Weldarc 200i AC/DC

Weldarc 200i AC/DC Arc/TIG Welder

Model No. MC105-0 (From serial no. M1052B*)

Operators Manual
06/17

MC105-40 Rev C
Welding Industries of Australia
A division of ITW Australia Pty Ltd

1300 300 884

[email protected]
welding.com.au

Weldwell New Zealand

A Division of ITW New Zealand

Telephone: 06 8341 600

Email: [email protected]
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

Safe Practices When Using

Read First Welding Equipment
The information contained in this These notes are provided in the interests
manual is set out to enable you of improving operator safety. They should
to properly maintain your new be considered only as a basic guide to Safe
equipment and ensure that you obtain Working Habits. A full list of Standards
maximum operating efficiency. pertaining to industry is available from
the Standards Association of Australia,
Please ensure that this information is
also various State Electricity Authorities,
kept in a safe place for ready reference
Departments of Labour and Industry or
when required at any future time.
Mines Department and other Local Health
When ordering spare parts, please or Safety Inspection Authorities may have
quote the model and serial number additional requirements. Australian Standard
of the power source and part number AS1674.2 provides a comprehensive guide to
of the item required. All relevant safe practices in welding.
numbers are shown in lists contained
in this manual. Failure to supply this Eye Protection
information may result in unnecessary
NEVER LOOK AT AN ARC WITHOUT
delays in supplying the correct parts.
PROTECTION. Wear a helmet with
safety goggles or glasses with side shields
Safety
underneath, with appropriate filter lenses
Before this equipment is put into protected by clear cover lens. This is a MUST
operation, please read the Safe for welding, cutting, and chipping to protect
Practices section of this manual. the eyes from radiant energy and flying
This will help to avoid possible injury metal. Replace the cover lens when broken,
due to misuse or improper welding pitted, or spattered.
applications.
Recommended Shade Filter Lens
Plastic Handles on Power Pulsed
Source Amps TIG MMAW MIG MIG

Please note that the handle fitted to 0-100 10 9 10 12-13

the Weldarc 200i inverter is intended 100-150 11 10 10 12-13

for carrying the equipment by hand 150-200 12 10-11 11-12 12-13
only. 200-300 13 11 12-13 12-13
DO NOT use this handle for 300-400 14 12 13 14
suspending or mounting the Weldarc 400-500 — 13 14 14
in any other manner.
500 + — — 14 14

2 Trusted by the best

 Weldmatic 200i AC/DC

Burn Protection coating is removed from the work surface,

the area is well ventilated, or the operator
The welding arc is intense and visibly bright.
wears an air-supplied respirator.
Its radiation can damage eyes, penetrate
light-weight clothing, reflect from light- Work in a confined space only while it is
coloured surfaces, and burn the skin and being ventilated and, if necessary, while
eyes. Burns resulting from gas-shielded arcs wearing air-supplied respirator.
resemble acute sunburn, but can be more Vapours from chlorinated solvents can be
severe and painful. decomposed by the heat of the arc (or
Wear protective clothing – leather or heat flame) to form phosgene, a highly toxic
resistant gloves, hat, and safety-toed boots. gas, and lung and eye irritating products.
Button shirt collar and pocket flaps, and The ultra-violet (radiant) energy of the arc
wear cuffless trousers to avoid entry of can also decompose trichlorethylene and
sparks and slag. perchlorethylene vapours to form phosgene.
Do not weld or cut where solvent vapours
Avoid oily or greasy clothing. A spark may can be drawn into the welding or cutting
ignite them. Hot metal such as electrode atmosphere or where the radiant energy
stubs and work pieces should never be can penetrate to atmospheres containing
handled without gloves. even minute amounts of trichlorethylene or
percholorethylene.
Ear plugs should be worn when welding in
overhead positions or in a confined space.
Fire And Explosion Prevention
A hard hat should be worn when others are
working overhead. Be aware that flying sparks or falling slag can
pass through cracks, along pipes, through
Flammable hair preparations should not be
windows or doors, and through wall or floor
used by persons intending to weld or cut.
openings, out of sight of the operator. Sparks
and slag can travel up to 10 metres from the arc.
Toxic Fumes
Keep equipment clean and operable, free of
Adequate ventilation with air is essential.
oil, grease, and (in electrical parts) of metallic
Severe discomfort, illness or death can
particles that can cause short circuits.
result from fumes, vapours, heat, or oxygen
depletion that welding or cutting may If combustibles are present in the work
produce. NEVER ventilate with oxygen. area, do NOT weld or cut. Move the work if
practicable, to an area free of combustibles.
Lead, cadmium, zinc, mercury, and beryllium Avoid paint spray rooms, dip tanks, storage
bearing and similar materials when welded areas, ventilators. If the work can not be
or cut may produce harmful concentrations moved, move combustibles at least 10 metres
of toxic fumes. Adequate local exhaust away out of reach of sparks and heat; or
ventilation must be used, or each person in protect against ignition with suitable and
the area as well as the operator must wear snug-fitting fire-resistant covers or shields.
an air-supplied respirator. For beryllium, both
must be used. Walls touching combustibles on opposite
sides should not be welded on or cut. Walls,
Metals coated with or containing materials ceilings, and floor near work should be
that emit fumes should not be heated unless protected by heat-resistant covers or shields.

