WIA Weldarc 145 Stick TIG Welders Instruction Manual
- June 13, 2024
- WIA
Table of Contents
- Safe Practices
- INTRODUCTION
- RECEIVING
- SPECIFICATIONS
- FEATURES
- CONTROLS 145 & 185 POWER SOURCE
- INSTALLATION
- BASIC WELDING INFORMATION
- GENERAL MAINTENANCE
- EXTERNAL TROUBLE SHOOTING
- TROUBLE SHOOTING CHART
- SERVICE INFORMATION
- CIRCUIT DIAGRAMS
- ASSEMBLY AND PARTS LIST
- AUSTRALIAN WARRANTY INFORMATION
- NEW ZEALAND WARRANTY INFORMATION
- Customer Support
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
WIA Weldarc 145 Stick TIG Welders
Safe Practices
READ FIRST
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.
HANDLES ON POWER SOURCE
Please note that the handle fitted to the Weldarc welder is intended for
carrying the equipment by hand only.
DO NOT use this 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,
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 | Pulsed 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 |
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 an 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 perchloroethylene 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 perchloroethylene.
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.
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.
INTRODUCTION
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 135, 145 and 185 has been designed to be used with 2.0mm, 2.5mm,
3.2mm diameter electrodes, and the 185 can also be used with 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.
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 quality all position stainless steel welding. Extra smooth running, high
arc stability, easy re-strike, excellent slag removal and bead appearance.
Staincord 309Mo-16, Classification E309LMo-16
For high quality all position stainless steel welding. This extra low carbon
alloy is specifically indicated for AISI 309Mo type alloys, but is also ideal
for joining mild/low alloy steel to a range of 300 and 400 series stainless
steels. Features extra smooth running, high arc stability, easy re-strike,
excellent slag removal and bead appearance.
GTAW (TIG Welding)
For Weldarc 145 & 185 only.
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,
but is not suitable for welding Aluminium for which an AC machine is required.
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 & Cable
- Work Clamp & Cable
- (This) Operating Manual
Optionally available
- TIG Torch with Gas Valve TIG001 for Weldarc 145
- TIG Torch with Gas Valve TIG002 for Weldarc 185
- Argon flow gauge regulator REG003
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 should have continuous rating and incorporate output voltage
regulation. Refer to Specifications for minimum generator capacity.
Generators without voltage regulation must have a minimum capacity of 10 kW.
SPECIFICATIONS
Manufactured to Australian Standard – AS60974.1
VRD Complies with – AS1674.2 Category C.
| WELDARC 135| WELDARC 145| WELDARC 185
---|---|---|---
Primary Voltage| 220-240 Vac, 50/60 Hz| 220-240 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 185 Amps, 27.4 V, 25% duty 92 Amps,
23.7 V, 100% duty TIG 185 Amps, 17.4 V, 25% duty 92 Amps, 13.7 V, 100% duty
Continuous Rated Output@ 40°C| 60 Amp| 56 Amp| 92 Amp
Welding Current| 20 – 135 Amps| 25 – 145 Amps| 25 – 185 Amps
Open Circuit Voltage VRD Enabled VRD Disabled| Uo = 10V Uo = 82V| Uo = 23 V Uo
= 78 V| Uo = 13 – 17 V Uo = 78 V
Shipping Weight| 8.0kg – Includes leads| 11kg – Includes leads| 11kg –
Includes leads
Shipping Dimensions| 400mm W x 200mm D x 310mm H| 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| Fan cooled. Operates on temperature demand|
Fan cooled. Operates on temperature demand
IP Rating| IP21S| IP23S| IP23S
Generator Power| 8KVA @ 240 V| 9KVA @ 240V| 11.2KVA @ 240 V
FEATURES
VRD Function (Voltage Reduction Device)
The VRD function is a safety feature, to provide reduced open circuit voltage,
when not welding.
The VRD reduces the likelihood of electrocution due to electrode handling,
while physically connected to work piece.
The VRD on the Weldarc 135, 145 and 185 complies with the requirements of AS
1674.2 for use in ‘Category C’ environments.
The machine will be supplied with VRD enabled or disabled, depending on the
end market.
VRD Disabled
The open circuit output voltage is maximum Volts DC.
