WC-1 Weld Control Box
Owner’s Manual
Product: WC-1-110
Manual: 091-0249
Serial: n/a
Voltage Rating: 115 VAC
Revision: June 1999 Rev A
Model Number: n/a
SAFETY CONSIDERATIONS
ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION
OR MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate
application by commercial/industrial
users and for operation by persons trained
and experienced in the use and
maintenance of welding equipment.
Operation should not be undertaken
without adequate training in the use of
such equipment. Training is available
from many public and private schools or
similar facilities.
Safe practices in the installation,
operation and maintenance of this
equipment requires proper training in the
art, a careful study of the information
provided with the equipment, and the use
of common sense. Rules for safe use
are generally provided by suppliers of
welding power sources, compressed gas
suppliers, and electrode suppliers.
Careful compliance with these rules will
promote safe use of this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualified help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING
PRODUCES HIGH INTENSITY HEAT
AND ULTRAVIOLET RADIANT
ENERGY WHICH MAY CAUSE
SERIOUS AND PERMANENT EYE
DAMAGE AND WHICH MAY DAMAGE
ANY EXPOSED SKIN AREAS.
Wear helmet with safety goggles or
glasses with side shields underneath,
appropriate filter lenses or plates
(protected by clear cover glass). This is
a must for welding or cutting (and
chipping) to protect the eyes from radiant
energy and flying metal. Replace cover
glass when broken, pitted, or spattered.
Medical first aid and eye treatment. First
aid facilities and a qualified first aid
person should be available for each shift
unless medical facilities are close by for
immediate treatment of flash burns of the
eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. 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.
Flammable hair preparations should not
be used by persons intending to weld or
cut.
Hot metal such as electrode stubs and work
pieces should never be handled without
gloves.
Ear plugs should be worn when working on
overhead or in a confined space. A hard
hat should be worn when others work
overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may
result in exposure to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.
Adequate ventilation. Severe discomfort,
illness or death can result from fumes,
vapors, heat, or oxygen enrichment or
depletion that welding (or cutting) may
produce. Prevent them with adequate
ventilation. NEVER ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-,
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 toxic fumes should not be heated
unless coating is removed form 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 an air-supplied respirator.
Gas leaks in a confined space should be
avoided. Leaked gas in large quantities can
change oxygen concentration dangerously.
Do not bring gas cylinders into a confined
space.
Leaving confined space, shut OFF gas
supply at source to prevent possible
accumulation of gases in the space if
downstream valves have been accidentally
opened or left open. Check to be sure that
the space is safe before reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or
flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating
products. The ultraviolet (radiant) energy
of the arc can also decompose
trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD
or cut where solvent vapors can be drawn
into the welding or cutting atmosphere or
where the radiant energy can penetrate to
atmospheres containing even minute
amounts of trichloroethylene or
perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are:
combustibles reached by the arc, flame,
flying sparks, hot slag, or heated
material, misuse of compressed gases
and cylinders, and short circuits.
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 goggled operator. Sparks can fly
many feet.
To prevent fires and explosion:
Keep equipment clean and operable, free
of oil, grease, and (in electrical parts) of
metallic particles that can cause short
circuits.
If combustibles are in 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 cannot be moved,
move combustibles at least 35 feet away,
out of reach of sparks and heat; or protect
against ignition with suitable and snugfitting, 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.
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
1. Appreciable combustibles (including
building construction) are within 35 feet.
2. Appreciable combustibles are further
than 35 feet, but can be ignited by sparks.
3. Openings (concealed or visible) in
floors or walls within 35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can be
ignited by radiant or conducted heat.
Hot work permit should be obtained
before operation to ensure supervisor’s
approval that adequate precautions have
been taken.
After work is done, check that area is free
of sparks, glowing embers, and flames.
An empty container that held
combustibles, or that can produce
flammable or toxic vapors when heated,
must never be welded on or cut, unless
container has first been cleaned in
accordance with industry standards.
This includes: a thorough steam or
caustic cleaning (or a solvent of water
washing, depending on the combustible’s
solubility), followed by purging and
inerting with nitrogen or carbon dioxide,
and using protective equipment.
Water-filling just below working level may
substitute for inerting.
A container with unknown contents
should be cleaned (see paragraph
above). Do NOT depend on sense of
smell or sight to determine if it is safe to
weld or cut.
Hollow castings or containers must be
vented before welding or cutting. They
can explode.
