®
CP137-40 Rev A
Weldmatic 200i
[internal wirefeeder]
Operators Manual
Weldmatic 200i MIG, Arc/TIG welder
Model No. CP137-2, Iss A
02/15
Welding Industries of Australia
A division of ITW Australia Pty Ltd
1300 300 884
Info@welding.com.au
welding.com.au
Weldmatic 200i
Model No CP137, Iss A 02/15 1
Contents
Section General Information Page
Safe Practices 2
1 Introduction 5
2 Receiving 6
3 Specifications 7
4 Controls 8
5 Installation 10
6 Normal Welding Sequence 12
7 Basic Welding Information 12
8 General Maintenance 20
9 External Trouble Shooting 21
10 Service Information 22
10.1 Circuit Diagram 23
11 Assembly and Parts Lists
11.1 Power Source 24
11.2 Wirefeed assembly 26
11.3 Gun and Cable Assembly 27
12 Warranty information 29
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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 200i 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 200i
Model No CP137, Iss A 02/15 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-toed 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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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.
Weldmatic 200i
Model No CP137, Iss A 02/15 5
1 Introduction
The Weldmatic 200i is a multiprocess
welding machine capable of Gas Metal Arc
Welding (GMAW or MIG), Manual Metal Arc
Welding (MMAW or Stick) and Gas Tungsten
Arc Welding (GTAW or TIG).
GMAW (MIG Welding)
Gas Metal Arc Welding (GMAW) 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 200i has been designed to
be used with consumable wires in the range
from 0.6mm to 0.9mm 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 GMAW 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 GMAW using the correct consumable
wire and shielding gas.
The Weldmatic 200i wirefeeder has been
designed to feed a range of hard, soft, and
flux-cored wires for the GMAW 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.
MMAW (Stick Welding)
Manual Metal Arc Welding (MMAW) is a
process where an arc is struck between a
flux-coated consumable electrode and the
work piece. The arc and the weld pool are
both shielded by gases generated by the flux
coating of the electrode.
The Weldmatic 200i has been designed to
be used with 2.0mm, 2.5mm, 3.2mm and
4.0mm diameter electrodes. The smaller
electrodes are used when welding at lower
currents, such as sheet metal applications.
Increasing the electrode diameter permits
higher welding currents to be selected.
WIA supplies a wide range of mild steel and
special purpose electrodes which cater for home
workshop, rural, and industrial requirements.
Some popular AUSTARC electrodes are listed
below. The correctly selected AUSTARC
electrode will influence the quality of the weld,
and the stability of the arc.
Austarc 12P, Classification E4313-A
A popular general purpose electrode used
with ease in all positions, vertical up or
down. The smooth forceful arc makes it
an ideal electrode for all general mild steel
applications.
Austarc 13S, Classification E4313-A
A smooth running electrode with a soft arc,
particularly suited to light sheetmetal and
smooth mitre fillet welds.
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Austarc 16TC, Classification E4916-A
A low hydrogen electrode with good
arc stability and out-of-position welding
characteristics. This electrode is ideal for
medium carbon steels, or steels of unknown
analysis.
Austarc 11, Classification E4311-A
A high cellulose electrode for all positional
welding, AC or DC. Particularly suited for
vertical and incline pipe welding where
complete root penetration is required.
Unicord 312, Classification ES312-16
A high tensile (50tsi), chromium nickel
electrode specially formulated for joining all
alloy steels and irons, and for tool and die
maintenance.
GTAW (TIG Welding)
Gas Tungsten Arc Welding (GTAW) is a
welding process where the arc is struck
between a non-consumable tungsten
electrode and the work piece. A ceramic
nozzle surrounds the tungsten electrode and
directs a flow of inert gas, usually Argon, over
the electrode and the weld zone. If filler metal
is required, it is hand fed into the welding arc.
The DC current output of the Weldmatic 200i
is suitable for welding most ferrous and
non-ferrous metals, but is not suitable for
welding Aluminium for which an AC machine
is required.
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 200i package contains;
• Weldmatic 200i Power Source
• Euro MIG Gun and Cable Assembly
• Twist-lock Electrode Holder
• Work Clamp 3m
• Drive Roll 0.6/0.8 V Groove
• Drive Roll 0.9/1.2 Knurled
• Sample wire 0.8 ES6
• Tips 0.6, 0.8, 0.9
• Argon Flow Gauge Regulator REG003
• (This) Operating Manual CP137-40.