Model No MC105 3
Operators Manual

A person acting as Fire Watcher must be Shock Prevention

standing by with suitable fire extinguishing
Exposed conductors or other bare metal
equipment during and for some time after
in the welding circuit, or ungrounded
welding or cutting if;
electrically alive equipment can fatally shock
• Combustibles (including building a person whose body becomes a conductor.
construction) are within 10 metres. Ensure that the equipment is correctly
connected and earthed. If unsure have the
• Combustibles are further than 10 metres
equipment installed by a qualified electrician.
but can be ignited by sparks.
On mobile or portable equipment, regularly
• Openings (concealed or visible) in floors inspect condition of trailing power leads
or walls within 10 metres may expose and connecting plugs. Repair or replace
combustibles to sparks. damaged leads.
• Combustibles adjacent to walls, ceilings, Fully insulated electrode holders should be
roofs, or metal partitions can be ignited used. Do not use holders with protruding
by radiant or conducted heat. screws. Fully insulated lock-type connectors
should be used to join welding cable lengths.
After work is done, check that area is free of
sparks, glowing embers, and flames. Terminals and other exposed parts of
electrical units should have insulated knobs
A tank or drum which has contained
or covers secured before operation.
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.

4 Trusted by the best

 Weldmatic 200i AC/DC

1 Introduction
MMAW (Stick Welding) Austarc 11, Classification E4311-A
Manual Metal Arc Welding (MMAW) is a A high cellulose electrode for all positional
process where an arc is struck between a welding, AC or DC. Particularly suited for
flux-coated consumable electrode and the vertical and incline pipe welding where
work piece. The arc and the weld pool are complete root penetration is required.
both shielded by gases generated by the flux
Unicord 312, Classification ES312-16
coating of the electrode.
A high tensile (50tsi), chromium nickel
The Weldarc 200i has been designed to
electrode specially formulated for joining
be used with 2.0mm, 2.5mm, 3.2mm and
all alloy steels and irons, and for tool and
4.0mm diameter electrodes. The smaller
die maintenance.
electrodes are used when welding at lower
currents, such as sheet metal applications.
GTAW (TIG Welding)
Increasing the electrode diameter permits
higher welding currents to be selected. Gas Tungsten Arc Welding (GTAW) is a
welding process where the arc is struck
WIA supplies a wide range of mild steel and
between a non-consumable tungsten
special purpose electrodes which cater for home
electrode and the work piece. A ceramic
workshop, rural, and industrial requirements.
nozzle surrounds the tungsten electrode and
Some popular AUSTARC electrodes are listed
directs a flow of inert gas, usually Argon,
below. The correctly selected AUSTARC
over the electrode and the weld zone. If
electrode will influence the quality of the weld,
filler metal is required, it is hand fed into
and the stability of the arc.
the welding arc. The DC current output of
Austarc 12P, Classification E4313-A the Weldarc inverter is suitable for welding
most ferrous and non-ferrous metals. The AC
A popular general purpose electrode
current output is for welding Aluminium.
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.

Model No MC105 5
Operators Manual

2 Receiving 3 Operation
Check the equipment received against the Whenever the welding output of the Weldarc
shipping invoice to make sure the shipment inverter is open circuit (ie not arcing), the
is complete and undamaged. If any damage voltage across the welding leads is reduced
has occurred in transit, please immediately to a safe level. This provides an increased
notify your supplier. level of safety to the welding operator during
operations such as changing the electrode.
The Weldarc inverter package contains;
The “VRD SAFE” indicator on the front
• Weldarc Inverter Power Source panel is on to confirm the output is in the
safe condition.
• Twist-lock Electrode Holder
The term VRD refers to a “Voltage Reducing
• Work Clamp 3m
Device”which complies with AS1674.2 for
• (This) Operating Manual MC105-40. Category “C” conditions.
• TIG Torch Complete WP17V121625
with valve, 5m cable with twist-lock
connection and fitted with 2.4mm collet
If the supply cable is damaged it
and ceriated tungsten
must be replaced by the manufacturer,
• TIG Consumable KIT their service agent or a similarly
qualified person.
• Argon flow gauge regulator REG003

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.