Explosive atmospheres. NEVER weld
or cut where the air may contain
flammable dust, gas, or liquid vapors
(such as gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous
industry publications. The following
general rules cover many of the most
common situations.
1. Pressure Regulators
Regulator relief valve is designed to
protect only the regulator from
overpressure; it is not intended to protect
any downstream equipment. Provide
such protection with one or more relief
devices.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
Remove faulty regulator from service
immediately for repair (first close cylinder
valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does not
move off stop pin when pressurized, nor
returns to stop pin after pressure release.
Repair. Do NOT attempt repair. Send
faulty regulators for repair to
manufacturer’s designated repair center,
where special techniques and tools are
used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avoid electrical circuit contact with
cylinders including third rails, electrical
wires, or welding circuits. They can
produced short circuit arcs that may lead
to a serious accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
Identifying gas content. Use only
cylinders with name of gas marked on
them; do not rely on color to identify gas
content. Notify supplier if unmarked.
NEVER DEFACE or alter name, number,
or other markings on a cylinder. It is
illegal and hazardous.
Empties: Keep valves closed, replace
caps securely; mark MT; keep them
separate from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep
cylinders clear of areas where they may be
stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive
heat, sparks, slag, and flame, etc. that may
cause rupture. Do not allow contents to
exceed 55 degrees C (130 degrees F.) Cool
with water spray where such exposure
exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases
in a cylinder.
NEVER refill any cylinder.
Cylinder fittings should never be modified
or exchanged.
3. Hose
Prohibited use. Never use hose other than
that designed for the specified gas. A
general hose identification rule is: red for
fuel gas, green for oxygen, and black for
inert gases.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to fittings.
No copper tubing splices. Use only
standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coil excess hose to prevent kinks and
tangles.
Protect hose from damage by sharp edges,
and by sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and
loose connections. Immerse pressured
hose in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that
may clog orifices and damage seats before
connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet
away from people and sources of ignition.
Wipe with a clean, lintless cloth.
Match regulator to cylinder. Before
connecting, check that the regulator label
and cylinder marking agree, and that the
regulator inlet and cylinder outlet match.
NEVER Connect a regulator designed for
a particular gas or gases to a cylinder
containing any other gas.
Tighten connections. When assembling
threaded connections, clean and smooth
seats where necessary. Tighten. If
connection leaks, disassemble, clean,
and retighten, using properly fitting
wrench.
Adapters. Use a CGA adapter (available
from your supplier) between cylinder and
regulator, if one is required. Use two
wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identified by right hand threads
for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder (or
manifold valve) by turning adjusting
screw in (clockwise). Draining prevents
excessive compression heat at high
pressure seat by allowing seat to open
on pressurization. Leave adjusting screw
engaged slightly on single-stage
regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that
regulator pressure increases slowly.
When gauge is pressurized (gauge
reaches regulator maximum) leave
cylinder valve in following position: for
oxygen and inert gases, open fully to seal
stem against possible leak; for fuel gas,
open to less than one turn to permit quick
emergency shut-off.
Use pressure charts (available from your
supplier) for safe and efficient
recommended pressure settings on
regulators.
Check for leaks on first pressurization
and regularly thereafter. Brush with soap
solution. Bubbles indicate leaks. Clean
off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment
from service immediately for repair.
Read and follow user manual
instructions.
F. Leaving Equipment Unattended
Close gas supply at source and drain
gas.
G. Rope Staging-Support
Rope staging-support should not be used
for welding or cutting operation; rope may
burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2, and
this section. Arc Welding, properly done,
is a safe process, but a careless operator
invites trouble. The equipment carries
high currents at significant voltages. The
arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy
radiates, weldments are hot, and
compressed gases may be used. The
wise operator avoids unnecessary risks
and protects himself and others from
accidents.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly
bright. Its radiation can damage eyes,
penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the
skin and eyes. Skin burns resemble
acute sunburn; those from gas-shielded
arcs are more severe and painful. DON’T
GET BURNED; COMPLY WITH
PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,
use additional protective clothing such
as leather jacket or sleeves, flameproof
apron, and fire-resistant leggings. Avoid
outer garments of untreated cotton.
Bare skin protection. Wear dark,
substantial clothing. Button collar to
protect chest and neck, and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes
may be damaged by radiant energy when
exposed to the electric arc, even when
not looking in the direction of the arc.
Never look at an electric arc without
protection.
Welding helmet or shield containing a
filter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY.
Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST
be worn under the helmet to give some
protection to the eyes should the helmet
not be lowered over the face before an
arc is struck. Looking at an arc
momentarily with unprotected eyes
(particularly a high intensity gas-shielded
arc) can cause a retinal burn that may
leave a permanent dark area in the field
of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed
bay is best. In open areas, surround the
operation with low-reflective,
noncombustible screens or panels. Allow
for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields
for all persons who will be looking directly
at the weld.
Others working in area. See that all persons
are wearing flash goggles.
Before starting to weld, make sure that
screen flaps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented
to the outside air. Carbon monoxide can
kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not
overload arc welding equipment. It may
overheat cables and cause a fire.
Loose cable connections may overheat or
flash and cause afire.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area
that can cause a violent rupture or lead to
such a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or other
bare metal in the welding circuit, or in
ungrounded, electrically-HOT
equipment can fatally shock a person
whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding without
suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in
damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness
or sweat cannot be avoided. Sweat, sea
water, or moisture between body and an
electrically HOT part - or grounded metal reduces the body surface electrical
resistance, enabling dangerous and
possibly lethal currents to flow through the
body.
1. Grounding the Equipment
When installing, connect the frames of each
unit such as welding power source, control,
work table, and water circulator to the
building ground. Conductors must be
adequate to carry ground currents safely.
Equipment made electrically HOT by stray
currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to a
pipe carrying ANY gas or a flammable liquid
such as oil or fuel.
Three-phase connection. Check phase
requirement of equipment before installing.
If only three-phase power is available,
connect single-phase equipment to only two
wires of the three-phase line. Do NOT
connect the equipment ground lead to the
third (live) wire, or the equipment will
become electrically HOT - a dangerous
condition that can shock, possibly fatally.
Before welding, check ground for continuity.
Be sure conductors are touching bare metal
of equipment frames at connections.
If a line cord with a ground lead is provided
with the equipment for connection to a
switch box, connect the ground lead to
the grounded switch box. If a three-prong
plug is added for connection to a
grounded mating receptacle, the ground
lead must be connected to the ground
prong only. If the line cord comes with a
three-prong plug, connect to a grounded
mating receptacle. Never remove the
ground prong from a plug, or use a plug
with a broken ground prong.
2. Connectors
Fully insulated lock-type connectors
should be used to join welding cable
lengths.
3. Cables
Frequently inspect cables for wear,
cracks, and damage. IMMEDIATELY
REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock from bared cable. Cables
with damaged areas may be taped to
give resistance equivalent to original
cable.
Keep cable dry, free of oil and grease,
and protected from hot metal and sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT
when the power switch of gas metal-arc
welding equipment is ON and welding
gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and
circuit breakers should not be
disconnected or shunted out.
Before installation, inspection, or service
of equipment, shut OFF all power, and
remove line fuses (or lock or red-tag
switches) to prevent accidental turning
ON of power. Disconnect all cables from
welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change
polarity while welding. If, in an
emergency, it must be disconnected,
guard against shock burns or flash from
switch arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be
available near the welding power source.
THIS PAGE INTENTIONALL BLANK
Table of Contents
Introduction ............................................................7
Section 1 SPECIFICATIONS ........................................................... 8
Section 2 SUPPORT EQUIPMENT REQUIRED ................................ 8
Section 3 OPTIONAL KIT ............................................................... 8
Section 4 OPTIONAL ACCESSORY ................................................. 8
Section 5 INSTALLATION............................................................... 8
Location ................................................................................................. 8
Contactor Selection ................................................................................. 8
115 VAC Co nnection ................................................................................ 9
Posa Start Connections .......................................................................... 1 0
Spool Gun Connections........................................................................... 10
Section 6 OPERATION.................................................................. 10
General ................................................................................................ 10
CC Posa Start Operation......................................................................... 11
CV Posa Start Operation......................................................................... 11
Section 7 MAINTENANCE............................................................. 11
WC-1 Recommended Spare Parts List ...................................................... 1 2
Section 8 TESTING THE TORCH ................................................... 12
Motor Check ......................................................................................... 12
T esting The Potentiometer...................................................................... 12
T esting The Micro Switch ....................................................................... 12
Section 9 RELAY K2 OPERATION ................................................. 12
Section 10 TESTING THE 115 VAC CIRCUITS ............................... 12
Section 11 TESTING THE SPEED CONTROL ................................... 13
Section 12 INTERCONNECTIONS ................................................... 13
Section 13 TROUBLESHOOTING .................................................... 14
Section 14 MAIN P.C. BOARD CONNECTIONS ............................... 15
Section 15 MAIN P.C. BOARD PARTS PLACEMENT ....................... 16
Section 16 FRONT PANEL P.C. BOARD LAYOUT ............................ 18
Section 17 DRAWINGS AND SCHEMATICS .................................... 19
Limited Warr ant y................................................................24
THIS PAGE INTENTIONALL BLANK
Introduction
This manual details the installation and operation of your WC-1 weld control.
