WIA WELDMATIC 200 User manual

WELDING.COM.AU
From serial numbers C1502A*
MIG & Multi-Process Welder
OPERATORS MANUAL | CP150-1

3ii
WELDING INDUSTRIES
AUSTRALIA
A Division of ITW Australia Pty Ltd
ABN: 63 004 235 063
1300 300 884
Email: [e-mail]
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: [e-mail]
weldwell.co.nz

3ii
CONTENTS
Section General Information Page
Safe Practices 4
1 Introduction 7
2 Receiving 9
3 Specifications 10
4 Controls 12
5 Installation 14
6 Normal Welding Sequence 17
7 Basic Welding Information 17
8 General Maintenance 26
9 External Trouble Shooting 27
10 Trouble Shooting Chart 28
11 Service Information 31
11.1 Circuit Diagram 32
12 Assembly & Parts Lists
12.1 Power Source 33
12.2 Wirefeeder 35
12.3 Gun & Cable 36
13 Australian Warranty
Information 38
14 New Zealand Warranty
Information 40

Weldmatic 200 | Operator Manual | Model No CP150-1
54
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 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

54
Burn Protection
The welding arc is intense and visibly bright.
Its radiation can damage eyes, penetrate
light-weight clothing, reflect from light-
coloured 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 cuff less trousers to avoid entry of
sparks and slag.
Avoid oily or greasy clothing. A spark may
ignite them. Hot metal such as electrode
stubs and work pieces should never be
handled without gloves.
Ear plugs should be worn when welding in
overhead positions or in a confined space.
A hard hat should be worn when others are
working overhead.
Flammable hair preparations should not be
used by persons intending to weld or cut.
Toxic Fumes
Adequate ventilation with air is essential.
Severe discomfort, illness or death can
result from fumes, vapours, heat, or oxygen
depletion that welding or cutting may
produce. NEVER ventilate with oxygen.
Lead, cadmium, zinc, mercury, and
beryllium bearing and similar materials
when welded or cut may produce harmful
concentrations of toxic fumes. Adequate
local exhaust ventilation must be used,
or each person in the area as well as
the operator must wear an air-supplied
respirator. For beryllium, both must be used.
Metals coated with or containing materials
that emit fumes should not be heated
unless coating is removed from the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing air-supplied respirator.
Vapours from chlorinated solvents can
be decomposed by the heat of the arc (or
flame) to form phosgene, a highly toxic
gas, and lung and eye irritating products.
The ultra-violet (radiant) energy of the arc
can also decompose trichlorethylene
and perchloroethylene vapours to form
phosgene. Do not weld or cut where solvent
vapours can be drawn into the welding or
cutting atmosphere or where the radiant
energy can penetrate to atmospheres
containing even minute amounts of
trichlorethylene or perchloroethylene.
Fire and Explosion Prevention
Be aware that flying sparks or falling slag
can pass through cracks, along pipes,
through windows or doors, and through
wall or floor openings, out of sight of the
operator. Sparks and slag can travel up to 10
metres from the arc.
Keep equipment clean and operable, free
of oil, grease, and (in electrical parts) of
metallic particles that can cause short circuits.
If combustibles are present in the work
area, do NOT weld or cut. Move the work if
practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage
areas, ventilators. If the work can not be
moved, move combustibles at least 10metres
away out of reach of sparks and heat; or
protect against ignition with suitable and
snug-fitting fire-resistant covers or shields.

Weldmatic 200 | Operator Manual | Model No CP150-1
76
Walls touching combustibles on opposite
sides should not be welded on or cut. Walls,
ceilings, and floor near work should be
protected by heat-resistant covers or shields.
A person acting as Fire Watcher must be
standing by with suitable fire extinguishing
equipment during and for some time after
welding or cutting if;
– Combustibles (including building
construction) are within 10 metres.
– Combustibles are further than 10
metres but can be ignited by sparks.
– Openings (concealed or visible) in floors
or walls within 10 metres may expose
combustibles to sparks.
– Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can
be ignited by radiant or conducted heat.
After work is done, check that area is free of
sparks, glowing embers, and flames.
A tank or drum which has contained
combustibles can produce flammable
vapours when heated. Such a container
must never be welded on or cut, unless
it has first been cleaned as described in
AS.1674-2. This includes a thorough steam
or caustic cleaning (or a solvent or water
washing, depending on the combustible’s
solubility), followed by purging and inerting
with nitrogen or carbon dioxide, and using
protective equipment as recommended in
AS.1674-2. Water-filling just below working
level may substitute for inerting.
Hollow castings or containers must be
vented before welding or cutting. They can
explode. Never weld or cut where the air
may contain flammable dust, gas, or liquid
vapours.
Shock Prevention
Exposed conductors or other bare metal
in the welding circuit, or ungrounded
electrically alive equipment can fatally
shock a person whose body becomes
a conductor. Ensure that the equipment
is correctly connected and earthed. If
unsure have the equipment installed by a
qualified electrician. On mobile or portable
equipment, regularly inspect condition of
trailing power leads and connecting plugs.
Repair or replace damaged leads.
Fully insulated electrode holders should
be used. Do not use holders with
protruding screws. Fully insulated lock-type
connectors should be used to join welding
cable lengths.
Terminals and other exposed parts of
electrical units should have insulated knobs
or covers secured before operation.