6 Trusted by the best

 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 25 kg
Dimension L × W × H 530 x 240 x 420 mm
Shipping Dimension L × W × H 770 x 335 x 460 mm

8 Trusted by the best

 Weldmatic 200i AC/DC

5 Controls
Power Switch
11 13 12 14
Located on the rear panel

Welding Industries of Australia

welding.com.au

AMPS 1

2
10 AC/DC

HOT IGNITION UP
START CURRENT SLOPE
WELDING
CURRENT
PEAK BASE DOWN
CURRENT CURRENT SLOPE
CRATER
CURRENT 3
PULSE
RATIO

9 PULSE HERTZ
4

HF
MODE GAS 5
PRESS

WIN567B
GAS PURGE

8 6 7 6

Fig 1 Weldarc 200i AC/DC Controls

1 VRD Safe Mode Indicator 200i AC/DC

2 Over Temperature Indicator
WIN567B 200i AC/DC
When the machine is in MMA stick mode This light will come on if any internal thermal
the light will be on when the voltage across protection devices have operated due to
the output terminals is reduced to safe level. overheating, caused by the duty cycle
The VRD will operate in accordance the being exceeded.
requirements of AS1672.2 2007 Category C
The machine will not weld but the fan will
Environment.
continue to operate to cool the machine.
When a safe temperature has been reached,
the thermal protection device will reset and
welding can continue.

Model No MC105 9
 Operators Manual

5 Controls
3 Voltage Range Indicator 4.2 4 STEP
In this mode the torch trigger switch is
This light will be on when the input supply
pressed to start the arc.
voltage is too high or too low. There will be
no output. The current will stay at the ARC IGNITION
setting.
Low voltage can occur on a weak power
supply, or if the machine is operated from a When trigger is released the current
long power cable from a weak supply, or an will increase to the WELDING CURRENT
under rated generator. setting, according to the UP SLOPE time.
High voltage can occur on some rural power Output will continue at WELDING
supplies and lightly loaded generators. CURRENT setting.
4 Latch Mode 2T/4T When torch trigger is pressed again then
the weld output will decrease down to
Latch mode provides a 2 STEP or 4 STEP
CRATER CURRENT setting, according to the
trigger control while in TIG mode:
DOWN SLOPE time.
4.1 2 STEP
Weld output will remain at CRATER
In this mode the torch trigger must be
CURRENT until torch trigger is released,
pressed on to initiate welding and held
then gas will flow for POST GAS time.
on till welding is finished.
Up slope and down slope, ignition
current and crater current cannot
used in the 2 STEP.

Press + Hold Release

Torch Trigger Torch Trigger

WELDING CURRENT
Amps

PRE GAS POST GAS

Time

Fig 2 Latch Mode–2 STEP

Press + Hold Release Press + Hold Release

Torch Trigger Torch Trigger Torch Trigger Torch Trigger

WELDING CURRENT
Amps

IGNITION UP SLOPE DOWN SLOPE CRATER

CURRENT CURRENT

PRE GAS POST GAS

Time

Fig 3 Latch Mode–4 STEP

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 Weldmatic 200i AC/DC

5 Gas Purge is pressed, then a high energy spark is

created to jump from the tungsten to
Press and hold the gas purge button to allow
work piece and initiate an Arc.
gas to flow without output weld voltage or
current. This feature can be used when a gas
9 Pulse Mode
bottle is connected and air can be purged
from the gas line and torch. It can also be When in LIFT-ARC TIG or HF TIG mode, then
used to safely set shielding gas flow rate Pulse TIG can be selected and the parameters
at the gas flowmeter, without the welding for adjusting the pulse shape will be available
current outputs being live. for adjustment.
Peak Current, Pulse Ratio, Frequency Hertz,
6 Parameter Select
and Base Current.
Use these buttons to cycle through the
Welding parameters, which can then be 10 AC/DC Mode
adjusted by knob 7. If no adjustment is made
The polarity of the output current can be
after 4 seconds the parameter will change
selected between Alternating Current (AC)
back to WELDING CURRENT.
or Direct Current (DC).
7 Adjustment Knob AC mode can only be selected in TIG mode.
The alternating current arc can be used
This knob is used to adjust the parameter of
specifically for welding aluminium.
the weld function, as selected by button 6.
11 AMPS Display
8 Weld Mode Selection
The Left hand digital display will show
The Weld Mode can select between the three
Amps while adjusting current with knob 7,
mode of operation.
and then display weld Amps while welding
8.1 Stick MMA Mode is in progress.
In this mode the machine performs as
12 Multi Parameter Display
a DC stick MMA welding machine. The
HOT START and ARC FORCE parameters The right hand display will show the value
can be adjusted on the front panel. of a parameter being adjusted. The type of
parameter will be indicated by one of the 4
8.2 Lift Arc TIG
indicators next to the display.
In this mode the machine will perform as
For example if the AC Frequency is being
a AC or DC TIG machine. The arc start is
adjusted then Hz indicator will be on and the
by Lift Arc technique.
display will show the frequency that is being
8.3 High Frequency Start TIG adjusted by knob 7.
In this mode the machine will perform as
AC or DC machine with High Frequency
(HF) arc start. When the tungsten is near
the work piece and the torch trigger

