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
""-
. "-111
~~ ~~
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.

Page 6 WELDARC 400 MANUAL
As the solidified weld deposit forms, move the end of the electrode slowly along
theweld path, aiming to maintain
a pool of molten weldmetal behind the arc.
Decreasing this rate of travel will result in a widerweld deposit, and similarly
increasing it will narrowthe
weld deposit.
Always fill the crater which tendsto format 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.
Maintam steady arc length
FIGURE 3. STRIKING THE ARC
7. PARTS LIST
WELDARC 400 POWER SOURCE
ITEM # PART # DESCRIPTION
1 ................. MC90-12 ................... Transformer CoreAssembly
2 ................. MC90-13 ................... PrimaryCoil Assembly
3 ................. MC90-14 ................... Secondary CoilAssembly
4 ................. MC904 1 /1 ............... Adjusting Shaft
5 ................. MC90-11/2 ...............
Current Indicator
6 ................. MC90-1 l /3 ............... Primary Connection Board
7 ................. MC20-30 ...................
CompressionSpring
8 ................. MC90-15 ................... InductanceAssembly
9 ................. MC90-16 ...................
BaseAssembly
10 ............... MC90-17 ................... Front Panel
11 ............... MC90-18 ...................
Rear Panel
12 ............... MC90-19 ................... Side Panel
13 ............... MC90-20 ................... Top Cover
14 ............... Mm-21 ................... FanBracket
15 ............... MC90-22 ...................
Current Adjusting Handle
16 ............... MC90-24 ...................
MainsTerminal Board
17 ............... MC90-28 ...................
Handle
18
............... CP29-0/7 ..................
Fan Motor (415 Volts)
19 ............... CP33-0/4 ..................
FanBtade
20 ............... AA40 ......................... Terminal Assembly
21 ............... MC66-24 ................... Adjusting Knob
22 .............. .AM235-0/2 ............... Rubber W heel
23 ............... 08029F ......................
Eye Nut
24 ............... MC84-0/2 ................. Cable Gland
25 ............... MC84-0/4 ................. Cable Gland Nut

WELDARC 400 MANUAL Page 7
m
FtGURE 4. ASSEMBLY DIAGRAM

Page 8 WELDARC 400 MANUAL
8. MAINTENANCE
Care should be taken to prevent excessive build-up of dust anddirtwithin the
welding power source. It is recommended that at regular intervals, according to the
prevailing conditions, the machine covers be removed andany accumulateddust be
removedbythe use ofdry, low pressure compressedair, or a vacuum cleaner.
9. FAULT FtNDING, NO WELDING CURRENT
Cheek that MainsSupply is available at the WELDARC 400 Power Source, i.e. that
Check continuity
of the welding current circuit, i.e., work lead, workclampand
the cooling fan
is running .
electrode holder,
If equipmentfailure is suspected, forward the unit to your nearest WtA Sales and
Service Branch, or to
a qualified service agent.

WELDARC 400 MANUAL Page 9
IO. SAFE PRACTICESWHEN USING WELDING EQUIPMENT
Thesenotesareprovidedin the interestsof improving operator safety. Theyshouldbeconsidered
only as a basicguide to Safe Working Habits. Afull list of Standards pertaining
to industry is available from
the Standards Associationof Australia, also various StateElectricityAuthorities, Departments of Labour and
Industry
or Mines Department and other Local Health or Safety Inspection Authorities may have additional
requirements. WTIA TechnicalNoteTN7-98also provides acomprehensiveguide to safepracticesin
welding.
EYE PROTECTION
NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or glasses
with sideshields underneath, with appropriate filter lenses protected by clear cover lens.This is a MUST for
welding,cutting,andchipping to protect the eyes from radiantenergyand flying metal. Replacethecover
lens when broken, pitted, or spattered.
Recommended shade filter lens.
Amps TIG MMAW MIG Pulsed MIG
0-100 ............. 10 .................. 9 ................... 10 .................
100-150 ......... 11 .................. 10 .................
10 .................
150-200 .........
12 .................. 10-11 ............ 11-12 ............
200-300 ......... 13 .................. 11 .................
12-13 ............
300-400 .........
14 .................. 12 ................. 13 .................
2-7 3
2-1 3
2-t 3
2-1 3
4
4QO-500 ............................ " 13 ................. 14 ................. 14
500 + ................................................... " " 14 ................. 14
BURN PROTECTION.
Theweldingarc is intenseand visibly bright. Its radiationcandamageeyes,penetratelightweight
clothing, reflect from light-coloured surfaces, and burn the skin and eyes. Burns resulting from gas-shielded
arcs resemble acute sunburn, but can be more severe and painful.
Wear protectiveclothing
- leather orheatresistantgloves,hat,andsafety-toeboots.Buttonshirt
collar and pocket flaps, and wearcufflesstrousers
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 withoutgloves.
Earplugsshouldbewornwhenwelding in overheadpositionsor in aconfinedspace.
A hardhat
should be worn when others are working overhead.
Flammable hair preparations shouldnot be usedby persons intending
to weld or cut.
TOXIC FUMES.
Adequate ventilation with air is essential. Severe discomfort, illness or death cmresult from fumes,
vapours, heat, or oxygen depletion that weldingor cutting may produce. NEVERventilate 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,oreach
person inthe area
as well as the operator must wear an air-supplied respirator, For beryllium, both must be
used. Metalscoatedwithorcontainingmaterials that emit fumesshouldnotbeheatedunlesscoatingis
removed from the work surface, the areaiswell ventilated,
or the operator wears an air-supplied respirator.
Work in a confined space only whileit isbeingventilated and,
if necessary, while wearing air-supplied
respirator.

