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WELDING.COM.AU

Operators Manual | MC114-40 | RevB

WELDING INDUSTRIES

AUSTRALIA

A Division of ITW Australia Pty Ltd

ABN: 63 004 235 063
1300 300 884

Email: [email protected]

welding.com.au

WELDWELL

NEW ZEALAND

A Division of ITW New Zealand

NZBN: 9 429 039 833 129

GST NO: 080 177 186
0800 9353 9355

Email: [email protected]
weldwell.co.nz

Summary of Contents for MC114-0

Page 1: ...WELDING COM AU From serial numbers M1142A Stick TIG Welder OPERATORS MANUAL MC114 0 ...

Page 2: ...of ITW Australia Pty Ltd ABN 63 004 235 063 1300 300 884 Email info welding com au welding com au WELDWELL NEW ZEALAND A Division of ITW New Zealand NZBN 9 429 039 833 129 GST NO 080177186 0800 9353 9355 Email info weldwell co nz weldwell co nz ...

Page 3: ...s 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 ...

Page 4: ... 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...

Page 5: ...th 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 phosg...

Page 6: ...s 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...

Page 7: ...6 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 q...

Page 8: ...el 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 servi...

Page 9: ...aker 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 H...

Page 10: ...al Model No MC114 2 10 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 ...

Page 11: ...he button and knob have different function depending on which Screen Menu the controller is operating in 1 1 Colour LCD Display 1 2 LEFT Button Press this button to Select the option the screen menu is displaying 1 3 RIGHT Button Press this button to Select the option the screen menu is displaying 1 4 SELECT Knob From Start Menu use the SELECT knob to select the required process Select from DC TIG...

Page 12: ...hat OCV is safe Press right button for memory 2 3 Parameter election Press left button to return to home menu DC Stick 2 2 2 VRD Indication When VRD is enabled then open circuit voltage will be reduced a level less than 35V DC which is compliant with AS1674 2 Category C requirements Arc starts can be more difficult with VRD enabled The start technique is Touch Twist Lift If VRD is not suitable for...

Page 13: ...e activate the parameter Continue to select other parameter or press Right Button to EXIT 2 3 1 1 Hot Start Rotate SELECT Volt Knob to adjust Hot Start value from 0 to 100 of the set Weld current Hot Start will provide a boost current at the arc start to help arc starting particularly on cold material 2 3 1 2 Weld current The Weld Current value can be adjusted Weld Current can also be adjusted fro...

Page 14: ...s suitable for Aluminium welding Aluminium material develops an oxide coating which is an insulator the AC current provides some positive current which cleans the oxide from the weld surface Both AC and DC can use pulse mode where the weld current can be pulsed high low when the required TIG mode has been selected the specific weld parameter needs to be selected 3 1 Electrode Polarity The first sc...

Page 15: ...u There are two levels of adjustments possible Weld Arc Parameter Machine Function The Menu selection is similar for all the TIG modes A Memory Current Parameter Knob A DC TIG 46 Welding Mode Press for Parameter menu Rotate for Current adjust Press for Memory Parameter Status Set Current Press for Home start screen Press and Hold the trigger to purge the gas from the gas line ...

Page 16: ...Weld Current Down Slope Final Current Post Gas Recommended Electrode Size Parameter Setting Use Left button to select Exit Rotate knob to move to Parameter Press knob to accept Parameter Use Left button to select Function Machine Function Status AC TIG Parameters Frequency Balance Pre Gas Start Current Upslope F Pulse DC TI G AUTO AUTO AUTO Peak Current Background Current Pulse Radio Frequency ...

Page 17: ...nsition from the WELDING CURRENT value to the FINAL CURRENT value The time can be adjusted from 0 to 15 seconds 3 3 1 6 Final Current The current at the WELD can be adjusted to a value 0 100 of WELD CURRENT which will allow controlled finish of the weld The end of weld pool Crater can be filled 3 3 1 7 Post Gas The Gas Flow after the end of the weld can be adjusted from 0 to 30 seconds This featur...

Page 18: ...EQUENCY or BALANCE can be adjusted 3 3 1 12 1 Balance BALANCE is expressed as a of the time that the polarity is negative Adjustment is from 50 85 For new clean aluminium an AC BALANCE of 65 70 is a good starting point Low Balance Less time negative More time positive More cleaning action More heat in the tungsten Wider weld with shallower penetration High Balance More time negative Less time posi...

Page 19: ...fter the PRE FLOW gas time has elapsed the Arc will start and the current will stay at the START CURRENT setting When trigger is released the current will increase to the WELDING CURRENT setting according to the UP SLOPE time Output will continue at WELDING CURRENT setting When the torch trigger is pressed again then the weld output will decrease down to FINAL CURRENT setting according to the DOWN...

Page 20: ...ed to the machine remote control socket FIG 7 Turn the machine on First the machine needs to be adjusted to the maximum desired current To do this the remote control knob on the TIG torch needs to be adjusted to maximum Adjust to the desired maximum current such as 150A on the machine with the control knob FIG 1 7 The AMPs digital display will then shoe 150A Adjust the control knob on the TIG torc...