Model No MC105 11
Operators Manual

5 Controls
13 Welding Parameters 13.5 Welding Current
13.1 Pre Gas The setting for actual weld current.
Pre gas flow can be set to a maximum 13.6 Pulse Welding
of 5 seconds, to allow gas flow before
Pulse welding allows the current to
Arc Start.
be pulsed between two different
13.2 Hot Start values, the frequency and ratio can be
adjusted. This feature can be used on
Only available in Stick MMA mode, Hot
thin material.
Start will provide a current boost at the
start of the arc. The parameter can be 13.6.1 Peak Current
adjusted up to 70Amps which will add
Set the Peak current Amps.
to the preset welding current.
13.6.2 Pulse Ratio
13.3 Ignition Current
Set the ratio in % for the peak
While in 4 STEP latch mode the arc will
current compared to the back
start and maintain the Ignition current
ground current. Range is 15%
output until the trigger torch is released.
to 85%.
The IGNITION CURRENT can be more or
13.6.3 Hertz
less than the WELD CURRENT setting.
The frequency of the pulse can be
Setting the IGNITION CURRENT high
set, as number of pulses per second
can be useful for joint preheat.
(HERTZ) 0.5Hz to 200Hz.
13.4 Up Slope
13.6.4 Base Current
The UP SLOPE time is the time taken
Set the Base current Amps.
for the weld current to transition from
the IGNITION CURRENT value to WELD
CURRENT value. The time can be
adjusted from 0 to 15 seconds.

HOT IGNITION UP WELDING PEAK BASE DOWN CRATER

START CURRENT SLOPE CURRENT CURRENT CURRENT SLOPE CURRENT

PULSE
RATIO

HERTZ

Fig 4 Weldarc 200i AC/DC Welding Parameters

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 Weldmatic 200i AC/DC

13.6.5 Down Slope 13.8 AC Balance Or Arc Force

The DOWN SLOPE time is the 13.8.1 AC Balance
time taken for the weld current
When AC TIG mode is selected
to transition from the WELDING
then the proportion of positive
CURRENT value to CRATER
and negative in the cycle can be
CURRENT value. The time can be
adjusted. This is referred to as the
adjusted from 0 to 25 seconds.
BALANCE and is expressed as a
13.6.6 Crater Current % of the time that the polarity
is negative. Adjustment is from
The current at the end of WELD
35% - 90%.
can be adjusted to a value which
will allow controlled finish of the Arc Welding of aluminium is difficult
weld. The end of weld pool (Crater) because the metal readily forms an
can be filled. oxide layer, which is an electrical
insulator, and inhibits arc formation.
13.6.7 Post Gas
The Oxide needs to be “cleaned
The Post Gas time can be adjusted off”. Electrode positive will remove
to allow gas to flow after weld has the oxide off the surface as the
stopped. This feature can be used to electrons flow off the aluminium to
provide a gas shield to the cooling the tungsten electrode. Continuous
weld pool. Adjustable from 0 to 30 electrode positive will burn the
seconds. tip away, so the current has to be
reversed to electrode negative, for
13.7 AC Frequency
some of the time.
When AC mode is selected by button
For new clean aluminium an
(10) then actual AC frequency can be
AC BALANCE of 65% is a good
adjusted from 15 to 150Hz.
starting point.
Increasing the frequency makes the
welding current change direction at a
faster rate. The arc becomes constricted, + +
more stable and directional, providing
deep penetrating narrow welds. %− %−

When the frequency is lower the arc is

wide with shallow penetration, suitable Fig 5 AC Balance
for butt or edge welds on thin material.

Model No MC105 13
Operators Manual

5 Controls
13.8.1.1 Low % Balance 15 Remote Control Adjustment
›› Less time negative The output current of the machine can
be controlled remotely by On/ Off trigger
›› More time positive
switch control and current control
›› More cleaning action adjustment, located in the torch hand
piece, or in foot control.
›› More heat in the tungsten
The Remote control adjustment will allow
›› Wider weld with shallower
minimum -100% of the current setting on
penetration
the machine.
13.8.1.2 High % Balance
For example if the machine is set to 150A the
›› More time negative remote adjustment will adjust 10-150A.
›› Less time positive 15.1 TIG torch used for remote
control adjustment
›› Less cleaning action
The TIG torch will require a trigger switch
›› Less heat in the tungsten,
and current control potentiometer in the
higher current for smaller
hand piece.
electrode
Control plug of the TIG torch is
›› Narrow weld beads with
connected to the machine remote control
deeper penetration
socket FIG 7.
›› Smaller heat affected zone
Turn the machine on.
13.8.2 Arc Force
First the machine needs to be adjusted to
When machine is in Stick MMA maximum desired current.
mode, selecting the ARC FORCE
To do this the remote control knob
allows adjustment of the % increase
on the TIG torch needs to be adjusted
in current that will occur when the
to maximum.
arc starts to short circuit, or snap out.
Adjusting this value can be useful Adjust to the desired maximum current
when using cellulose electrodes. (such as 150A) on the machine with the
control knob FIG 1 (7). The AMPs digital
14 Power On/Off Switch display will then show 150A.

In the OFF position, this switch isolates the Adjust the control knob on the TIG torch,
power source from mains power supply. the AMPS display will then change as the
The switch is located on the rear panel. knob is adjusted.