page 18 WELDARC 400 MANUAL
Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form
PHOSGENE, a highly toxicgas, and lung andeye irritating products.The ultra-violet (radiant)energyof
the arc can also decompose trichlorethylene and perchlorethylenevapors 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 trichlorethylene or
percholorethylene.
FIRE AND EXPLOSION PREVENTION.
Beaware that flyingsparks or falling slagcan pass through cracks, along pipes, throughwindows
or doors,andthrough wall or flooropenings,
out of sightof the operator.Sparksandslagcan travel up
to 10 metres from thearc.
Keep equipment clean and operable, free of oil, grease, and (inelectricalparts)ofmetallic
partlcles thatcancauseshort circuits.
If combustiblesare present in the workarea, do NOT weld or cut.Movethe work if practicable, to
an areafree of combustibles. Avoid paint spray rooms,dip tanks, storageareas, 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-resistantcoversor shields.
Walls touching combustibles on opposite sides should not be welded on
or cut. Walls, ceilings,
andfloor near work should be protectedby heat-resistantcoversor shields.
A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment
during and forsometime after weldingor cutting
if;
m Combustibles(includingbuildingconstruction) arewithin 10 metres.
m Combustiblesarefurther than l0 metresbut can be ignited bysparks.
m Openings(concealed or visible)infloors or walls within 10 metresmay expose combustibles
m Combustiblesadjacenttowalls, ceilings,roofs,or metal partitionscan beignited by radiantor
After work is done, checkthat area is free of sparks,glowing embers, andflames.
An tank or drum whichhas contained combustiblescan produce flammable vapors when heated.
Such
a container mustneverbe weldedonorcut, unless it has first been cleaned as describedin
AS. 1674-1 974, the S.A.A. Cutting andWelding SafetyCode. This includes a thorough steamor caustic
cleaning
(or a solvent or waterwashing, depending on the combustible’s solubility),followed by
purging and inerting with nitrogenor carbon dioxide, and using protectiveequipment as recommended
in AS.1674-1974. Water-fillingjust below working levelmaysubstitute for inerting.
tosparks.
conductedheat.
Hollowcastings or containers must bevented before welding or cutting.They can explode. Never
weld or cutwhere theair maycontainflammable dust, gas, orliquidvapours.
SHOCK PREVENTION.
Exposed conductors or other bare metal in the weldlng circuit, or ungrounded electrically alive
equipment can fatally shock a person whose body becomes a conductor. Ensure that the machine is
correctly connectedand earthed.
If unsurehavemachineinstalled by a qualified electriclan.On mobile
orportable equipment, regularly inspect conditionoftrailing power leads andconnectingplugs.
Repair orreplacedamaged leads.
Fully insulatedelectrodeholdersshould beused. Do not use holderswithprotruding screws.
Fully insulated lock-type connectors should beused
to join welding cablelengths.
Terminals and other exposed parts of electricalunitsshould have insulatedknobs or covers
securedbefore operation.