The ‘VRD SAFE’ indicator on the front panel will only light up momentarily
during power up.
Machine is supplied with an orange tag on the supply lead advising VRD is
disabled.
VRD Enabled
When not welding the ‘VRD SAFE’ indicator on the 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 start
condition and increase the output voltage to start welding. The ‘VRD SAFE’
indicator will turn off.
To restrike a used electrode it may be necessary to remove excess flux from
electrode tip.
The most effective strike action is a touch – twist – lift.
Fan on Demand
Weldarc 145 & 185 has Fan on Demand feature which operates the cooling fan
only when the internal temperature reaches a preset level. Once the internal
temperature has dropped the fan will turn off.
When the machine is first turned on the fan will operate momentarily, when the
machine is turned off the fan will also operate momentarily while the internal
power supply decays.
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.
Attaching the Weldarc Shoulder Strap
Hot Start
Hot start is a boost current which is applied at arc start. The extra current
at start helps get arc established, particularly on cold material.
For Weldarc 145 & 185 this can be adjusted in setup mode.
Arc Force
Arc force is a voltage boost. The extra voltage is used when arc voltage drops
due to arc shorts.
For Weldarc 145 & 185 this can be adjusted in setup mode.
Power Factor Correction (PFC)
For Weldarc 145 & 185 only.
PFC provides a input power conditioner system to smooth the input current.
On a conventional inverter machine the input current presents in short high
current pulses every half mains cycle. These pulses, cause input voltage drop,
on extension leads and generators.
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
CONTROLS 145 & 185 POWER SOURCE
-
VRD Safe Mode Indicator
If VRD is enabled, this light is on when the voltage across the output terminals is reduced to a safe level.
If VRD is disabled, this light will always be off. -
Power On Indicator
-
Over Temperature Indicator
This light is on if any internal thermal protection devices have operated. Allow the machine to cool down. -
Weld Mode Selection Switch (145 & 185 only)
Use this switch to select between modes.
There are two weld modes available: -
TIG Welding (GTAW):
Lift arc start, using TIG welding torch with separate gas supply. -
Stick Electrode Welding (MMAW).
This mode is used for all MMAW stick electrode process. -
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 button, the digital display will show ”AF”. The Arc Force Voltage can be increased or decreased, by adjusting the Weld Control Knob. Adjust -10% to +10% of factory setting. Press MODE button again to return to normal operation.
CONTROLS 135 POWER SOURCE
-
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. -
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.
INSTALLATION
Connection to Electrical Mains Power Supply
The Weldarc 135 & 145 is fitted with a 10 Amp supply cable and plug.
The Weldarc 185 is fitted with a 15 Amp supply cable and plug 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 3.
The minimum recommended main power supply circuit breaker ratings for Weldarc
inverters are listed in Section 3.
If it becomes necessary to replace the mains flexible supply cable, use only
cable with correct current rating. See Section 3.
If it is necessary to use an extension power supply cable, ensure that it is
rated as per Section 3. 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.
Machines with PFC will be tolerant of poor generator voltage regulation.
BASIC WELDING INFORMATION
Stick Welding (MMAW)
Connection for Stick Welding
It is important to select the electrode polarity in accordance with the
manufacturer’s recommendations for that electrode. Most common electrodes,
including cellulose types, are operated with the electrode at positive
polarity, as illustrated in Figure 3.
Fig 3 Connections for Stick Welding (MMAW), Electrode Positive
Stick Welding
Be certain that you are wearing suitable protective clothing, gloves etc and
that you are working in a non-hazardous area.
If necessary, refer again to Section 1 – Safe Practices in this manual.
Connect the work clamp to the work piece. Place the desired electrode in the
electrode holder.
Turn on the power switch located on the rear panel. Wait approximately 5
seconds as the unit goes through its initiation sequence.
For Weldarc 145 & 185 only, use the Weld Mode Selection Switch to select Stick
Mode.
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.
To Strike the Arc:
With VRD enabled, touch-twist-lift.
With VRD disabled, drag the end of the electrode along the work piece 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 good weld appearance. An arc
which is too long may cause an unwieldy flow of metal with a rough weld
appearance and reduced penetration. An arc too short 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. Decreasing this rate of travel will result in a wider weld deposit, and
similarly increasing it will narrow the weld deposit.
