WIA MC110-0, Operator'S Manual

Page 1: ...WELDING COM AU From serial numbers M1102A M1112A M1122A Stick TIG Welders OPERATORS MANUAL MC110 0 MC111 0 MC112 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: ...1 5 Controls 145 185 12 Controls 135 13 6 Installation 14 7 Basic Welding Information 14 16 8 General Maintenance 16 9 External Trouble Shooting 16 10 Trouble Shooting Chart 17 18 11 Service Information 19 12 Circuit Diagrams 20 22 13 Assembly Parts List Power Source 135 23 24 14 Assembly Parts List Power Source 145 25 26 15 Assembly Parts List Power Source 185 27 28 16 Australia Warranty Informat...

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: ... 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 an air supplied respirator Vapours from chlorinated solvents can be decomposed by the heat of the arc or flame to form phos...

Page 6: ...s 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 N...

Page 7: ...4916 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 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 qual...

Page 8: ... 240 Vac 50 60 Hz 220 240 Vac 50 60 Hz Rated Primary Current I eff 9 9 Amps 8 5 Amps 12 5 Amps Maximum Primary Current I max 22 2 Amps 19 Amps 25 Amps Rated Output 40 C Duty cycle based on 10 minute cycle time Stick 135 Amps 25 4 V 20 duty 78 Amps 23 1 V 60 duty 60 Amps 22 4 V 100 duty Stick 145 Amps 25 8 V 20 duty 56 Amps 22 2 V 100 duty TIG 145 Amps 15 8 V 20 duty 56 Amps 12 2 V 100 duty Stick 1...

Page 9: ...530mm W x 185mm D x 415mm H 530mm W x 185mm D x 415mm H Power Source Weight 4 0kg 7 0kg 8 0kg Main Circuit Breaker Rating 20 Amps 20 Amps 25 Amps Supply Plug 10 Amp 10 Amp 15 Amp Fitted Supply Cable 1 5 mm2 Three Core Heavy Duty PVC 1 5 mm2 Three Core Heavy Duty PVC 2 5 mm2 Three Core Heavy Duty PVC Power Supply Outlet 240 V Extension Lead Rating 10 Amp 10 Amp 15 Amp Cooling Fan Cooled Continuous ...

Page 10: ... front panel will come on and the output voltage will be reduced to the VRD voltage level which is below the required safe level of 35V DC Change VRD Function If the VRD function does not suit the application the VRD can be enabled or disabled by an authorised WIA service agent Electrode Striking and Restriking VRD Enabled When the electrode is struck on the work piece the machine will detect a st...

Page 11: ...rators The PFC spreads the current pulse over the whole mains cycle The overall effect is PFC provides stable operation on challenging power supplies particularly on long supply leads and generators Power Factor Correction 4 3 Shoulder Strap To attach the shoulder strap to the Weldarc feed the strap through the slot underneath the handle at front and rear of machine 4 4 Hot Start Hot start is a bo...

Page 12: ...ply 4 2 Stick Electrode Welding MMAW This mode is used for all MMAW stick electrode process 4 3 Setup Mode 145 185 only In Setup Mode the amount of Hot Start and Arc Force can be adjusted Press and hold MODE button for 4 seconds until Digital Display will show HS The Hot Start current can be increased or decreased by adjusting the Weld Control Knob Adjust 10 to 10 of factory setting Press MODE but...

Page 13: ...8B Mock up with knob Proof only DO NOT PRINT 2 1 3 5 6 Power On Off Switch In the OFF position this switch isolates the power source from the mains power supply The switch is located on the rear panel 5 Weld Current Control This control sets the output current level of the power source within the available range Rotate the knob clockwise to increase the output current ...

Page 14: ...e from the equipment As noted previously it is not recommended that the Weldarc inverter be powered from small engine driven generator sets unless they have adequate voltage regulation Poor regulation results in peaks of supply voltage which can occur with some equipment of this type Excessive voltage peaks can damage the circuits of the welder Machines with PFC will be tolerant of poor generator ...

Page 15: ...hich tends to form at the end of a weld deposit by pausing momentarily before withdrawing the electrode to break the arc Unfilled craters are a point of weakness and can lead to weld cracking TIG Welding GTAW Connection for TIG Welding 145 185 only For TIG Welding the torch is connected negative terminal Figure 4 illustrates the correct connection of the welding torch The machine does not have an ...

Page 16: ...ded that at regular intervals according to the prevailing conditions the equipment covers be removed and any accumulated dust be removed by the use of a dry low pressure compressed air or a vacuum cleaner The machine should be blown out with compressed air at least every 12 months as grinding dust can settle on PCB componentry causing failure Failure to maintain machines may void warranty Before r...

Page 17: ...sufficiently The duty cycle should be observed and understood No welding current display on The weld 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 process wire ty...

Page 18: ...rned on Gas flow too low Not enough Pregas time Polarity should be confirmed for the process wire type in use Review gas set up 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 presen...

Page 19: ...al 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 requires service or repair take ...