The WC-1 can be used with any constant voltage(CV) or constant current(CC)
power source having its own contactor. A secondary contactor is available for
the WC-1, for those power supplies not having a contactor system. CC Posa
start "Run-in Speed" is included as a standard feature.
The WC-1 has a 7 pin "W" clocked amphenol connector and is designed for
use with Prince® and Prince® XL Spool guns models 146-XXX and 216-XXX.
In order to assure optimum performance of your WC-1, familiarize yourself with
the contents of this manual and carefully follow all instructions.
This manual will not only guide you in installing your WC-1, but will also be a
handy reference for optional items and replacement parts.
Owner’s Manual - Page 8
Section 1 SPECIFICATIONS
Power Input ....................................................................... 115 VAC 50/60 Hz.
Weight.........................................................................................6 3/4 pounds
Shipping Weight ................................................................................ 8 pounds
For Use with Torch Numbers ................................................ 146-XXX, 216-XXX
Section 2 SUPPORT EQUIPMENT REQUIRED
C. V. or C.C. power source of sufficient capacity for your needs.
Regulated gas supply and hoses.
Properly sized power lead from power source to ground.
Section 3 OPTIONAL KIT
CV POSA START ADAPTOR KIT
005-0339
Used only when having arc starting problems with a CV power source.
Section 4 OPTIONAL ACCESSORY
SECONDARY CONTACTOR BOX
001-3066
Used in conjunction with the WC-1 on power sources that do not have a
contactor system. Mounts on top of the WC-1 and is rated at 200 amps, 100%
duty cycle.
Section 5 INSTALLATION
Location
The WC-1 should be secured to the power supply or another suitable locations
where it can be secured to protect it from damage. Lead lengths and
accessibility to a 115 VAC 50/60 Hz power source must also be considered
when installing the control. Refer to specifications for dimensional information.
Contactor Selection
The WC-1 is shipped from the factory in the closing contacts position. A six
foot contactor/Posa Start sense cable is supplies with the unit to which the
black and white wires supply the contactor signal.
Refer to the power supply owner's manual for location of
and type of contactor signal required.
Disconnect the WC-1 from all power sources before changing contactor.
If a 115 VAC signal is required, remove the four screws from both sides on the
control box, and remove cover. Locate black and white wire on #3 and #4 of
terminal strip J6. Move black wire to #4 and white wire to #3 of terminal strip
J5. The unit will now supply 115 VAC on the black (hot) and white (neutral)
wires.
NOTE:
WARNING:
Owner’s Manual - Page 9
ClosingClosing
Closing
ClosingClosing
ContactsContacts
Contacts
ContactsContacts
ConnectionConnection
Connection
ConnectionConnection
WARNING:
In the 115 VAC Contactor Mode, the contactor leads will
be "LIVE" with 115 VAC whenever the trigger is pulled.
Leads should be protected to prevent accidental
contact and labeled 115 VAC.
FRONTFRONT
FRONT
11
1
11
WHITEWHITE
WHITE
WHITEWHITE
BLACKBLACK
BLACK
BLACKBLACK
J6J6
J6
J6J6
22
2
22
J5J5
J5
J5J5
33
22
44
33
4
3
44
33
11
1
11
3
2
33
22
44
4
44
BLACKBLACK
BLACK
BLACKBLACK
WHITEWHITE
WHITE
WHITEWHITE
FRONTFRONT
115 VAC115 VAC
115 VAC
115 VAC115 VAC
ContactorContactor
Contactor
ContactorContactor
ConnectionConnection
Connection
ConnectionConnection
115 VAC Connection
Connect the supplied 6' power cord to a 115 VAC 50/60 Hz outlet.
The cord is connected to the PC Board on terminal strip J5 #1 (neutral) and #2
(hot) and Ground to the WC-1 chassis.