14 Trusted by the best

 Weldmatic 200i AC/DC

15.2 Foot Control for remote

control adjustment
The WIA foot control (part number
AA76) has an in built trigger switch and
current control and can be used to
control the weld start and weld current.
Control plug of the TIG torch is
connected to the machine remote control
socket FIG 7.
Turn the machine on.
First the machine needs to be adjusted to
maximum desired current
Select LIFT TIG MODE to prevent HF
during setup.
Press the foot control pedal to maximum.
Adjust to the desired maximum current
(such as 150A) on the machine with the
control knob FIG 1 (7). The AMPs digital
display will then show 150A.
Release the foot control pedal and the
current to will adjust down from 150A
to 10A.
HF MODE can now be selected
if required.

Model No MC105 15
Operators Manual

6 Installation
Connection to Electrical Mains Power
Supply
The Weldarc 200i AC/DC is fitted with a
15 Amp plug and socket, recognisable by
a wide Earth pin. Power Supply authorities
require that equipment fitted with a 15 Amp
plug shall ONLY be connected to a 240 Volt,
15 Amp power point. DO NOT modify
the plug.
The minimum capacity of the main power
supply wiring and power outlet supplying a
welder is selected according to the Effective
Primary Current of the equipment. Refer to
Section 4.
The minimum recommended main power
supply circuit breaker rating for Weldarc
inverter are listed in Section 4.
The current rating of the mains cable
depends on cable size and method of
installation. Refer to AS/NZS 3008.1, Table 9.
If it becomes necessary to replace the mains
flexible supply cable, use only cable with
correct current rating. See Section 4.
If it is necessary to use an extension power
supply cable, ensure that it is rated as per
Section 4. Voltage drop which will occur over
long lengths of cable will reduce the quality
of welds and the maximum welding current
available 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.

16 Trusted by the best

 Weldmatic 200i AC/DC

7 Basic Welding Information

Stick Welding (MMAW) To strike the arc, drag the end of the
electrode along the work piece as if striking
Connection for Stick Welding
a match. As the arc initiates, lift the electrode
It is important to select the electrode polarity slightly away, aiming to establish an arc
in accordance with the manufacturers length of approximately 3mm.
recommendations for that electrode. Most
As the electrode end is consumed, feed the
common electrodes, including cellulose
electrode into the arc in order to maintain
types, are operated with the electrode at
arc length. As a general rule, the arc should
positive polarity, as illustrated in Figure 6.
be held as short as possible while still giving
stable burn off and good weld appearance.
An arc which is too long causes an unwieldy
flow of metal with a rough weld appearance
Work and reduced penetration. An arc too short
Electrode Clamp leads to a narrow weld deposit and “stuttery”
arc characteristics, and the electrode is liable
to freeze onto the work piece.
As the solidified weld deposit forms, move
the end of the electrode slowly along
the weld path, aiming to maintain a pool
of molten weld metal behind the arc.
Fig 6 Connections for Stick Welding (MMAW) Decreasing this rate of travel will result in a
wider weld deposit, and similarly increasing it
Stick Welding will narrow the weld deposit.
Be certain that you are wearing suitable Always fill the crater which tends to form
protective clothing, gloves etc and that at the end of a weld deposit, by pausing
you are working in a non-hazardous area. momentarily before withdrawing the electrode
If necessary, refer again to Section 1 - Safe to break the arc. Unfilled craters are a point
Practices in this manual. of weakness, and can lead to weld cracking.
Connect the work clamp to the work
Current Range for General Purpose
piece. Place the desired electrode in the
Electrodes
electrode holder.
Diameter (mm) Current (Amps)
Turn on the power switch located on the rear
panel. Wait approximately 5 seconds as the 2.0 40 -60
unit goes through its initiation sequence.
2.5 60 - 85
Use the Weld Mode Selection button to
3.2 90 - 130
select Stick Mode.
4.0 130 - 180
Select an appropriate welding current for
the electrode diameter by setting the knob
on the machine front panel. WIA AUSTARC
electrodes will give the best results.

Model No MC105 17
Operators Manual

7 Basic Welding Information

TIG Welding (GTAW) Electrode TIG
Connection for TIG Welding Thoriated Tungsten electrodes are normally
used for DC welding current, and Zirconiated
For TIG Welding, the TIG torch is connected
Tungsten electrodes are normally used for AC
to the negative terminal. Figure 7 illustrates
TIG welding.
the correct connection of the welding torch
and gas supply. Welding grade Argon is the For AC TIG welding a Thoritated tungsten
shielding gas most commonly used for AC/ (red tip) can be used for low current AC TIG
DC GTAW welding. The torch will require a but the tip does not ball well and the arc can
tungsten electrode. then wander.
Before first use of the welding torch, Ceriated or Lanthinated are preferred for
allow gas to purge the torch and hoses for advanced AC Welding with square wave
1 minutes at approximately 10 litres/min. For output. They can also be used on DC TIG,
welding purposes, the gas flow rate should so they are a good AC or DC electrode if
be set in the range 5-11 litres/min. only one electrode type is to be used.