Page 20: ...N FAN 5 2 3 4 1 C N401 L N B D1 PTC1 C2 C3 R LY1 VCC T3 C5 C6 C10 R2 R3 1 G 2 C 3 E Q1 1 G 2 C 3 E Q3 R9 C7 R8 C8 G1 G3 E1 E3 2 5 6 1 3 4 T2 A1 K A2 D1 R 13 C13 A1 K A2 D3 R 12 C12 R16 C14 C15 DGND AGND U C N1 U C N1 U D20 R 14 R15 C N1 CN1 PE E arth 1 G 2 C 3 E Q2 1 G 2 C 3 E Q4 G2 G4 A1 K A2 D2 A1 K A2 D4 C4 24V C67 C68 R107 C70 NO CS CS CHARGE E2 E4 5 2 3 4 1 P1 HandyArc 142 162i PANEL I f LINE...

Page 21: ...G1 R115 R116 R114 R113 C4 C5 3W R43 C84 C83 C82 PE VSS T3 V V G C E Q1 IGBT G C E Q2 IGBT C85 C86 C87 C88 G C E Q3 IGBT G C E Q4 IGBT R6 DC DC 1 DC 2 1 3 4 RLY1 VCC R5 out 1 2 3 4 AC L Earth 1 2 1 2 SW1 AC N PE 1 2 CN201 PLY DC 1 Vss T3 B T3 A E3 G3 E2 G2 E4 G4 E1 G1 1 2 CN205 NTC1 FAX GND VCC RX1 3V3 TX1 CN502 CN12 GND VCC RX1 3V3 TX1 DC 1 ESTICK 203E PFC ESTICK PFC DC L Rs CN2 CN1 PFC 15V 2 VSS ...

Page 22: ...E2 G1 G3 E1 VCC SGND E4 NTC E3 RLY1 PE RT2 1 RT2 2 2 5 3 1 4 T1 D1 D2 D3 D4 C1 Q1 Q3 Q2 Q4 C1 2 R1 115 C8 2 R4 R117 C6 2 R2 116 C9 2 R5 R118 C4 C7 C5 C3 R3 RH1 C2 5 R2 R1 R7 5 R4 R5 R6 1 2 S4 LED3 LED4 LED1 LED2 DTIG200PFC CTRL 1 2 1 2 SW1 DIS 01 1 3 2 RP3 12 COM COM COM 8 g 5 d 2 b 7 a 11 9 e 1 c 4 f 10 dp 3 LED1 LF1 LF LF2 LF GND GND 1 2 3 4 BD1 1 2 CN205 1 2 3 4 5 CN502 1 2 CN201 2 XS1 1 2 3 CN...

Page 23: ...23 13 ASSEMBLY AND PARTS LIST WELDARC 135 POWER SOURCE Fig 8 Weldarc 135 Power Source Assembly 9 10 11 12 13 14 1 2 3 4 5 6 7 8 ...

Page 24: ...06 Front Panel Plastic 1 7 M0104 Knob 1 8 SA 140 0 2 135 Output Socket 1 9 WIN671 LOGO Sticker 135 1 10 WIN678 Front Sticker 2 11 FAN022 Fan 1 12 M0107 Rear Panel Plastic 1 13 E0078 Main Switch 1 14 Supply Cable 1 5mm 10A Plug 1 15 REG003 Argon Regulator 1 16 SA32 0 1 Dinse Plug 1 17 62513 Gas Hose 5mm 1 18 CLA002 Work Clamp 1 Not shown M112 40 Operating Manual 1 15 16 17 18 13 ASSEMBLY AND PARTS ...

Page 25: ...25 Fig 9 Weldarc 145 Power Source Assembly 14 ASSEMBLY AND PARTS LIST WELDARC 145 POWER SOURCE 10 11 7 12 13 14 1 2 3 4 5 6 7 8 9 ...

Page 26: ...107 PCB Main Control 145 1 4 5 R0032 Thermister 1 6 PWA064 PCB Front Panel 145 1 7 M0108 Panel Plastic 2 8 M0104 Knob 1 9 SA 140 0 2 Output Socket 2 10 PWA106 PCB PFC 1 11 FAN023 Fan 1 12 E0078 Main Switch 1 13 Supply Cable 1 5mm 10 A Plug 1 14 WIN625 Front Sticker 145 1 15 REG003 Argon Regulator 1 16 SA32 0 1 Dinse Plug 1 17 62513 Gas Hose 5mm 1 18 CLA002 Work Clamp 1 Not shown MC112 40 Operating...

Page 27: ...27 15 ASSEMBLY AND PARTS LIST WELDARC 185 POWER SOURCE Fig 10 Weldarc 185 Power Source Assembly 5 4 3 2 1 6 7 9 8 10 11 7 15 13 12 14 ...

Page 28: ...109 PCB Main Control 185 1 6 R0032 Thermister 1 7 M0108 Panel Plastic 1 8 PWA110 PCB Front Panel 185 2 9 WIN628 Front Panel Control Sticker 185 1 10 M0104 Knob 1 11 CX58 Output Socket 2 12 PWA111 PCB Rectifier 1 13 PWA061 PCB PFC 1 14 E0078 Main Switch 1 15 Supply Cable 2 5mm2 15 A Plug 16 REG003 Argon Regulator 1 17 CX22 Dinse Plug 1 18 62513 Gas Hose 5mm 1 19 CLA002 Work Clamp 1 Not shown MC112 ...

Page 29: ...lt 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 replacement product if original found to be faul...

Page 30: ... to have 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 ...

Page 31: ... 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 17 NEW ZEALAND WARR...

Page 32: ...USTRALIA A Division of ITW Australia Pty Ltd ABN 63 004 235 063 1300 300 884 Email info welding com au 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 MC112 40 RevB ...