Optionally available
• TIG Torch Complete WP17V121625
with valve, 3m cable with twist-lock
connection and fitted with 2.4mm collet
and thoriated tungsten.
Weldmatic 200i
Model No CP137, Iss A 02/15 7
3 Specifications
Manufactured to Australian Standard
AS60974.6.
Primary Voltage
240 Vac, 50/60 Hz
Rated Primary Current (I eff)
14 Amps
Maximum Primary Current (I max)
36 Amps
Recommended Generator kVA
10 kVA
Rated Output @ 40
o
C
Duty cycle based on 10 minute cycle time
MIG
200 Amp, 24 V, 15% duty
77 Amp, 17.9 V, 100% duty
Stick
170 Amp, 26.8 V, 15% duty
66 Amp, 22.6 V, 100% duty
TIG
200 Amp, 18 V, 15% duty
77 Amp, 13.1 V, 100% duty
Welding Current
30 - 200 Amps
Open Circuit Voltage
71 V
VRD 13.5 V
Shipping weight
19 kg - Includes leads
13 kg - Power Source only
Mains Circuit Breaker Rating
25 Amps
Supply plug
15 Amp
Fitted Supply Cable
2.5 mm
2
Three Core, Heavy Duty PVC
Cooling
Fan cooled, air drawn in through front 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.
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WIN540D
AMP S
VOLTS
ARC
FORCE
ARC
CONTROL
GASLESS
0.8/0.9/1.2 mm
Fig 1 Weldmatic 200i Controls
2
1 Control Panel
2 Euro Gun/Cable Connector
3 Positive Welding Output Terminal
4 Negative Welding Output Terminal
5 Polarity Selection Cable
6 m/min Indicator
When this light is on the Digital Display
(12) is indicating the selected wire speed in
metres per minute (MIG Mode).
7 Amps Indicator
When this light is on the Digital Display (12)
is indicating the selected Amps (Stick or TIG
Mode).
8 Power On Indicator
9 Over Temperature Indicator
This light is on if the machine overheats
or mains voltage os too high or low – the
machine will prevent weld output until the
machine has cooled down or mains voltage
returns to normal. Welding output can then
recommence.
10 VRD Safe Indicator
This light is on when the machine is in Stick
Mode (MMAW) and the output voltage is
reduced to a safe level.
11 Weld Current & Wire Speed
Adjustment Control/ Inch Button
Stick Mode (MMAW): This control sets the
Weld Current level.
MIG Mode (GMAW): This control sets Wire
Speed.
4 Controls
109 11
12 13 14
8
7
6 15
16 17 18
1945
3
1
Weldmatic 200i
Model No CP137, Iss A 02/15 9
12 Digital Display – Amps or m/min
During welding actual welding Amps will be
displayed and then held for 30 seconds after
the end of the weld.
Stick Mode (MMAW) or TIG Mode (GTAW):
The Amps Indicator (7) light will be on and the
selected welding Amps will be displayed when
adjusted with Weld Current & Wire Speed
Adjustment Control (11).
MIG Mode (GMAW): The m/min Indicator
light (6) will be on and the wire speed in
metres per minute (m/min) will be displayed
when adjusted with Weld Current & Wire
Speed Adjustment Control (11).
13 Voltage Adjustment Control/
Purge Button
Stick Mode: Adjusts Arc Force (0-10). When
the welding machine detects a sudden drop
in the weld arc voltage, the machine will
compensate momentarily by increasing the
weld current and weld voltage. A higher arc
force might be useful for difficult electrodes
such as Cellulose.
MIG Mode: Adjusts weld volts.
Purge: Press to open the gas solenoid valve
without energising the welding power source.
14 Digital Display – Volts
During welding actual welding Volts will be
displayed and then held for 30 seconds after
the end of the weld.
Stick Mode: The amount of Arc Force (0-10)
will be displayed.
MIG Mode: Weld Volts will be displayed when
adjusted with Voltage Adjustment Control (13).
15 Arc Control
When in MIG (GMAW) mode the harshness
of the arc can be adjusted.