J6J6
J6
J6J6
11
2
1
22
11
4
3
44
33
44
33
22
11
1
11
22
2
22
J5J5
J5
J5J5
33
3
33
BLACKBLACK
BLACK
BLACKBLACK
WHITEWHITE
WHITE
WHITEWHITE
44
4
44
115 VAC115 VAC
115 VAC
115 VAC115 VAC
INPUTINPUT
INPUT
INPUTINPUT
Owner’s Manual - Page 10
GREENGREEN
GREEN
GREENGREEN
Posa Start Connections
When using a constant current power supply, the Posa Start sensing leads
must be connected to the power source. Place the red wire on the power
supply positive terminal and the green wire on the power supply negative
terminal. When using a constant voltage power supply, the sensing leads
need not be connected, and the Posa Start should be turned off. The Posa
Start Sense Leads are internally connected to the P.C. Board on terminal strip
J6 terminal 1 (red) and terminal 2 (green).
11
1
11
Spool Gun Connections
Connect the gun control cable amphenol plug to the WC-1, and secure.
Attach the power cable lug from the gun to the positive terminal of the power
supply, and the negative terminal of the power supply to work ground.
Connect gas hose to regulator/flowmeter on gas supply.
Section 6 OPERATION
General
The WC-1 is designed to interface the Prince® XL Spool Gun to most DC
Constant Current, Constant Voltage, and pulsed power supplies.
J6
22
2
22
GREEN
RED
33
3
33
44
4
44
WORK
+ WELD
J5
33
22
11
1
11
3
2
33
22
44
4
44
The Posa Start feature allows the WC-1 to be used in combination with
constant current DC welding power sources of open circuit voltage in excess of
55 volts.
NOTE:
Reverse polarity MUST be used)
CAUTION:
Do not operate a WC-1 on a power source having a high frequency
starting circuit before making sure that the high frequency
portion of the power source is turned off. Failure to take this
precaution will cause permanent damage to the posa start circuitry.
The Posa Start Run-in Speed Control, located on the front panel, provides
adjustment for slow wire run-in. Once the arc has been established, the wire
feed speed is automatically changed from the slow run-in speed to the welding
speed set on the torch potentiometer.
Owner’s Manual - Page 11
CC Posa Start Operation
Attach the WC-1 to a CC power source according to the installation
instructions.
Insure power supply high frequency switch is in the “OFF” position, and power
supply is set to DC reverse polarity.
The power supply contactor should be set to “Remote” or “Tig” and the
amperage control set to “Panel” or “Standard” depending on power supply.
Turn the WC-1 power switch to the “ON” position and the Posa Start switch to
the “OFF” position.
Adjust power source to desired amperage for your weld condition.
Press gun trigger and adjust wire feed speed at gun to match current setting.
If approximate wire feed speed is not known, it is better to start with excess
wire feed rather than too little, in order to prevent possible damage to the
contact tip.
Turn Posa Start switch to the “ON” position. Press torch trigger and, using
Run-in Speed Control, adjust wire feed speed to approximately 10% of the
welding wire speed.
Strike an arc; if the wire stubs out, reduce wire feed rate at gun, or increase
amperage setting on power source.
Because the Posa Start Run-in Speed always remains a percentage
of the actual welding wire feed rate, the Posa Start run-in speed
will always slow down or speed up proportional to any adjustment you
now make at the gun. Therefore, if you slow down the welding wire
feed speed, you will have to increase the Run-in Speed setting.
CV Posa Start Operation
(005-0339 kit must be installed)
Attach WC-1 to CV power source according to the installation instructions.
Turn the WC-1 to the “ON” position and the Posa Start to the “OFF” position.
Adjust power source to desired voltage for your weld condition.
Depress gun trigger and adjust wire feed speed at gun to match voltage
setting. If approximate wire feed is not known, it is better to start with excess
wire feed rather than too little, in order to prevent a “burn-back”.
Strike an arc, and adjust wire feed rate at gun until correct condition is
achieved.
Section 7 MAINTENANCE
Maintenance of the torch will normally consist of a general cleaning of the wire
guide system, including tubes, drive rolls, and liners at regular intervals.
Remove spatter build-up from inside of nozzles with a hardwood stick.
NOTE:
The only parts of the spool gun that are subject to normal wear are the contact
tips, gas cups, front and rear liners, wire guides, drive and idler rolls. A supply
of these parts should be maintained on hand.
If repairs do become necessary, any part can easily be replaced by a qualified
shop maintenance person.
Owner’s Manual - Page 12
Your WC-1 is designed to provide years of reliable service. Normal wear and
component failure may require occasional service.
The number of units in operation and the importance of minimal "down time"
will determine to what extent spare parts should be stocked on hand. The
following list comprises the most commonly replaced parts on the WC-1.