Tungsten Electrode Preperation

The tungstens needs to be ground to a point,
Work TIG the grinding should only be in the direction
Clamp Torch
of the point and should be done on a fine
grit grinding wheel. The resulting grind
pattern will produce a sharp directed arc.
Poor tip preparation will result in arc wander.
A common practice is to grind the tip such
that the length of the points is approximately
2 times the diameter. The result will be an
included angle of 30 degrees.
Fig 7 Connections for TIG Welding
For AC tip preparation, creating a blunt end
will assist a symmetrical and small ball to
develop at the tip.
It is important to maintain the electrode
point for DC or ball for AC. If the tip
accidently touches weld pool it will become
contaminated and the arc will become
erratic, and will need to be re ground.
Tungstens containing at least 2% lanthana
will hold a point when used with both DC
and AC welding currents

18 Trusted by the best

 Weldmatic 200i AC/DC

Tungsten Current Ranges

Electrode Gas DC AC Filler Wire

Diameter (mm) Cup Size Current Amps Current Amps Diameter (mm)

1.0 6 15-80 20-60 1.6

1.6 6 70-150 50-100 1.6-2.4

2.4 8 150-250 100-160 2.4-3.2

30°
Safety Consideration Thoritated
Tungsten. D

Thoriated Tungsten contains the element 30° x

Thorium (Th). Thorium is a radioactive
Fig 8 Tungsten Preparation
element which mainly emits alpha
x = 1.5 to 4 times diameter
particles. Alpha particles cannot penetrate (2 x D = 30° included angle)
skin, or clothing, but can be a harmful
carcinogen if released inside the digestive
tract, or lungs. D

There is almost no release of radioactive x

material during arcing.
Fig 9 AC Advanced Preparation
There is no significant hazard in handling x = 1.5 to 4 times diameter

and storage. The Thoria is inside the

tungsten electrode, it is enclosed in a
tungsten matrix and so there is little
radiation emitted externally.
The greatest risk of exposure is during
the grinding of the thoriated tungsten
electrodes. Care needs to be taken, to
control the dust. A dust mask should be Fig 10 Correct Grind Direction
worn, and grinder area clean up should
be done with a vacuum cleaner.

Fig 11 Incorrect Grind Direction

Model No MC105 19
Operators Manual

7 Basic Welding Information

TIG Welding Operation LIFT TIG Operation
Connect the Work Clamp to the work piece. When the Welding mode is set to LIFT TIG
then the arc start can be achieved with the
Turn on the power switch located on the rear
following procedure.
panel. Wait approximately 5 seconds as the
unit goes through its initiation sequence.
Use the Weld Mode Selection Switch to
select LIFT TIG or HF TIG Mode.
Select an appropriate welding current for
the job by setting the knob on the machine
front panel.

HF Start
1 2 3 4
When HF Start TIG is selected then the
electrode tip is bought close to the work Fig 12 Lift TIG Operation Procedure
piece, but not touching.
Pressing the trigger will produce a high
1 Touch the electrode lightly against the
voltage spark that will jump to the work
work piece.
piece and initiate an arc.
2 Press the torch trigger switch. The
HF TIG can be used where work piece
shielding gas will start to flow and a
contamination by the electrode is a
small current will pass through the
concern. Also where repetitive starts causes
electrode.
contamination of the electrode, which
produces an unstable arc. 3 While still holding the electrode against
the work piece, roll the hand piece over
until the cup rests on the work piece.
Use the cup as a pivot point to roll the
hand piece over allowing the electrode to
lift of the work piece.
The arc will ignite.
4 Immediately lift the cup of the work
piece, the current will rise to the welding
level within the up-slope time.
Use of a copper striking plate can be
used to avoid electrode contamination.
The electrode can also be contaminated
by contact with the filler rod.
A contaminated electrode produces an
unstable arc. If this occurs regrind the
electrode tip.

20 Trusted by the best

 Weldmatic 200i AC/DC

8 External Trouble Shooting

No Welding Current
If you are in Australia and the
following checks do not identify Check:
the fault condition, the equipment 1 Check that mains supply is available
should be returned to a WIA at the Weldarc inverter power source.
Service agent. Phone 1300 300 884 The display panel lights should be
for details of your nearest on. If not, test outlet using a known
service agent. working appliance.
2 Check that the welding and work leads
are connected securely to the output
If you are in New Zealand and the sockets at the front of the machine.
following checks do not identify
the fault condition, the equipment 3 Check for continuity of the work lead,
should be returned to the original work clamp and electrode holder. Loose
place of purchase with proof of connections can prevent proper flow of
purchase, or contact Weldwell the welding current.
on 06 8341 600.
4 The Weldarc inverter welding power
source incorporates an in built protection
device which will operate if the unit is
overloaded. In this event, the machine
will not deliver welding current, and the
Over Temp light will be on. Leave the
machine energised with the fan running
to achieve the maximum cooling rate.
5 If the supply voltage is too high or too
low then the Voltage Range Indicator
light will be on and the machine will not
deliver welding current.
Check the mains voltage supply. Long
extension cords can cause low voltage.
A generator can cause high voltage.
The electrical components of the equipment
are shown in the circuit diagram below.
The Weldarc inverter is an inverter type
design, where the mains supply is first
rectified, filtered then chopped to a high
frequency before being applied to the
welding transformer. The output of this
transformer is rectified to form the welding
output of the machine.