For example aluminium welding would
require a different setting to steel welding.
16 Mode Selection Button
Press this button to step between modes.
A mode is selected when the light is on.
There are three weld modes available:
• Stick Electrode Welding (MMAW)
• TIG Welding (GTAW): Lift arc start, using
TIG welding torch with separate gas supply.
• MIG Welding (GMAW)
Using MIG welding torch and gasshielded or gasless welding wire.
17 Latch Select Button and Indicator
Press this button to select and deselect
Latch Mode. When Latch Mode is selected,
the operator needs to close the gun switch
momentarily to commence welding, and
again momentarily to end welding. This can
help to reduce operator fatigue during long
welding runs.
18 Gas Select Button and Indicator
Press to select which type of gas is being
used, or if gasless wire is being used. See
page 12 for information on selecting the
shielding gas.
19 Wire Select Button and Indicator
Press to select the wire size being used. Sizes
0.6, 0.8mm or 0.9mm can be used.
When Gas setting is set to Gasless then there
is no need to select wire size. Sizes 0.8mm,
0.9mm or 1.2mm can be used.
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5 Installation
Connection to Electrical Mains Power
Supply
The Weldmatic 200i is factory fitted with a
3 metre, 3 core 2.5mm2 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 200i is
14 Amps.
The minimum recommended mains circuit
breaker rating for a Weldmatic 200i is
20 Amps. Note : Due to normal variations
of sensitivity, the tripping time of some
20 Amp circuit breakers may limit the duty
cycle available from the Weldmatic 200i.
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.
The replacement cable must be fitted and
retained in the same manner as the original.
Output Voltage Polarity
The design of the Weldmatic 200i allows
selection of the output voltage polarity.
Positive Wire
MIG welding (GMAW), with solid
consumable wires and gas shielding, 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 terminal
on the power source, and the Polarity
Selection Cable from the power source into
the (+) output terminal, as in Figure 2.
Negative Wire
Some ‘self-shielded’ flux cored gasless
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
terminal on the power source, and the
Polarity Selection Cable from the power
source into the (-) output terminal, as in
Figure 3.
Fig 2 Positive Wire
Work clamp
Gun cable
(-) output
terminal
(+) output
terminal
Polarity selection cable
Weldmatic 200i
Model No CP137, Iss A 02/15 11
Fig 3 Negative Wire
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
Remove the spool holder knob, spring and
flange. Fit the spool of welding wire. Refit
the spool holder knob, spring and flange.
Check 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.
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. Holding the trigger for 5 seconds
without welding will allow wire to feed at
maximum speed.
Compression screw
Top roller arm
Groove
size
(-) output
terminal
(+) output
terminal
Work
clamp
Gun
cable
Polarity
selection cable
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7 Basic Welding Information
MIG Welding (GMAW)
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 200i are:
• Mild Steel Argon + 18% Oxygen ;
Argon + 2% Oxygen +
5% Carbon dioxide;
• Aluminium Argon;
• Stainless Steel Argon + 1 to 2%
Oxygen.
Consult your gas supplier if more specific
information is required.
Shielding Gas Flow Rate
In GMAW, one function of the shielding gas
is to protect the moulten 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:
• The gas valve is energised and gas flow
commences;
• 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;
• The welding current stops.
• The gas valve is de-energised and the
flow of shielding gas ceases.
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.
Weldmatic 200i
Model No CP137, Iss A 02/15 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;
• Wirefeed speed,
• Welding arc voltage.
The Weld Settings Chart in Figures 6a, 6b,
and 6c can be used to preset the machine
for an approximate welding current. For any
voltage control 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.