76
1 INTRODUCTION
The Weldmatic 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 has been designed to be
used with consumable wires of different
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 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 200 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.

Weldmatic 200 | Operator Manual | Model No CP150-1
98
Austarc 13S, Classification E4313-A
A smooth running electrode with a soft arc,
particularly suited to light sheetmetal and
smooth mitre fillet welds.
Staincord 316L-016, Classification
E316L-16
For quality all position stainless steel
welding. Extra smooth running, high arc
stability, easy re-strike, excellent slag
removal and bead appearance.
Staincord 309Mo-16, Classification
E309LMo-16
For high quality all position stainless steel
welding. This extra low carbon alloy is
specifically indicated for AISI 309Mo type
alloys, but is also ideal for joining mild/low
alloy steel to a range of 300 and 400
series stainless steels. Features extra
smooth running, high arc stability, easy
re-strike, excellent slag removal and
bead appearance.
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.
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.
Equipment options Part #
TIG
Torch
(135A complete with
valve, 4m cable with
twist-lock connection
and fitted with 2.4mm
collet and thoriated
tungsten)
TIG001
Trolley Kit
Gas Bottle + Drawer AM357
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200 is suitable for welding most
ferrous and non-ferrous metals, but is not
suitable for welding Aluminium for which an
AC machine is required.

98
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 200 package contains:
– Weldmatic 200 Power Source
– Euro MIG Gun and Cable Assembly
– Twist-lock Electrode Holder
– Work Clamp 3m
– Gas Hose
– Drive Roll 0.6/0.8 V Groove
– Drive Roll 0.9/1.2 Knurled
– Sample wire ES6 0.8mm
– Sample wire Austfil T-11 0.9mm Gasless
– Tips 0.6, 0.8, 0.9, 1.2mm
– Argon Flow Gauge Regulator REG003
– (This) Operating Manual CP150-40.
IMPORTANT NOTICE: Warranty may
be voided if equipment is powered
from an unsuitable engine driven
generator.
Generators used to power
this equipment must have the
recommended minimum capacity and
incorporate output voltage regulation.
Due to variation between generators
by different manufacturers, it is
impossible for WIA to validate
operation from all
generators. Therefore, correct
operation
of welding equipment on the generator
should be confirmed by the
manufacturer, before purchasing the
generator.

Weldmatic 200 | Operator Manual | Model No CP150-1
1110
3 SPECIFICATIONS
WELDMATIC 200
Manufactured to Standards AS60974.1
IEC60974.10
Rated Input Voltage 220 – 240V
Power Frequency 50/60 Hz
Generator Single Phase Capacity 13KVA
Rated Maximum Supply Current Imax 36A
Maximum Effective Supply Current Ieff 14A
Output No Load Voltage 71V
VRD Safe 13.5V
Rated Output @40°C 10 Min Cycle Time
MIG
Gmaw
10% Duty
15% Duty 200Amps @ 24V
20% Duty
100% Duty 77Amps @ 17.9V
Stick
MMA
10% Duty
15% Duty 170Amps @ 26.8V
20% Duty
100% Duty 66Amps @ 22.6V
TIG
10% Duty
15% Duty 200Amps @ 18V
20% Duty
100% Duty 77Amps @ 13.1V

1110
WELDMATIC 200
Spool Size ES6 – 1kg & 5kg
Supply Plug 15Amp
Supply Cable 2.5mm2 3 Core Heavy Duty PVC
Mains Circuit Breaker Rating 25A
Wire Speed Range 2-14.5 Metre/min
Wire Size (Solid) 0.6mm-0.9mm
Wire Size (Cored) 0.8-1.2mm
Cooling Type Air cooling
Efficiency ≥ 85%
Power Factor 0.62
Insulation H 140°C Rise
Protection IP21S
Weight 15kg
Shipping Weight 25kg
Dimension L × W × H 525 x 260 x 410mm
Shipping Dimension
L x W x H
705 x 320 x 495mm
3 SPECIFICATIONS (CONT)

Weldmatic 200 | Operator Manual | Model No CP150-1
1312
Fig 1 Weldmatic 200 Controls
2
6 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, in accordance with
AS1672.2 2007 Category C.
7 Weld Current & Wire Speed
Adjustment Control
Stick Mode (MMAW) and TIG Mode:
This control sets the Weld Current level.
MIG Mode (GMAW): This control sets
Wire Speed.
4 CONTROLS
10 911
12 13 14
8
7
6
15
45
3
1
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1 Control Panel
2 m/min Indicator
When this light is on the Digital Display (8)
is indicating the selected wire speed in
metres per minute (MIG Mode).
3 Amps Indicator
When this light is on the Digital Display
(8) is indicating the selected Amps (Stick
or TIG Mode).
4 Power On Indicator
5 Over Temperature Indicator
This light is on if the machine overheats
or mains voltage is 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.