WC-1 Recommended Spare Parts List
QTY P/N DESCRIPTION
1 003-1636 Main P.C. Board
1 003-1644 Front Panel Board
Section 8 TESTING THE TORCH
Motor Check
Remove the amphenol connector from the WC-1.
Using the torch amphenol, check the resistance across pins “A” and “B”
(motor leads). The resistance across the motor should be between 5-10
ohms.
If an open circuit or short exist, check the motor leads and motor
independently.
Testing The Potentiometer
Using the torch amphenol, check the resistance across pin “D” (wiper) and pin
“C”. The resistance should vary from 0 - 5K ohms.
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms.
Testing The Micro Switch
Using the torch amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.
Section 9 RELAY K2 OPERATION
When the torch trigger is pressed, 24VAC is sent to the coil of relay K2. When
K2 is energized, 115VAC is sent to the 115VAC contactor. Relay K2 is also
responsible for sending 24VAC to the speed control circuit and shorting the
torch motor leads together when the trigger is released for the dynamic braking
system. K2 also provides the closing contactor signal.
Section 10 TESTING THE 115 VAC CIRCUITS
The 115 VAC circuit is protected by fuse F3. If either continually blows,
remove J5-3,4 (115 VAC Contactor) from the P.C. Board. Replace fuse, and
retrigger system.
Section 11 TESTING THE SPEED CONTROL
NOTE:
The torch should be tested first and the amphenol must be
connected to the WC-1 to perform this test.
Owner’s Manual - Page 13
Place a voltmeter across diode D10 and press torch trigger. A reading of 0 -
24VDC should be observed, as the potentiometer is varied.
24.0
VDC
D10
Section 12 INTERCONNECTIONS
Prince® XL Spool Gun 216-xxx connected to a WC-1
Weld Control Box 001-3062
115 VAC Plug
Contactor Leads
+
CONSTANT VOLTAGE
CONSTANT CURRENT
_
OR
POWER SUPPLY
Weld Control Box
Electrical Cable
NOTE:
The Posa Start feature permits the WC-1 to
be used in combination with any Constant
Current DC power source with an open
circuit voltage in excess of 55 volts.
Gas Hose
COUPLER - AW-430-RH
M.K. P/N 753-3377
Owner’s Manual - Page 14
RED
GREEN
Power Cable
CONSTANT CURRENT
POSA START SENSING
+
WC-1
LEADS. NOT NEEDED
WITH CONSTANT
VOLTAGE SUPPLIES
_
Ground Lead
CUSTOMER
SUPPLIED
Section 13 TROUBLESHOOTING
TROUBLE CAUSE REMEDY
F3 fuse i n WC-1 blown. Check 115VAC circuit. Replace fuse.
No wi re feed at torch
Wire feeds, but
weldi ng wire is no t
energ ized.
F1 fuse in WC-1 blown.
Micro-switch defective/not being
activated. Broken electrical cable.
Rela y K2 inoperati ve. Check/Replace relay K2.
Loose P.C. board connectors. Check connectors.
Bad potentiometer. Check potentiometer with meter.
Bad torch motor. Check/replace motor.
Broken e lectrical cable
Bad speed control/PCB. C heck/Replace P.C. board.
Loose or no cable connections.
Re l ay K2 not sending c ont actor
signal.
Contactor control cable loose or in
wrong position.
Welding power source. Check power source for operation.
Check motor leads for shorts, then re place
with 4A fuse.
Replace switch. C heck switch for
operation. Check micro switch wires for
continuity.
Check motor and potentiometer wires for
continuity.
Check all po wer connectio ns.
Check/replace relay K2.
Check power supply owners manual for
locati o n and type of contactor signal
requi red, i.e., closing contacts or 115VA C .
Wire fe eds e rratic a lly.
Wire feeds one
speed only.
Wire walks out of
drive rolls
Excessive spool drag pressure. Decrease spool dra g pressure.
Dirty or worn liners. Blow out or replace liners.
Incorrect pressure on drive rolls. Adjust pressure at both feeder and torch.
Idler roll stuck.
Wrong size contact tip. See conta ct tip table.
Ba d potentiometer. Check wi th meter.
Broken e lectrical cable.
Bad speed control. Check/replace P.C. board.
Idler roll upside-down. Place groove in idler roll towards top.
Rear wi re guide missing. Replace wire guide.
Che ck for lo ck was he r under id ler roll, o r
replace if damaged.
Check potentiometer wires for continuity or
short.
