Weldarc MC105-0 User manual

Weldarc 200i AC/DC

Weldarc 200i AC/DC Arc/TIG Welder
Model No. MC105-0

(From serial no. M1052A*)

Operators Manual

01/21

MC105-40 Rev C

Welding Industries of Australia

A division of ITW Australia Pty Ltd

1300 300 884
[e-mail]

welding.com.au

Weldwell New Zealand

A Division of ITW New Zealand

Telephone: [phone]
Email: [e-mail]

www.weldwell.co.nz

Weldmatic 200i AC/DC

Contents

Section General Information Page

Safe Practices 2

1 Introduction 5

2 Receiving 6

3 Operation 6

4 Specifications 7

5 Controls 9

6 Installation 16

7 Basic Welding Information 17

8 External Trouble Shooting 21

9 Service Information 2

9.1 Circuit Diagram 23

10 Assembly and Parts Lists

Power Source 24

11 Australian Warranty Information 27

12 New Zealand Warranty Information 28

Model No MC105 1

Operators Manual

Read First

Safe Practices When Using
Welding Equipment

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 200i 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.

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

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

Pulsed

MIG

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Weldmatic 200i AC/DC

Burn Protection

The welding arc is intense and visibly bright.
Its radiation can damage eyes, penetrate
light-weight clothing, reflect from light­coloured surfaces, and burn the skin and
eyes. Burns resulting from gas-shielded arcs
resemble acute sunburn, but can be more
severe and painful.

Wear protective clothing – leather or heat
resistant gloves, hat, and safety-toed boots.
Button shirt collar and pocket flaps, and
wear cuffless trousers to avoid entry of
sparks and slag.

Avoid oily or greasy clothing. A spark may
ignite them. Hot metal such as electrode
stubs and work pieces should never be
handled without gloves.

Ear plugs should be worn when welding in
overhead positions or in a confined space.
A hard hat should be worn when others are
working overhead.

Flammable hair preparations should not be
used by persons intending to weld or cut.

Toxic Fumes

Adequate ventilation with air is essential.
Severe discomfort, illness or death can
result from fumes, vapours, heat, or oxygen
depletion that welding or cutting may
produce. NEVER ventilate with oxygen.

Lead, cadmium, zinc, mercury, and beryllium
bearing and similar materials when welded
or cut may produce harmful concentrations
of toxic fumes. Adequate local exhaust
ventilation must be used, or each person in
the area as well as the operator must wear
an air-supplied respirator. For beryllium, both
must be used.

Metals coated with or containing materials
that emit fumes should not be heated unless

coating is removed from the work surface,
the area is well ventilated, or the operator
wears an air-supplied respirator.

Work in a confined space only while it is
being ventilated and, if necessary, while
wearing air-supplied respirator.

Vapours from chlorinated solvents can be
decomposed by the heat of the arc (or
flame) to form phosgene, a highly toxic
gas, and lung and eye irritating products.
The ultra-violet (radiant) energy of the arc
can also decompose trichlorethylene and
perchlorethylene vapours to form phosgene.
Do not weld or cut where solvent vapours
can be drawn into the welding or cutting
atmosphere or where the radiant energy
can penetrate to atmospheres containing
even minute amounts of trichlorethylene or
percholorethylene.

Fire And Explosion Prevention

Be aware that flying sparks or falling slag can
pass through cracks, along pipes, through
windows or doors, and through wall or floor
openings, out of sight of the operator. Sparks
and slag can travel up to 10 metres from the arc.

Keep equipment clean and operable, free of
oil, grease, and (in electrical parts) of metallic
particles that can cause short circuits.

If combustibles are present in the work
area, do NOT weld or cut. Move the work if
practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage
areas, ventilators. If the work can not be
moved, move combustibles at least 10 metres
away out of reach of sparks and heat; or
protect against ignition with suitable and
snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite
sides should not be welded on or cut. Walls,
ceilings, and floor near work should be
protected by heat-resistant covers or shields.

Model No MC105 3

Operators Manual

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.