Always fill the crater which 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.
Current Range for General Purpose Electrodes
Diameter (mm) | Current (Amps) |
---|---|
2.0 | 40 – 60 |
2.5 | 60 – 85 |
3.2 | 90 – 130 |
4.0 | 130 – 180 |
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 internal gas valve, therefore, the gas supply
needs to be controlled externally with a torch that incorporates a manual
valve in the hand piece. Welding grade Argon is the shielding gas most
commonly used for DC GTAW welding.
Before first use of the welding torch, allow gas to purge the torch and hoses
for 30 seconds at approximately 10 litres/min.
For welding purposes, the gas flow rate should be set in the range 2-5
litres/min.
Tungsten electrodes for DC GTAW should be 1-2% Thoriated. This type will
provide the best arc initiation, arc stability and tip shape retention
characteristics. Thoriated electrodes can be recognised by a red coded end.
The tungsten electrode is ground to a point, with the grinding marks pointing
towards the tip. For welding currents less than 20 amps, the included angle of
the point should be 30o , for currents greater than 20 amps, the recommended
angle is 60o
. When set in the torch, the tungsten should protrude 6mm from the ceramic gas
nozzle.
TIG Welding Operation
Connect the Work Clamp to the work piece.
Turn on the power switch located on the rear panel. Wait approximately 5
seconds as the unit goes through its initiation sequence.
Use the Weld Mode Selection Switch to select TIG Mode.
Select an appropriate welding current for the job by setting the knob on the
machine front panel.
To initiate the arc, lightly touch the tungsten electrode onto the work piece,
then smoothly lift it away to establish an arc length slightly longer than the
diameter of the electrode.
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.
Fig 4 Cable Connections for TIG welding
GENERAL MAINTENANCE
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.
Dust
Care should be taken to prevent excessive build-up of dust and dirt within the
welding power source. It is recommended 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.
EXTERNAL TROUBLE SHOOTING
If you are in Australia and the following checks do not identify the fault
condition, the equipment should be returned to a WIA Service agent.
Phone 1300 300 884 for details of your nearest service agent.
If you are in New Zealand and the following checks do not identify the fault condition, the equipment should be returned to the original place of purchase with proof of purchase, or contact Weldwell on 06 8341 600.
TROUBLE SHOOTING CHART
Problem | Likely Reason | Outcome |
---|
All Inverter Multi-Process Models
No welding current, no display.| The machine is not turned on at both the
mains supply and the machine power switch.| If confirmed that the machine is
switched on correctly, test the same outlet using a known serviceable
appliance.
Mains circuit breaker nuisance tripping during welding.| Mains circuit breaker
inadequately rated, or duty cycle exceeded.| The circuit breaker may be rated
for Ieff (effective current). If Weld output is greater than the 100% rating
the machine will require mains current higher than Ieff. The duty cycle should
be observed and understood.
Machine continually cuts out on thermal overload| The machine duty cycle has
been exceeded.| Leave the machine energized, with the fan running until the
machine has cooled 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 type in use. The
return lead contacts and connections should be inspected and cleaned, and the
workbench cleared of waste materials.
Machine works fine on mains power but does not work when connected to a
generator. Machine works fine on mains power but does not work when connected
with extension lead.| Generator cannot provide high peak cycle currents for
inverter. Extension leads creating additional resistance, and voltage drop|
Use larger kVA generator or sometimes a different band generator will work..
Use larger cable size, and keep extension lead as short as possible.
MMA/STICK Models
In MMAW (Stick), the arc is difficult to strike.| The technique required for
VRD enabled welding machines is not the same as earlier stick welding units.|
The technique to strike should be reviewed, not as a ‘strike’ but more as
‘touch, twist, lift’ motion. If VRD is not a site requirement, VRD can be
disabled by service agent .
GTAW/TIG Models
Tungsten burns up on arc start.| The polarity of the electrode/return cables
is incorrect. Gas not turned-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 (presence of porosity).| The gas hose
is not securely connected at the machine or at the regulator.| Ensure the gas
connections from regulator through to the torch connection are sufficiently
tightened.
Presence of porosity at weld start.| The torch gas hose has not been purged
sufficiently.| Purge the system and confirm sufficient gas flow through the
regulator.