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
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Weldmatic 200i Settings Chart
Fig 6a Weld Settings Chart
Suggested Settings for Fillet Weld Mild Steel – Gasless Wire
Wire type
• Gasless / Flux Cored
• Negative Polarity
• 4.5kg Spool
• Knurled Drive Roll
• Arc Control 1
Material
Thickness
Wire Size
0.8mm 0.9mm 1.2mm
Wirefeed Volts Wirefeed Volts Wirefeed Volts
8mm
5.5 25.0
5mm
5.9 20.0 7.4 24.0 5.0 25.0
3mm
5.6 18.5 5.6 21.0 5.6 18.4
1.6mm
4.0 14.0 2.6 14.0 2.0 14.5
1.2mm
3.0 13.5 2.4 13.0
0.8mm
2.0 13.0
Weldmatic 200i
Model No CP137, Iss A 02/15 15
Weldmatic 200i Settings Chart (cont)
Suggested Settings for Fillet Weld Mild Steel – Solid Wire
Wire type
• Carbon Steel ES6
• Positive Polarity
• 5kg Spool
• Gas: Ar + 5% CO
2
+ 2% O
2
• Arc Control 5
Material
Thickness
Wire Size
0.6mm 0.8mm 0.9mm
Wirefeed Volts Wirefeed Volts Wirefeed Volts
8mm
10.5 24.5
5mm
11.5 24.0 9.0 22.5
3mm
11.0 22.0 7.0 20.0 5.6 19.5
1.6mm
6.0 18.0 4.0 17.0 3.7 17.5
1.2mm
5.0 17.0 3.8 16.5 3.0 16.2
0.8mm
4.0 16.0 3.0 16.0
Fig 6b Weld Settings Chart
16
Operators Manual
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Fig 6c Weld Settings Chart
Weldmatic 200i Settings Chart (cont)
Suggested Settings for Fillet Weld Mild Steel – Solid Wire
Wire type
• Carbon Steel ES6
• Positive Polarity
• 5kg Spool
• Gas: Ar + 18% CO
2
• Arc Control 5
Material
Thickness
Wire Size
0.6mm 0.8mm 0.9mm
Wirefeed Volts Wirefeed Volts Wirefeed Volts
8mm
10.0 24.0
5mm
10.5 24.0 9.0 21.0
3mm
13.0 25.0 6.5 19.5 5.5 19.5
1.6mm
7.0 18.5 4.5 17.5 3.7 17.5
1.2mm
5.0 17.0 3.5 16.5 3.0 16.5
0.8mm
4.0 16.5 2.8 16.2
Weldmatic 200i
Model No CP137, Iss A 02/15 17
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, with the
nozzle end pointing away from the direction
of travel, referred to as ‘dragging’ the weld.
Gasless flux cored wires should be operated
with approximately 10-15mm of wire ‘stickout’ from the welding contact tip as shown
in Figure 7c.
10-
Fig 7a Gas Shielded Solid Wires
Fig 7b Gasless Flux Cored Wires
Fig 7c Wire Stickout for Gasless Welding
Stick Welding (MMAW)
Connection for Stick Welding
It is important to select the electrode polarity
in accordance with the manufacturers
recommendations for that electrode. Most
common electrodes, including cellulose
types, are operated with the electrode at
positive polarity, as illustrated in Figure 8.
Fig 8 Connections for stick welding (MMAW),
electrode pawositive
Work clampTo electrode holder
(-) output
terminal
(+) output
terminal
18
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Stick Welding Operation
Be certain that you are wearing suitable
protective clothing, gloves etc and that you
are working in a non-hazardous area. If
necessary, refer again to Section 1 - Safe
Practices in this manual.
Connect the work clamp to the work piece.
Place the desired electrode in the electrode
holder.
Turn on the power switch located on the rear
panel. Wait approximately 5 seconds as the
unit goes through its initiation sequence.
Press the Weld Mode button until the Stick
Mode light is on.
Select an appropriate welding current for
the electrode diameter by setting the knob
on the machine front panel. WIA AUSTARC
electrodes will give the best results.
To strike the arc, drag the end of the
electrode along the work piece as if striking
a match. As the arc initiates, lift the electrode
slightly away, aiming to establish an arc
length of approximately 3 mm.
As the electrode end is consumed, feed the
electrode into the arc in order to maintain
arc length. As a general rule, the arc should
be held as short as possible while still giving
stable burn off and good weld appearance.
An arc which is too long cause an unwieldy
flow of metal with a rough weld appearance
and reduced penetration. An arc too short
leads to a narrow weld deposit and “stuttery”
arc characteristics, and the electrode is liable
to freeze onto the work piece.
As the solidified weld deposit forms, move
the end of the electrode slowly along
the weld path, aiming to maintain a pool
of moulten weld metal behind the arc.