Model No MC105 21
Operators Manual

9 Service Information

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.

Before removing the equipment

cover, ENSURE that the equipment
is disconnected from the mains
power supply. When the equipment
is energised LETHAL VOLTAGES
are present on the electrical
components enclosed.

The electrical components of the equipment

are shown in the circuit diagram below.
The Weldarc inverter is an inverter type
design, where the mains supply is first
rectified, filtered then chopped to a high
frequency before being applied to the
welding transformer. The output of this
transformer is rectified to form the welding
output of the machine.

22 Trusted by the best

 HEAT SINK
HEAT SINK SINK
HEAT HEAT (DOWN)
SINK(DOWN) HEAT
HEAT SINK
SINK(UP) (UP)

CN2 CN4
CN5 CN5 CN1 DC+
XS QF DigitalWave-Primary
L X1 DigitalWave-Sencondary
X2 X8 OUT +
X3 + -M GND
N C
DC-
CN2 CN1 CN4 CN3
PE
OUT -

CN1 CN2 CN6

DC- DC+
DigiWave-MtArc CN1
HFStartArc
CN2 CN1 CN2 CN3 CN5

CN3
9.1 Circuit Diagrams – Power Source

CN506 CN400 CN202 CN300

CN600
CN1 CN2 DigitalWave-MainCtl

Fig 13 Weldarc 200i Circuit Diagram

CN3 CN200 CN201 CN401

CN402
CN500 CN100

BLUE
RED
10
CN2

GREEN

CN4
BLACK
CN1 CN3
CN1
RED DigiWave-Panel

BLUE
GREEN
Weldmatic 200i AC/DC

Model No MC105 23
BLUE
BLACK
 Operators Manual

10 Assembly and Parts List - Weldarc 200i AC/DC Power Source

22

3
6

7
23

4
25

28
18
21

24
10

20

19
5

16

10
14

13 17 15 12 11 25

Fig 14 Weldarc 200i AC/DC Power Source Assembly

24 Trusted by the best

 Weldmatic 200i AC/DC

Item # Part # Description Qty

1 M0067 HANDLE 1
2 PAN161 ENCLOSURE 1
3 PWA024 PCB ASSY ARC STABILIZER 1
4 E0089 SWITCH ON OFF 1
5 FAN013 FAN 240V 1
6 PWA025 PCB ASSY POWER SUPPLY 24V 1
7 PWA043 PCB ASSY HV ARC IGNITION 1
8 D0036 DIODE BRIDGE 35A 1000V 2
9 PWA027 PCB ASSY PRIMARY INVERTER MC105 1
10 D0038 IGBT 12
11 M0068 FOOT PLASTIC 4
12 L0033 HF COUPLING TRANSFORMER 1
13 M0069 GAS CONNECTION FRONT M10 1
14 E0079 PLUG 5 PIN MC105 1

15 M0070 FRONT PANEL PLASTIC MC105 1

16 M0058 KNOB, BLACK 200i 1
17 CX58 PANEL MOUNT DINSE SOCKET 2
18 M0074 BACK PANEL 1
19 PWA028 PCB ASSY FRONT PANEL MC105 1
20 E0080 HALL EFFECT TRANSDUCER MC105 1
21 D0039 FAST RECOVERY DIODE 2
22 PWA029 PCB ASSY TRIGGER ISOLATION 1
23 PWA045 PCB ASSY MAIN CONTROL MC105 1
24 E0041 GAS VALVE 1
25 R0032 THERMISTOR 3
26 REG003 ARGON REGULATOR 1
27 CLA002 WORK CLAMP 1
28 PWA039 SECONDARY INVERTER 1
Not Shown MC105-40 OPERATING MANUAL 1
Not Shown DGT26FX8M200 TIG TORCH 1

26 27

Model No MC105 25
Operators Manual

10 Assembly and Parts List – Torch

Item # Part # Description Qty

10N31 COLLET BODY 1.6mm 1

10N32 COLLET BODY 2.4mm 1
10N28 COLLET BODY 3.2mm 1
10N23 COLLET 1.6mm 1
10N24 COLLET 2.4mm 1
10N25 COLLET 3.2mm 1
10N50 CERAMIC NOZZLE SIZE 4 (6mm) 1
10N49 CERAMIC NOZZLE SIZE 5 (8mm) 1
10N48 CERAMIC NOZZLE SIZE 6 (10mm) 1
10N47 CERAMIC NOZZLE SIZE 7 (11mm) 1
10N46 CERAMIC NOZZLE SIZE 8 (12.5mm) 1
57Y04 SHORT BACK CAP 1
57Y03 MEDIUM BACK CAP 1
57Y02 LONG BACK CAP 1
E0087 CABLE PLUG 1
M0075 GAS CONNECTOR 1