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1 Introduction

Weldmatic 200i AC/DC

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 200i has been designed to
be used with 2.0mm, 2.5mm, 3.2mm and

4.0mm diameter electrodes. The smaller
electrodes are used when welding at lower
currents, such as sheet metal applications.
Increasing the electrode diameter permits
higher welding currents to be selected.

WIA supplies a wide range of mild steel and
special purpose electrodes which cater for home
workshop, rural, and industrial requirements.
Some popular AUSTARC electrodes are listed
below. The correctly selected AUSTARC
electrode will influence the quality of the weld,
and the stability of the arc.

Austarc 12P, Classification E4313-A

A popular general purpose electrode
used with ease in all positions, vertical up
or down. The smooth forceful arc makes
it an ideal electrode for all general mild
steel applications.

Austarc 13S, Classification E4313-A

A smooth running electrode with a soft arc,
particularly suited to light sheetmetal and
smooth mitre fillet welds.

Austarc 16TC, Classification E4916-A

A low hydrogen electrode with good
arc stability and out-of-position welding
characteristics. This electrode is ideal
for medium carbon steels, or steels of
unknown analysis.

Austarc 11, Classification E4311-A

A high cellulose electrode for all positional
welding, AC or DC. Particularly suited for
vertical and incline pipe welding where
complete root penetration is required.

Unicord 312, Classification ES312-16

A high tensile (50tsi), chromium nickel
electrode specially formulated for joining
all alloy steels and irons, and for tool and
die maintenance.

GTAW (TIG Welding)

Gas Tungsten Arc Welding (GTAW) is a
welding process where the arc is struck
between a non-consumable tungsten
electrode and the work piece. A ceramic
nozzle surrounds the tungsten electrode and
directs a flow of inert gas, usually Argon,
over the electrode and the weld zone. If
filler metal is required, it is hand fed into
the welding arc. The DC current output of
the Weldarc inverter is suitable for welding
most ferrous and non-ferrous metals. The AC
current output is for welding Aluminium.

Model No MC105 5

Operators Manual

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

• (This) Operating Manual MC105-40.

• TIG Torch TIG007 complete with 8m
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.

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Weldmatic 200i AC/DC

4 Specifications

Manufactured to Australian Standard AS60974-1
IEC60974-10 6.3.2 6.3.3.

TERM VALUE UNIT

Rated Input Voltage 220 - 240 V

Power Frequency 50/60 Hz

Rated Input Capacity 7.9 KVA

Generator Capacity 10 KVA

Rated Maximum Supply Current Imax 34 A

Maximum Effective Supply Current Ieff 13 A

Output No Load Voltage 71 V

Supply Main Circuit Breaker 25 A

Supply Cable 2.5mm2 & Plug Rating 15 A

Extension Lead Rating 15 A

VRD Safe 13.5 V

Rated Output 240 ° C

Stick MMA 170 Amps @26.8 Volts 15% Duty

Stick MMA 66 Amps @22.6 Volts 100% Duty

TIG 200 Amps 18 Volts 15% Duty

TIG 77 Amps 13.1 Volts 100% Duty

Current Up Slope Time 0 - 15 S

Current Down slope Time 0 - 25 S

Pulse Frequency 0.5 - 200 Hz

Pulse Ratio Width Adjustment 15 - 85 %

AC Balance Control, Negative 35 - 90 %

AC Frequency 15 -150 Hz

Arc Force Control MMA 0 -100 %

Arc Start MMA 0 - 70 A

Arc Start MMA 0.2 S

Post Gas Time 0 - 30 S

Pre Gas Time 0 - 5 S

Cooling Type Fan on Demand

Efficiency ≥ 85% n

Power Factor 0.92 Cos§

Model No MC105 7

Operators Manual

4 Specifications (cont)

Insulation Degree H

Cover Protection Degree IP21S IP

Weight 19.5 kg

Shipping Weight 30.5 kg

Dimension L × W × H 530 x 240 x 420 mm

Shipping Dimension L × W × H 770 x 335 x 460 mm

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