Decreasing this rate of travel will result in a
wider weld deposit, and similarly increasing it
will narrow the weld deposit.
Always fill the crater which tends to form
at the end of a weld deposit, by pausing
momentarily before withdrawing the electrode
to break the arc. Unfilled craters are a point
of weakness, and can lead to weld cracking.
Current Range for General Purpose
Electrodes
Diameter (mm) Current (Amps)
2.0 40 -60
2.5 60 - 85
3.2 90 - 130
4.0 130 - 180
TIG Welding (GTAW)
Connection for TIG Welding
For TIG welding, the torch is connected to
the negative terminal. Figure 9 illustrates
the correct connection of the welding torch
and gas supply. Welding grade Argon is
the shielding gas most commonly used for
DC GTAW welding. The gas us cinnected
directly to the torch.
Before first use of the welding torch,
allow gas to purge the torch and hoses for
5 minutes at approximately 10 litres/min. For
welding purposes, the gas flow rate should
be set in the range 2-5 litres/min.
Tungsten electrodes for DC GTAW should
be 1-2% Thoriated or Witstar. This type will
provide the best arc initiation, arc stability and
tip shape retention characteristics. Thoriated
electrodes can be recognised by a red coded
end. The tungsten electrode is ground to
a point, with the grinding marks pointing
towards the tip. For welding currents less
than 20 amps, the included angle of the
point should be 30
o
, for currents greater than
20 amps, the recommended angle is 60o.
When set in the torch, the tungsten should
protrude 6 mm from the ceramic gas nozzle.
Weldmatic 200i
Model No CP137, Iss A 02/15 19
TIG Welding Operation
Connect the Work Clamp to the work piece.
Turn on the power switch located on the rear
panel. Wait approximately 5 seconds as the
unit goes through its initiation sequence.
Press the Weld Mode button until the TIG
Mode light is on. The Weldmatic 200i keeps
the last mode used in memory, so this step is
only necessary when using a different mode
to that used last.
Select an appropriate welding current for the
job by setting the knob on the machine front
panel.
To initiate the arc, lightly touch the tungsten
electrode onto the work piece, then smoothly
lift it away to establish an arc length slightly
longer than the diameter of the electrode.
Use of a copper striking plate can be used to
avoid electrode contamination. The electrode
can also be contaminated by contact with
the filler rod. A contaminated electrode
produces an unstable arc. If this occurs
regrind the electrode tip.
To TIG Torch
Fig 9 Cable and hose connections for TIG welding
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. 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 200i, 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 10 Duty Cycle Rating
200
Maximum welding time
per 10 min
Work
clamp
(-) output
terminal
(+) output
terminal
20
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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 GMAW 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 11), 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 28). 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
Weldmatic 200i
Model No CP137, Iss A 02/15 21
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.
Power source has no output and no
wirefeed when gun switch is closed :
‘ON’ indicator light is not illuminated
1 Check equipment is connected to a
functional mains power outlet. Test outlet
using a known working appliance.
‘ON’ indicator light is illuminated
1 The gun switch circuit may be incomplete.
• Check the gun switch for continuity
with an ohm meter when the switch
is pressed. Replace if faulty
• Check the 2 pin receptacles in Euro
adaptor are making contact with the
mating pins from the gun Euro end.
2 Power source may have overheated.
• The Weldmatic 200i welding
power source incorporates an inbuilt over-temperature thermostat
which will trip if the welding load
exceeds the operating duty cycle.
The ‘OVERLOAD’ light will be
illuminated. The thermostat will reset
automatically - do not switch the
equipment off as the cooling fan will
assist the resetting of the thermostat
• If problem persists after the cool down
period, call your WIA service agent.
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.
9 External Trouble Shooting
Circuit breaker trips during welding
1 Check the rating of the mains supply
circuit breaker. The Weldmatic 200i
should be supplied from a 20 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 5
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 28 for fitting instructions.
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. Ensure that the work clamp
is securely tightened onto the work piece
so that good electrical contact is achieved
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.
22
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Porosity in weld caused by lack of
shielding gas
1 Check that the correct gas flow rate has
been set (refer page 12)
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.
10 Service Information
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.
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.
