WIA WELDARC 200AC/DC Manuel utilisateur

WELDING.COM.AU

From serial numbers M1142A*

Stick/TIG Welder

OPERATORS MANUAL | MC114-0

WELDING INDUSTRIES

AUSTRALIA

A Division of ITW Australia Pty Ltd

ABN: 63 004 235 063

1300 300 884

Email: info@welding.com.au

welding.com.au

WELDWELL

NEW ZEALAND

A Division of ITW New Zealand

NZBN: 9 429 039 833 129

GST NO: 080177186

0800 9353 9355

Email: info@weldwell.co.nz

weldwell.co.nz

CONTENTS

Section General Information Page

Safe Practices 4

1 Introduction 7

2 Receiving 8

3 Operation 8

4 Specifications 9

5 Controls 11

6 Installation 22

7 Basic Welding Information 23

8 General Maintenance 27

9 External Trouble Shooting 27

10 Trouble Shooting Chart 28

11 Service Information 30

11.1 Circuit Diagram 31

12 Assembly & Parts List

Power Source 32

13 Assembly & Parts List

Torch 34

14 Australian Warranty

Information 35

15 New Zealand Warranty

Information 37

Weldarc 200 AC/DC | Operator Manual | Model No MC114-2

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 handle fitted to

the Weldarc 200AC/DC inverter is

intended for carrying the equipment

by hand only.

DO NOT use this handle for

suspending or mounting the Weldarc

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 1 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

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 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 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.

Weldarc 200 AC/DC | Operator Manual | Model No MC114-2

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.

1 INTRODUCTION

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 Weldarc 200 AC/DC 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.

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.

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.

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 Weldarc inverter is suitable

for welding most ferrous and non-ferrous

metals. The AC current output is for

welding Aluminium.

Weldarc 200 AC/DC | Operator Manual | Model No MC114-2

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 Weldarc inverter package contains:

– Weldarc Inverter Power Source

– Twist-lock Electrode Holder

– Work Clamp 3m

– Gas Hose

– (This) Operating Manual MC114-40.

– TIG Torch Complete WP17V121625

with valve, 5m cable with twist-lock

connection and fitted with 2.4mm

collet and ceriated tungsten

– TIG Consumable KIT

– Argon flow gauge regulator REG003

3 OPERATION

Whenever the welding output of the

Weldarc inverter is open circuit (ie not

arcing), the voltage across the welding

leads is reduced to a safe level. This

provides an increased level of safety to the

welding operator during operations such as

changing the electrode. The “VRD SAFE”

indicator on the front panel is on to confirm

the output is in the safe condition.

The term VRD refers to a “Voltage Reducing

Device”which complies with AS1674.2 for

Category “C” conditions.

If the supply cable is damaged it

must be replaced by the manufacturer,

their service agent or a similarly

qualified person.

IMPORTANT NOTICE: Warranty

may be voided if equipment is

powered from an unsuitable engine

driven generator.

Generators used to power this

equipment must have a minimum

capacity of 10 kW continuous 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, we recommend that

operation of equipment on the

generator is received from the

manufacturer before purchasing

the generator.

4 SPECIFICATIONS

Manufactured to Australian Standard AS60974-1

IEC60974-10 6.3.2 6.3.3.

TERM WELDARC 200 AC/DC

Rated Input Voltage 220 - 240 V

Power Frequency 50/60 Hz

Rated Input Capacity 7.5 KVA

Generator Capacity 10 KVA

Rated Maximum Supply Current Imax 20 A

Maximum Effective Supply Current Ieff 12 A

Output No Load Voltage 81 V

Supply Main Circuit Breaker 25 A

Supply Cable 2.5mm2 & Plug Rating 15 A

Extension Lead Rating 15 A

VRD Safe 12 V

Rated Output @ 40°C

Stick MMA 160 A @ 26.4 V 30% Duty

88 A @ 23.5 V 100% Duty

TIG 200 A @ 18 V 30% Duty

110 A @ 14.4 Volts 100% Duty

Current Up Slope Time 0 - 10 S

Current Down slope Time 0 - 15 S

Pulse Frequency DC: 0.2-500 Hz

AC: 0.2-20 Hz

Pulse Ratio Width Adjustment 10 - 90 %

AC Balance Control, Negative 50 - 85 %

AC Frequency 50 - 150 Hz

Arc Force Control MMA 0 - 100 %

Arc Start MMA 0 - 100 A

Post Gas Time 1 - 60 S

Pre Gas Time 0 - 5 S

Cooling Type Fan on Demand

Efficiency ≥ 80% n

Power Factor 0.99 Cos§

Weldarc 200 AC/DC | Operator Manual | Model No MC114-2

1110

TERM WELDARC 200 AC/DC

Insulation Degree H

Cover Protection Degree IP21S

Weight 17.0kg

Shipping Weight 28.0kg

Dimension L × W × H 520 x 260 x 420 mm

Shipping Dimension L × W × H 705 x 320 x 495 mm

4 SPECIFICATIONS (CONT.)

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