Owner’s Manual - Page 15
Section 14 MAIN P.C. BOARD CONNECTIONS
115 vac only
J8 J7
J1
J2
J3
J4
jumper
FRONT PANEL
FRONT PANEL
not used
J5J6
44
33
22
11
2
1
22
11
4
3
44
33
44
33
22
11
2
1
22
11
4
3
44
33
not used
TRANSFORMER
115VAC CONTACTOR OUT
115VAC CONTACTOR OUT
115VAC INPUT
115VAC INPUT
GROUND
CLOSING CONTACTS OUT
CLOSING CONTACTS OUT
(-) WORK GROUND - GREEN
(+) WELD VOLTS - RED
Owner’s Manual - Page 16
Section 15 MAIN P.C. BOARD PARTS PLACEMENT
RV4
RV1
C5
D1
RV2
C2
C1
D6
RV3
D8
D7
F1
D9
24 vac supply - 4A
D3
R1
R2
D2 R3
C3
R7R8R9C7R11Q4Q3
J9
J10
R5
R4
Q2
D4D5R6
Q1
R13
R12
Q5C6
C10
JP3JP2
C4
R10
JP1
K1
D10
C8 C9
J1J1
J1
J1J1
J2
J3
K2
RV5
1
F2
J11
115 vac input - 2A
F3
2
34
J6
J8
J5
J7
RV6RV6
RV6
RV6RV6
321
4
J4
COMPONETS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY.
Owner’s Manual - Page 17
MAIN P.C. BOARD PARTS LIST (P/N 003-1636)
COMPONENT # P/N DESCRIPTION
K1 157-0144 RELAY, 5V 5000HM 200MA
R2, R3 115-0154 RESISTOR, carbon .25 watt 6.8K ohm
R4, R5 115-0042 RESISTOR, carbon .50 watt 6.8K ohm
R12, R13 115-0120 RESISTOR, carbon .25 watt 100 ohm
R6 115-0122 RESISTOR, carbon .25 watt 150 ohm
R7 115-0144 RESISTOR, carbon .25 watt 10K ohm
R8 115-0138 RESISTOR, carbon .25 watt 3.3K ohm
R9 115-0129 RESISTOR, carbon .25 watt 560 ohm
R10 115-0136 RESISTOR, carbon .25 watt 2.2K ohm
R11 115-0141 RESISTOR, carbon .25 watt 5.6K ohm
D1, D3 124-0002 DIODE, 1 amp 800 volts
D6-D10 124-0003 DIODE, 2.5 amps 1KV
D4 124-0011 DIODE, zener 1 watt 10 volts
Q2 122-0011 TRANSISTOR, NPN 500MA 250 volts
Q3 122-0004 TRANSISTOR, PNP 1 amp 50 volts
Q4 122-0013 TRANSISTOR, unijunction 30 volts
Q5 125-0028 THYRISTOR, 8 amps 400 volts
C1, C5, C8, C9 101-0016 CAPACITOR, ceramic .01uf 600VDC
C2 101-0013 CAPACITOR, Poly .047uf 200VDC
C4, C6 104-0002 CAPACITOR, tantalum 10uf 20VDC
C7 101-0021 CAPACITOR, ceramic .047uf 50VDC
RV1, RV5, RV6 124-0026 VARISTOR, 130 volts 10 amps
RV2, RV4 124-0028 V ARISTOR, 56 volts 8 amps
J1 153-0866 TERMINAL, header 2 pin
J2 153-0885 TERMINAL, header 26 pin
J3 153-0713 TERMINAL, header 4 pin
J5, J6 186-0057 TERMINAL, strip 4 pin
J8 153-0850 CONNECTOR, 6 pin
Fuse Holder 152-0008 FUSE HOLDER, PC mount
F3 151-0001 FUSE, AGC 2A 250V
K2 157-0022 RELAY, 24VAC 4PDT
K2 Socket 173-0026 SOCKET, relay 14 pin
F1 151-0043 FUSE, 3AG 4A, 250V
D5 124-0093 DIODE, zener, 1 watt, 5-1volts
Owner’s Manual - Page 18
Section 16 FRONT PANEL P.C. BOARD LAYOUT
COMPONENTS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY
FRONT PANEL P.C. BOARD
PARTS LIST
003-1644
COMPONENT # P/N DESCRIPTION
R2 119-0020 POTENTIOMETER, 100k ohm
R3 115-0037 RESISTOR, Carbon 2.7k ohm, 1/2watt
D1 124-0045 LED, green
J1A 153-0845 HEADER, 4 pin 90 degree
J2 153-0876 HEADER, 26 pin 90 degree
J3 153-0860 HEADER, 8 pin 90 degree
SW1 159-3587 SWITCH, DPDT, p.c. mount
SW3 159-3586 SWITCH, SPDT, p.c. mount
R2 (bracket) 435-0901 BRACKET, p.c. mount
Owner’s Manual - Page 19
Section 17 DRAWINGS
AND
SCHEMATICS
Owner’s Manual - Page 20
Owner’s Manual - Page 21
No. Qty. Part No. Description
1 1 438-0026 Base
2 1 003-1636 PCB, Main w/Posa Start 115V
3 4 342-0410 Spacer tacking #6-32 x 0.534 LG
4 4 336-0005 Screw, PH. FIL. #6-32 x 3/8
5 1 405-0716 Decal, B lock Diagram WC-1 115V
6 1 003-1644 PCB, Panel w/Posa Start
7
8 1 301-0023 Grommet pnl., mtg., LED
9 1 401-0012 Knob 1.00 Dia.