Weldmatic 200i
Model No CP137, Iss A 02/15 23
Fig 11 Weldmatic 200i Circuit Diagram
1 2
1 2
SW1
20A 250VAC
L1
7Z 6mH
C7
1uF 275VAC
AC1
AC2
1 2
3 4
220V~240VAC
C8
AC1
AC2
G
CEGCE
6
7
4
5
1
2
7:3:3
EARTH
+
1
2
O
3
G
4
3
5412
2
1
3 421
3 4
2
1
3 421
3 4
VCC
SGND
G
CE
G
CE
G
C
E
G
CE
G1 E1
G2 E2
NTC1
5K
AC1AC
2
+
3
-
4
2
1
3 4
NTC2
5K
AC1AC
2
+
3
-
4
12
3
FAN
FAN1
+24V
PWA021
G1 E1 G2 E2
QF
QF1
DC24 V
2
2
+
–
1
2
3
4
5
6
7
8
1CN6
1
2
3
4
5
6
7
8
2CN304
SW4
Torch
M
-
+
M1
24V
1
2
CN2
1
2
CN302
123
4
CN102
MOTOR+MOTOR
-
1
2
3
4
CN303
1
2
CN301
UFB+
UFB -
1
2
CN201
1
2
CN301
CN305
20
CN201
20
FAN+
FAN-
PWA019
PWA020
1uF 275VAC
10.1 Circuit Diagrams – Power Source
24
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Fig 12 Weldmatic 200i Power Source Assembly
11.1 Assembly and Parts List - Weldmatic 200i Power Source
2
1
3
6
7
8910
13
4
5
11
12
15
14
17
16
18
Weldmatic 200i
Model No CP137, Iss A 02/15 25
Item # Part # Description Qty
1 PAN154 Outer Cover 1
2 M0059 Handle 1
3 M0060 Rear Panel 1
4 E0041 Gas Valve 1
5 E0078 Main Switch 1
6 FAN011 Fan 1
7 PWA019 Main Control Panel PCB 1
8 PWA020 Wirefeeder Control PCB 1
9 M0063 Front Panel 1
10 SA140-0/2 Dinse Socket 2
11 PWA021 Front Panel Control PCB 1
12 WIN540 Front Panel Sticker 1
13 M0058 Knob 3
14 WF055 Wire Drive Assembly 1
15 WF056 Euro Adaptor 1
16 PAN155 Side Door 1
17 M0062 Latch 1
18 M0061 Wire Spool Holder Assembly 1
19 REG003 Argon Regulator 1
20 C200-CM Work Clamp 1
21 62513 Blue Oxy Single Gas Hose, 5 mm 1
Not shown CP137-40 Operating Manual 1
19
20 21
26
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Fig 13 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 200i
Model No CP137, Iss A 02/15 27
11.3 Assembly and Parts List - Gun and Cable Assembly
Item # Part # Description
1 BE4392 Nozzle, Brass, Tapered
2 see ‘Tips’ page 28 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 GUN003 Trigger
8 GUN005 Rigid Casing
9 BEL3B-15
BE43115X
Steel Liner 0.9 - 1.2mm
Nylon Liner 0.9 - 1.2mm
1
2
3
4
5
8
6
9
Fig 14 GUN001 (200 amp) Gun and Cable Assembly
7
28
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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 20mm past the
end of the body tube (5). Refit head, tip
and nozzle.
Fig 15 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 200i
Model No CP137, Iss A 02/15 29
12 Warranty Information
WIA Weldmatic MIG &
Weldarc MMA Equipment
2 Year Warranty Statement
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 2 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.
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.
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
Ph: 1300 300 884
Email: info@welding.com.au
Web: www.welding.com.au
• Lens and helmet comply with
Australian Standards AS/NZS
1338.1 (Auto-Darkening) and AS/
NZS 1337.1B (High Impact)
• Convenient external shade control
• Magnifying lens holder
WIA Blue Helmet
Part No: 235620
DESIGNED FOR THE WELDER
WHO WANTS PROTECTION,
PERFORMANCE & COMFORT
AT AN AFFORDABLE PRICE.
• 1 year warranty
(Auto-Darkening lens only)
• Battery powered with solar-assist
• Variable shade control
• Grind Mode.
For more information call 1300 300 884 or visit welding.com.au
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