Page 21: ...rieve previously saved weld setup Press SELECT to toggle Load mode Rotate and then press the SELECT button to choose the memory location Press Confirm Right Button Channel OK Channel No Data OK ESC Knob Save Load Channel Knob If loaded the current welding parameters will be replaced No Data OK 0 1 Success LOAD ESC Knob Save Load Channel Knob If saved the current channel parameters will be replaced...

Page 22: ...capacity of the main power supply wiring and power outlet supplying a welder is selected according to the Effective Primary Current of the equipment Refer to Section 4 The minimum recommended main power supply circuit breaker rating for Weldarc inverter are listed in Section 4 The current rating of the mains cable depends on cable size and method of installation Refer to AS NZS 3008 1 Table 9 If i...

Page 23: ... piece as if striking a match As the arc initiates lift the electrode slightly away aiming to establish an arc length of approximately 3mm 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 causes an unwield...

Page 24: ...y used for DC welding current Tungsten Electrode Preparation The tungstens needs to be ground to a point the grinding should only be in the direction of the point and should be done on a fine grit grinding wheel The resulting grind pattern will produce a sharp directed arc Poor tip preparation will result in arc wander A common practice is to grind the tip such that the length of the points is app...

Page 25: ...rium is a radioactive element which mainly emits alpha particles Alpha particles cannot penetrate skin or clothing but can be a harmful carcinogen if released inside the digestive tract or lungs There is almost no release of radioactive material during arcing There is no significant hazard in handling and storage The Thoria is inside the tungsten electrode it is enclosed in a tungsten matrix and s...

Page 26: ...e tip 7 BASIC WELDING INFORMATION 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 Use the Weld Mode Selection Switch to select LIFT TIG or HF TIG Mode Select an appropriate welding current for the job by setting the knob on the machine front panel HF Start...

Page 27: ... source covers 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 remov...

Page 28: ...ine has cooled sufficiently The duty cycle should be observed and understood No welding current display on The connections may not be made securely Ensure all connections are in position and securely made Machine gives poor quality weld The polarity of the electrode return cables is incorrect The return lead contacts or workbench surface requires cleaning Polarity should be confirmed for the proce...

Page 29: ...d be confirmed for the process wire type in use The weld has small black lumps or dots appearing in the pool Cleaning is poor Old or dirty filler rods can often be the cause of dirty TIG welding operations Switching filler rods to another type or batch may solve this issue Weld is contaminated with small bubbles presence of porosity The gas hose is not securely connected at the machine or at the r...

Page 30: ... are present on the electrical components enclosed CAUTION 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 If the welding machine requ...

Page 31: ...31 Fig 13 Weldarc 200 AC DC Circuit Diagram 11 1 CIRCUIT DIAGRAMS POWER SOURCE ...

Page 32: ...Weldarc 200 AC DC Operator Manual Model No MC114 2 32 Fig 14 Weldarc 200 AC DC Power Source Assembly 12 ASSEMBLY PARTS LIST WELDARC 200 AC DC POWER SOURCE 1 2 3 4 5 6 7 10 13 12 11 15 14 9 8 16 17 18 19 ...

Page 33: ...unt Dinse Socket 2 9 M0131 Gas Connection Front 1 10 E0079 Plug 5 PIN 1 11 M0127 Front Panel Plastic 1 12 PWA102 PCB Assy Front Panel 1 13 WIN635 Front Panel Sticker 1 14 M0105 Button 2 15 M0104 Knob 1 16 L0040 Inductance 1 17 L0035 Current Sensor 1 18 PWA103 Secondary Inverter PCB 1 19 FAN025 Fan 1 20 REG003 Argon Regulator 1 21 CLA002 Work Clamp 1 22 TIG010 TIG Torch 1 Not Shown MC114 40 Operati...

Page 34: ...6mm 1 10N24 Collet 2 4mm 1 10N25 Collet 3 2mm 1 10N50 Ceramic Nozzle Size 4 6mm 1 10N49 Ceramic Nozzle Size 5 8mm 1 10N48 Ceramic Nozzle Size 6 10mm 1 10N47 Ceramic Nozzle Size 7 11mm 1 10N46 Ceramic Nozzle Size 8 12 5mm 1 57Y04 Short Back Cap 1 57Y03 Medium Back Cap 1 57Y02 Long Back Cap 1 E0087 Cable Plug 1 M0131 Snap Gas Connector 1 13 ASSEMBLY AND PARTS LIST TORCH ...

Page 35: ...arranty Term The repair of your products may result in the loss of any user generated data Please ensure that you have made a copy of any data saved on your product 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...

Page 36: ...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...

Page 37: ... to the original place of purchase with proof of purchase or contact Customer Service on 0800 9353 9355 The warranty shall not apply to parts that fail due to normal wear For customers located in New Zealand you can contact Weldwell New Zealand Division of ITW New Zealand 59 Thames Street Napier 4110 New Zealand Ph 0800 9353 9355 Email info weldwell co nz Web www weldwell co nz 15 NEW ZEALAND WARR...

Page 38: ...Weldarc 200 AC DC Operator Manual Model No MC114 2 38 NOTES ...

Page 39: ...39 NOTES ...

Page 40: ...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 080 177 186 0800 9353 9355 Email info weldwell co nz weldwell co nz ...

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