WIA WELDARC 400 User manual

WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIES LPD
ACN
004 547 111
Head Office and International Sales
5 Allan Street, Melrose Park
SouthAustralia,
5039
Telephone [phone] Facsimile(08)82766327
OWNERS MANUAL
WELDARC
400
MODEL NO. MC98-0
REV.A
06/96
QUALITY WELDINGPRODUCTS, SYSTEMS AND SERVICE
4 y,;:

The information contained in this manual is set out to enable you to properly
maintain yournew equipment and ensure that you obtain maximum operating
efficiency.
Pleaseensure
that this information is kept in a safe place for readyreference
when required
at any future time.
When requesting spare parts, please quote the serial number of the machine and
if possible, the part number of the item required. All relevant numbersare shown in
this manual.Failure to supply this information may result in unnecessarydelays in
supplying the correct parts.
SAFETY
Before this equipment is put into operation, the SAFE PRACTtCESsection at the
back of the manual must be read completely. This will help to avoid possible injury
due to misuse
or improper welding applications.
CONTENTS
SECTION PAGE
1 ................... INTRODU~~ION ...........................
2 ....................... RECEIVING ............................. 3
3 .................. SPECIFICATIONS ......................... 4
4 ............... FITTING HANDLE KIT ...................... 4
5 ........... CONNECTION TO MAINS .................. 5
6 ...................... OPERATtON ............................. 5
7 ...................... PARTS LIST ............................. 6
8 ................... MAINTENANCE .......................... 8
9 ................... FAULT FINDING .......................... 8
IO ................ SAFE PRACTICES ........................ 9
FIGURE PAGE
1 ................ HANDLE POSlTtON ....................... 4
2 ...... MACHINE SUPPLY TERMINALS ............. 5
3 ................ STRIKING THE ARC ....................... 6
4 .............. ASSEMBLY DIAGRAM ..................... 7

WELDARC 400 MANUAL Page 3
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Manual Metal Are welding (M.M.A.) is a basically simple welding IJrQCeSS, where
anarc
is struck between a flux-coated consumableelectrode and the workpiece. The
arc and the weld pool are both shielded by gases generated by the flux coating of the
electrode.
The WELDARC
400 has beendesigned to be used with electrodes from 2.5mm to
6.0mm diameter, The smaller
sizes are used whenwelding at lower currents, such as
light fabrication. Increasing the electrode diameter permits higher welding currents
to be selected.
W.I.A. manufactures a wide range of mild steel
and special purpose electrodes
which cater for homeworkshop, rural,
and industrial requirements. Some popular
AUSTARC electrodes are listed
betow. The correctly selected AUSTARC electrode
used
in conjunction with yournew WELDARC 400 will influence the quality of the
weld, and the stability sf the arc.
Austarc 12P, Classification E41 12.
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 allgeneral mild steel
applications.
Austarc
133, Classification E41 13.
A smoothrunning electrode with a soft arc, particularly
suited to light sheetrnetal
and smooth mitre fillet welds.
Austarc 16TC, Classification E4816.
A low hydrogen electrode with good arc stability and out-
of-position welding characteristics. This electrode is ideal
for medium carbonsteels, or steels of unknownanalysis.
Unicord
31 2
A high tensile (50 tsiIlhighchromiumnickel electrode
specially formulated for joining all aby steels and irons,
andfor
tool and die maintenance.
2. RECEIVING
Check the e uiprnent received againstthe shipping invoice to make sure the
shipment
is comp v ete and undamaged. tf any damage has occurred intransit, please
immediately notify your supplier.
The WELDARC 400 carton contains:
m WELDARC 400 Welding PowerSupply
m Handlekit
II (This) Uwners Manual

Page.4 WELDARC 400 MANUAL
3. SPECIFICATIONS
INPUT VOLTAGE ..........................................
415 Volts AC, singlephase, 50 Hz
RATED INPUT CURRENT .............................
30 Amps
MAXIMUM SHORT CIRCUIT CURRENT
......
80 Amps
INPUTAT MAXIMUM OUTPUT
.....................
50 Amps
OPEN CIRCUIT VOLTAGE
........................... LOW range 80 Volts.
High range
52 Volts.
RATED OUTPUT CURRENT
......................... Low range
230 Amps, 29 Volts, 45% Duty cycle
155 Amps, 26 Volts, 100% Duty Cycle
........................ High range
400 Amps, 36 Volts, 35% Duty cycle
235 Amps, 29Volts, 100% Dutycycle
ELECTRODE RANGE
................................... 2.5mm to 6.0mm diameter
DIMENSIONS ................................................ H:86Omm W:400mm D:540mm
WEIGHT
........................................................ 180kg.
NOTE : Maximum output derates to 360 Amps for 380 Volts operation.
Duty Cycle is defined in Australian Standard AS1966.1 as the ratio
of arcing time to
5 minutesinany 5 minuteperiod, expressed as a percentage.
4. FITTING HANDLE KIT
Before removing the machine cover, ENSURE that the unit is disconnected from the
mains power supply, Whenthe unit
is energised LETHAL V01 TAGES are present on the
electrical components enclosed.
To fit the handle, first remove the top four screws holding the rearsheet metal panel.
The handle isthen fitted to the reartop
of the sheet-metal] as shown, using the same four
screws.
FIGURE 1, HANDLE POSITION

WELDARC 400 MANUAL Page 5
5. CONNECTION TO ELECTRICAL MAWS POWER SUPPLY
The WELDARC 400 must be fitted witha two core plus earth primary supply cable
with conductors not less than 6mm* (192/0.2). The machine supply terminals are
accessed by removing the teft hand
side sheet-metal panel (machine viewed from
front). Ensure the Earth connectionis correctly made, and that the supply cable is
firmly anchored toprevent stressing of
the electrical terminations.
Due to eak current requirements, the Electrical Mains sup ly to welding
machines is est protected by either HRC or rewirable type fuses. 8 ircuit Breakers
may trip frequently
if used in this application.
EARTH
TERMINAL
FtGURE 2. MACHINE SUPPLY TERMINALS
6. OPERATION
Be certain that you are wearing suitabte protective clothin , gloves etc, and that
you are working in a non-hazardous area. If necessary, re P er again to the SAFE
PRACTICESsection of this manual.
Connect the Work Clamp to the workpiece.Place
the desired electrode in the
Electrode holder, Select an appropriate welding current for the electrode diameter by
rotatingthe handfe on the machine top. Thefront panel indicator shows the
approximate welding current selected, however the actual current is affected by the
electrode type, and
by the operator technique. WIAAUSTARC electrodes will give
you thebest results.
To strike the arc, drag the end of the electrode along the workpiece 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 goodweld appearance. An arc which is too long
causes an unwieldly flow of metal with
a rough weld appearance andreduced
penetration. An arc too short leads to a narrow weld deposit and "stuttery" arc
characteristic, andthe electrode is liable to freeze onto theworkpiece.