10 1 003-1645 Cable, board to board
11 1 003-1646 Cable, power board to board
12 1 003-1642 Cable, board to torch "W"
13 1 003-0773 Transformer 115V Assy.
14 3 325-0135 Screw, PH. FIL> #6-32 x 1/2
15 7 333-0023 Washer, X star #6
16 2 341-0005 Nut Hex #6-32
17 4 331-0002 Washer flat #6
18 1 411-0157 Clamp, cable strain rel.
19 1 003-0796 Power cable
20 1 003-1302 C able, contact assy.
21 1 438-0025 Cover
22 8 336-0026 Screw, St T/A #6-32 x 3/8 LG.
23 1 003-1639 Jumper bypass assy.
24 1 405-0647 Decal, front WC-1
25 1 405-0709 Decal, rear WC -1 115V
26 2 345-0008 Nut, self locking #6-32
27 1 405-0725 Decal, terminal block
28 2 327-0110 Screw, ST-F #6-32 x 3/8 LG.
29 1 003-1301 C able, Posa Start assy.
30 2 331-0019 Washer flat #4
Owner’s Manual - Page 22
Owner’s Manual - Page 23
Effective January 1, 2000
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - MK Products,Inc.,Irvine,California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.
MK Products’ warranty does not apply to components having
normal useful life of less than one (1) year, such as relay
points, wire conduit, tungsten, and welding torch parts that
come in contact with the welding wire, including gas cups, gas
cup insulators, and contact tips where failure does not result
from defect in workmanship or material.
In the case of MK Products’ breach of warranty or any other
duty with respect to the quality of any goods, the exclusive
remedies therefore shall be at MK Products’ option:
(1) repair
(2) replacement
(3) where authorized in writing by MK Products, the reasonable
cost of repair or replacement at our Irvine, California plant; or
(4) payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Upon receipt of notice of
apparent defect or failure, MK Products shall instruct the
claimant on the warranty claim procedures to be followed.
As a matter of general policy only, MK Products may honor an
original user’s warranty claims on warranted equipment in the
event of failure resulting from a defect within the following
periods from the date of delivery of equipment to the original
user:
1. Torches and Weldheads ......................... 1 year
2. All Other Equipment .............................. 3 years
3. Repairs ................................................... 90 days
Classification of any item into the foregoing categories shall be
at the sole discretion of MK Products. Notification of any failure
must be made in writing within 30 days of such failure.
A copy of the invoice showing the date of sale must accompany
products returned for warranty repair or replacement.
All equipment returned to MK Products for service must be
properly packaged to guard against damage from shipping.
MK Products will not be responsible for any damages resulting
from shipping.
Normal surface transportation charges (both ways) for products
returned for warranty repair or replacement will be borne by
MK Products, except for products sold to foreign markets.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY, OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR
THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR OF FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MK PRODUCTS, IS EXCLUDED AND
DISCLAIMED BY MK PRODUCTS.
EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS
IN WRITING, MK PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MK PRODUCTS WARRANTIES DO NOT
EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO
EXTEND MK PRODUCTS’ WARRANTIES TO ANY
CONSUMER.
16882 Armstrong Ave.
Irvine, CA 92606
Tel (949)863-1234
Fax (949)474-1428
sales@mkprod.com
FORM :LW-9MK
DATE :January 1, 2000
MK PRODUCTS, INC.
16882 ARMSTRONG AVE.
IRVINE,CALIFORNIA 92606
TEL (949) 863-1234 FAX (949) 474-1428
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