26 Trusted by the best

 Weldmatic 200i AC/DC

11 Australian Warranty Information

The obligation of Welding Industries of
Australia under this warranty is limited to the
circumstances set out above and is subject to:
• The customer being able to provide
proof of purchase of the Product and the
WIA Weldmatic MIG & purchase price paid for the Product;
Weldarc MMA Equipment • The relevant defect in materials or
2 Year Warranty Statement workmanship;
Welding Industries of Australia (WIA) • The Product not having been altered,
warrants to the original retail purchaser tampered with or otherwise dealt with
that the Weldmatic welding machine by any person in a manner other than
purchased (Product) will be free from defects as intended in respect of the relevant
in materials and workmanship for a period Product; and
of 2 years from the date of purchase of • The Product not having been used or
the Product by the customer. If a defect in applied in a manner that is contrary to
material or workmanship becomes evident customary usage or application for the
during that period, Welding Industries of relevant Product or contrary to any stated
Australia will, at its option, either: instructions or specification of Welding
• Repair the Product (or pay for the costs Industries of Australia.
of repair of the Product); or For products purchased in Australia
• Replace the Product. Our goods come with guarantees that
In the event of such a defect, the customer cannot be excluded under the Australian
should return the product to the original Consumer Law. You are entitled to a
place of purchase, with proof of purchase, replacement or refund for a major failure and
or contact Welding Industries of Australia for compensation for any other reasonably
on 1300 300 884 to locate an authorised foreseeable loss or damage. You are also
service agent. entitled to have the goods repaired or
replaced if the goods fail to be of acceptable
Any handling and transportation costs
quality and the failure does not amount to
(and other expenses) incurred in claiming
a major failure. The benefits given by this
under this warranty are not covered by this
warranty are in addition to other rights and
warranty and will not be borne by Welding
remedies which may be available to the
Industries of Australia. Welding Industries of
customer under any law in relation to goods
Australia will return the replacement product,
and services to which this warranty relates.
if original found to be faulty, freight free to
the customer. Warranty provided by:
Welding Industries of Australia
This warranty covers the Weldarc power
(ABN 63 004 235 063)
source only, and does not extend to the
A Division of ITW Australia Pty Ltd
accessories included in the original purchase
5 Allan Street, Melrose Park
package.
South Australia 5039
Ph: 1300 300 884
Email: [email protected]
Web: www.welding.com.au

Model No MC105 27
Operators Manual

12 New Zealand Warranty Information

WIA Weldmatic MIG &

Weldarc MMA Equipment
2 Year Warranty Statement
In the event of defects listed in the Australian
warranty conditions, the customer should
return the Product to the original place
of purchase, with proof of purchase, or
contact Weldwell on 06 8341600.
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
64 Thames Street
Napier 4110
New Zealand
Ph: 06 8341 600
Email: [email protected]

28 Trusted by the best

 High Performing
Austarc Electrodes

Austarc 16TC Classification:

AS/NZS 4855-B –
• Smooth running, basic E49 16 A U H10
low hydrogen electrode,
AWS A5. 1: E7016 H8
developed for all positional
(except vertical down) Part Numbers:
welding, using AC or DC 16TC25 (2.5mm)
power sources. 16TC32 (3.2mm)
• Unique twin coating 16TC40 (4.0mm)
delivers significantly 16TC50 (5.0mm)
improved arc stability and 16TC60 (6.0mm)
control of all applications.

Austarc 18TC Classification:

AS/NZS 4855-B –
• An iron powder hydrogen E49 18-1 A U H5
controlled electrode used
AWS A5.1: E7018-1
primarily on C-Mn and low
alloy structural steels. Part Numbers:
• Unique twin coating 18TC25 (2.5mm)
design offers excellent AC 18TC32 (3.2mm)
tability and superb DC+ 18TC40 (4.0mm)
arc transfer.

Austarc 11 Classification:
AS/NZS 4855-B –
• High cellulose electrode E43 11 A
developed for all positional
AWS A5. 1: E6011
welding on both AC and
DC current. Part Numbers:
• It is particularly suited for 1125 (2.5mm)
vertical and incline pipe 1132 (3.2mm)
welding where complete 1140 (4.0mm)
root penetration is required. 1150 (5.0mm)

For more information call 1300 300 884 or visit welding.com.au

Miller Digital Elite Series™
AUTO-DARKENING HELMETS
Inferno P/N - 257217 Joker P/N - 257218
Lucky’s Speed Shop P/N - 257214 Black P/N - 257213

FOUR MODES –
WELD, CUT, GRIND & X-MODE

Black

Lucky’s
Speed Shop

Joker

Inferno

• Lens and helmet comply with • Lightweight headgear.

Australian Standards AS/NZS • Four independent arc sensors.
1338.1 (Auto-Darkening) and
• Suits MIG, Stick, Flux-Cored
AS/NZS 1337.1 B (High Impact)
and Pulse.
• Lightweight at only 510g.
• TIG rating 5 Amps.
• Improved digital controls.
• 3 year warranty (Auto-Darkening
• Battery powered with solar assist. lens only).

For more information call 1300 300 884 or visit welding.com.au