SERVICE INFORMATION
The electrical components of the equipment are shown in the circuit diagrams
on pages 20-22.
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.
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.
If the welding machine requires service or repair, take the machine to an
authorised service agent.
Australian service agents can be located on the
welding.com.
au website. Alternatively call customer service; Australian 1300 300 884 New
Zealand 0800 9353 9355. When contacting a service agent please have an
accurate description of the fault, and the machine serial number located on
the base on the machine.
M1102A………………
M1112A……………….
M1122A………………
CIRCUIT DIAGRAMS
135 POWER SOURCE
Fig 5 Weldarc 135 Circuit Diagram
145 POWER SOURCE
Fig 6 Weldarc 145 Circuit Diagram
185 POWER SOURCE
Fig 7 Weldarc 185 Circuit Diagram
ASSEMBLY AND PARTS LIST
WELDARC 135 POWER SOURCE
Fig 8 Weldarc 135 Power Source Assembly
Item # | Part # | Description | Qty |
---|---|---|---|
1 | M0109 | Handle | 1 |
2 | PAN175 | Outer Cover | 1 |
3 | R0032 | Thermistor | 1 |
4 | PWA062 | PCB Main Control 135 | 1 |
5 | PWA063 | PCB Front Panel 135 | 1 |
6 | M0106 | 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 1.5mm² 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 |
WELDARC 145 POWER SOURCE
Fig 9 Weldarc 145 Power Source Assembly
Item # | Part # | Description | Qty |
---|---|---|---|
1 | M0109 | Handle | 1 |
2 | PAN176 | Outer Cover | 1 |
3 | PWA107 | 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 1.5mm² 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 Manual | 1 |
WELDARC 185 POWER SOURCE
Fig 10 Weldarc 185 Power Source Assembly
Item # | Part # | Description | Qty |
---|---|---|---|
1 | M0109 | Handle | 1 |
2 | PAN182 | Outer Cover | 1 |
3 | FAN021 | Fan | 1 |
4 | PWA108 | PCB Filter | 1 |
5 | PWA109 | 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 | MC112-40 | Operating Manual | 1 |
AUSTRALIAN WARRANTY INFORMATION
WIA Weldmatic MIG &
Weldarc MMA Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
Welding Industries of Australia (WIA) warrants to the original retail
purchaser that the Weldarc welding machine purchased (Product) will be free
from defects in materials and workmanship for a period of 3 years from the
date of purchase of the Product by the customer. If a defect in material or
workmanship becomes evident during that period, Welding Industries of
Australia will, at its option, either:
- Repair the Product (or pay for the costs of repair of the Product); or
- Replace the Product.
In the event of such a defect, the customer should return the Product to the
original place of purchase, with proof of purchase, or contact Welding
Industries of Australia on 1300 300 884 to locate an authorised service agent.
Products presented for repair may be replaced by refurbished products of the
same type rather than being repaired. Refurbished parts may be used to repair
the product. Replacement of the product or any part does not extend or restart
the Warranty Term. The repair of your products may result 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 faulty, freight free
to the customer.
This warranty covers the Weldarc power source only, and does not extend to the
regulator, gun assembly or accessories included in the original purchase
package.
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 purchase price paid for the Product;
- The relevant defect in materials or workmanship;
- The Product not having been altered, tampered with or otherwise dealt with by any person in a manner other than as intended in respect of the relevant Product; and
- The Product not having been used or applied in a manner that is contrary to customary usage or application for the relevant Product or contrary to any stated instructions or specification of Welding Industries of Australia.
For products purchased in Australia
Our goods come with guarantees that cannot be excluded under the Australian
Consumer Law. You are entitled to a replacement or refund for a major failure
and for compensation for any other reasonably foreseeable loss or damage.
You are also entitled 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 63 004 235 063)
A Division of ITW Australia Pty Ltd
5 Allan Street, Melrose Park
South Australia 5039
Ph: 1300 300 884
Email: info@welding.com.au
Web: www.welding.com.au
NEW ZEALAND WARRANTY INFORMATION
WIA Weldmatic MIG &
Weldarc MMA Equipment
3 Year Gold Shield Warranty Statement
Effective 1st January 2022 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 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
Customer Support
WELDING INDUSTRIES
AUSTRALIA
A Division 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
References
- Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ
- Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ
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