1312
8 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 (3) light will be
on and the selected welding Amps will be
displayed when adjusted with Weld Current
& Wire Speed Adjustment Control (7).
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 (7).
9 Voltage Adjustment
Control/Purge Knob
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.
10 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 (9).
11 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.
12 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
gas-shielded or gasless welding wire.
13 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.
14 Gas Select Button and Indicator
Press to select which type of gas is being
used, or if gasless wire is being used. See
page 15 for information on selecting the
shielding gas.
15 Wire Select Button and Indicator
Press to select the wire size being used.
Sizes 0.6, 0.8mm or 0.9mm.
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.

Weldmatic 200 | Operator Manual | Model No CP150-1
1514
5 INSTALLATION
Connection to Electrical Mains
Power Supply
The Weldmatic 200 is factory fitted with a
3 metre, 3 core 2.5mm2Heavy 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 Ieff for the Weldmatic 200
is 14Amps.
The minimum recommended mains circuit
breaker rating for a Weldmatic 200 is
20 Amps.
Supply Cable
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.
Successful Operation
Successful operation will depend on a
number of factors:
– Variation in circuit breaker thresholds.
– Ambient temperature
– Number of previous circuit breaker
operations
– Actual weld conditions, resulting in
higher weld currents
– Repeated starts can result in repeated
surge currents raising circuit breaker
threshold
– Low supply voltage can result in
higher current
Repeated Circuit breaker operation at weld
start can sometimes be overcome by using
a “D” curve circuit breaker.
To reduce nuisance tripping, a higher
rated circuit breaker can be selected, but
the supply circuit wiring capacity must be
increased to suit.

1514
MIG Welding (GMAW)
Output Voltage Polarity
The design of the Weldmatic 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
(-) output
terminal
(+) output
terminal
Polarity
selection
cable
Work clamp
Fig 3 Negative Wire
(+) output
terminal
(-) output
terminal
Polarity selection cable

Weldmatic 200 | Operator Manual | Model No CP150-1
1716
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
Slide the spool over the retaining tab, locate
the drive pin, and push spool up against the
flange so the retaining tab engages
the spool hub.
Check wire spool rotation tension.
Adjust spool holder wing nut 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.
Wire “Inch” - “Load”
When the trigger is pressed the wire will
slowly feed out, until the wire touches the
work piece, then the arc will start and wire
speed will change to selected speed.
If the wire does not touch work piece within
5 seconds, then the wire speed will increase
to maximum to assist wire loading. The wire
speed cannot be adjusted during this time.
Compression
screw
Top roller arm
Groove
size

1716
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 200 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
The wire feed has an in built “creep” function.
When the trigger is pressed the wire will
slowly feed out, until the wire touches the
work piece, then the arc will start, wire
speed will change to set speed.
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 creeps out.
– The wire touches the work piece,
and the arc is established.
– Wire speeds up to selected speed
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 200 | Operator Manual | Model No CP150-1
1918
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 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 wire speed settings.
Wirefeed speed is adjusted by Knob in
Figure 1 (7). 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

1918
WELDMATIC SETTINGS CHART
Fig 6a Weld Settings Chart
Suggested Settings for Fillet Weld Mild Steel – Gasless Wire
Wire Type
Gasless / Flux Cored
Negative Polarity
Knurled Drive Roll
Arc Control 1
Material
Thickness
Wire Size
0.8mm 0.9mm 1.2mm
Wirefeed Volts Stick
Out Wirefeed Volts Stick Out Wirefeed Volts Stick Out
8mm
5.0 19.0 15mm
5mm
6.0 1 7. 0 10mm 7.0 18.0 12mm 4.5 1 7.0 15mm
3mm
5.5 16.0 10mm 5.6 1 7. 0 12mm 2.5 15.5 15mm
1.6mm
4.5 14.0 10mm 2.6 14.0 12mm 2.0 14.5 15mm
1.2mm
2.8 13.0 10mm 2.4 13.0 12mm
0.8mm
2.0 13.0 10mm
Stick Out

Weldmatic 200 | Operator Manual | Model No CP150-1
2120
WELDMATIC SETTINGS CHART (CONT)
Suggested Settings for Fillet Weld Mild Steel – Solid Wire
Fig 6b Weld Settings Chart
Wire Type
Carbon Steel ES6
Positive Polarity
Gas: Ar + 5% CO + 2% O
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 22.5 9.5 22.5
3mm
13.0 22.0 7.0 20.0 5.5 19.5
1.6mm
7. 5 18.5 4.0 1 7. 5 3.5 16.5
1.2mm
5.0 1 7. 0 3.5 16.5 2.8 15.5
0.8mm
4.0 16.0 3.0 16.0