1.2mm, Flux Cored Wire (knurled)
2 W26-9/8 0.9/1.2mm, Flux Cored Wire (knurled)
2 W26-3/8 1.0/1.2mm, Aluminium
Item # Part # Description Qty
1 W27-0/9 Retaining Screw 1
Feed Rolls
1
2
11.2 Assembly and Parts List - Wirefeeder
Weldmatic 150
Model No CP121, Iss B 07/08 23
Fig 13 GUN001 (200 amp) Gun and Cable Assembly
Item # Part # Description
1 BE4392 Nozzle, Brass, Tapered
2 see ‘Tips’ page 24 Contact Tip
3 BE4335 Gas Diffuser (Head)
4 BE4323 Cap
5 BEQT2-45
BEQT2-30
Body Tube, 2”, 45
o
(supplied)
Body Tube, 2”, 30
o
6 GUN002 Handle Kit (includes both halves, screws & trigger)
7 BE43115
BE43115X
Steel Liner 0.9 - 1.2mm
Nylon Liner 0.9 - 1.2mm
1
2
3
4
5
6
7
11.3 Assembly and Parts List - Gun and Cable Assembly
24
Operators Manual
Quality • Reliability • Performance
Cut Here
Compress Liner
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.
At the gun end, compress the liner within
the gun cable, then cut it one contact tip
length past the end of the body tube (5).
Refit head, tip and nozzle.
Fig 6 Replacing the gun cable liner
Wire diameter Short series (25mm)
0.6mm BE7497
0.8mm BE7488
0.9mm BE7489
1.0mm BE7496
1.2mm BE7490
Tips
20mm
Weldmatic 150
Model No CP121, Iss B 07/08 25
12 Warranty Information
WIA Gold Shield 3 Year Warranty
Effective 1st March 2005
At WIA, we are serious about product
quality.
Every new Weldmatic and Weldarc
machine comes fully backed by the WIA
‘Gold Shield 3 Year Warranty’, covering
parts and workmanship, so you can be
guaranteed you’re buying reliability and
performance.
This limited warranty supersedes all previous
WIA (Welding Industries of Australia)
warranties and is exclusive with no other
guarantees or warranties expressed or
implied.
Limited Warranty
Subject to the terms and conditions below, WIA
warrants to its original retail purchaser that new
WIA equipment sold after the effective date of
this limited warranty is free of defects in material
and workmanship at the time it is shipped by
WIA.
THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below,
WIA will repair or replace any warranted
parts or components that fail due to such
defects in material or workmanship. WIA
must be notified in writing within thirty (30)
days of such defect or failure, at which time
WIA will provide instructions on the warranty
claim procedures to be followed.
WIA shall honour warranty claims on
warranted equipment in the event of such a
failure within the warranty time periods. All
warranty time periods start on the date that
the equipment was delivered to the original
retail purchaser, or 18 months after the
equipment date of manufacture, whichever
is the earlier.
Parts and workmanship on Weldarc
and Weldmatic equipment are covered
for a period of 3 years (except for gas
regulator, gun cable and consumables
listed below.)
Items replaced under original warranty are
warranted for the remainder of the original
equipment warranty, or for a period of ninety
(90) days, whichever is the greater.
Gas regulator and gun/cable assembly are
warranted for 90 days.
WIA’s Limited Warranty shall not apply to:
1 Consumable components; such as
contact tips, cutting nozzles, contactors,
brushes, relays or parts that fail due to
normal wear.
2 Equipment that has been modified by any
party other than WIA, or equipment that
has been improperly installed, improperly
operated or misused based upon
industry standards, or equipment which
has not had reasonable and necessary
maintenance, or equipment which has
been used for operation outside of the
specifications for the equipment.
WIA PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAL /
INDUSTRIAL USERS AND PERSONS TRAINED
AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered
by this warranty, the exclusive remedies
shall be, at WIA’s option: (1) repair; or
26
Operators Manual
Quality • Reliability • Performance
(2) replacement; or, where authorised in
writing by WIA in appropriate cases, (3) the
reasonable cost of repair or replacement
by an authorised WIA service agent; or (4)
payment of or credit for the purchase price
(less reasonable depreciation based upon
actual use) upon return of the goods at
customer’s risk and expense.
WIA’s option of repair or replacement will be
F. O. B. Factory at Melrose Park, Adelaide,
or F. O. B. at a WIA authorised service
facility as determined by WIA. Therefore
no compensation or reimbursement for
transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE
REMEDIES PROVIDED HEREIN ARE THE SOLE
AND EXCLUSIVE REMEDIES. IN NO EVENT
SHALL WIA BE LIABLE FOR DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED
HEREIN AND ANY IMPLIED WARRANTY,
GUARANTEE OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT TORT OR ANY
OTHER
LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE
OR COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY WIA IS
EXCLUDED AND DISCLAIMED BY WIA.
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