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1
WELDARC
2
8
0
''WORKHORSE
I'
(
MC
77
)
"""""""""""
8/79
THE INFORMATION CONTAINED IN THE FOLDER
IS
SET OUT
TO
ENABLE
YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND
ENSUFE
THAT
YOU OBTAIN MAXIMUM OPEPCATING EFFECIENCY.
PLEASE ENSURE THAT THIS FOLDER
IS
KEPT
IN
A
SAFE PLACE
FOR
READY REFERENCE
WHEN
REQUIRED.
WHEN REQUESTING SPARE PARTS, QUOTE
THE
MODEL NO. AND SERIAL
NO.
OF
THE
MACHINE
AND
THE PART
NO.
OF
THE ITEM REQUIRED.
FAILURE TO SUPPLY THIS INFORMATION WILL
RF,SULT
IN
UNNECESSARY
BELAYS
IN
SUPPLYING THE CORRECT PARTS.
WELDING INDUSTRIES OF AUSTRALIA
PTY.,
LTD.
SALES
AND SERVICE DIVISIONS
Melbourne
429 4766 Sydney 534 2144
Newcastle
61 1668
Adelaide
352
3022
Brisbane
44 1391 Perth
361.
7088
STATE AGENTS
Hobart
34 7850
Darwin
81
6428
&
84
3076
-2-
INTRODUCTION
GENERAL
OPERATING
AND
MAINTENANCE
INSTRUCTIONS
WELDARC
-
280
(MC77)
This manual has been prepared especially for use in
familiar-
izing personnel
with
the design, installation, operation,
maintenance, and trouble shooting of this equipment.
All
information presented herein should
be
given careful consid-
eration to assure optimum performance
of
this equipment.
RECEIVING/HANDLING
Prior
to
installing this equipment, clean
all
packing material
from around the unit and carefully inspect for 'any damage that
may have occurred during shipment. Any
claims
for
loss
or
damage
that
may
have
occurred in transit must be
filed
by
the
purchaser with Welding Industries of Australia Pty. Ltd.
or
authorised agent immediately
(refer
to
EQUIPMENT
WARRANTY
card enclosed
with
Operating Instruction Manual.)
When
requesting information concerning
this
equipment,
it
is
essential to supply correct Model indentification
and
machine
Serial
No.
SAFETY
Before the equipment
is
put into operation, the
SAFETY PRACTICES
sect,ion
at
the
back
of
this
manual
MUST
BE
READ
COMPLETELY.
This
will
help avoid possible injury due to misuse or improper
welding applications.
CONTENTS
-
Operation
&
Maintenance
Installation
Parts
List
for Drawing No. MC77-0
Assembly Drawing No. MC77-0
Safety
Practices
-
2-
OPERATION
Rating:
The
Weldarc
280
is
rated
to Australian Standard
AS1966
-
1976
Light Industrial
Class.
The machine has a weld-
ing current range
of
70
-
280 amps infinitely variable
over two ranges.
LOW
CURFXNT
RANGE
(For
all
A.C.
electrodes, particularly low hydrogen and special
electrodes)
:-
70
-
220 amps
.at
78
volts
open circuit
-
DUTY
CYCLE
80
amps
23
volts
100%
150
amps
26
volts 25%
HIGH
CURRENT
RANGE
(For
all mild
steel
electrodes, cutting and
burning holes)
:-
90
-
280 amps
at
55
volts
open circuit.
I
DUTY
CYCLE
130A 25.2V
100%
200
amps 28 volts 25%
RATED
OUTPUT
:
LOW
CURRENT
RANGE
220
amps
29
volts
20% duty cycle.
HIGH
CURRENT
RANGE
280A 31V
20%
-
SELECTING
THE
CURRENT
RANGE
In general the high open circuit voltage low current range pro-
vides the
best
stable running conditions when
small
electrodes
and low currents
are
employed.
As
the welding current increases
so
the
arc
stability also increases and
lower
arc
voltages
can
be used. For high production conditions
select
the
high current
range
to
obtain
the
best
duty cycle.
On setting up the welder plug the work lead into the work terminal
by inserting
the
plug into
the
socket
until
it
locks into position.
This
self
locking action secures the plug and ensures
a
good
elec-
trical
connection.
Select
the
electrode you
wish
to
use and plug
the
welding
lead
into the appropriate current range socket. Adjust
the
current
by unlocking
the
T
bar
handle (turn to
Left
to
unlock) and moving
it
along until
the
shaft
is
aligned
with
the desired current
value, then
RELOCK
the handle firmly,by rotating
it
to the right.
MAINTENANCE
Your machine
is
lubricated
with
graphite
grease
before leaving
the factory. However,
in
dry dusty locations,
the
air
ducts
of
the
machine can clog causing
lack
of
ventilation resulting
in the overheating
of
the
machine transformer.
It
is
good
practice
to
blow the transformer out
at
regular intervals with
dry compressed
air.
ELECTRODES
For best results from your Weldarc 280 use
W.I.A.
-
'AUSTARC'
Electrodes obtainable from your
State
Branch
or
W.I.A.
Distrib-
utor.
-4-
..
This welding machine
is
designed for connection to
a
single phase
240
volts,
415
volt or 480 volt 50 hz supply.
_.
The rated currents and fusing
sizes
are:-
Primary supply voltage
240
vol-ts
415 volts
480
volts
Rated input current
34 amps
19.7
amps
17
amps
Max. short circuit current
90
amps
45 amps
39
amps
Wire
fuse
size
40
amps
30
amps
30
amps
H.R.C.
fuse size
60
amps
40
amps
40
amps
The installing
Electrician
should ensure that the primary cable
is
capable of carrying the rated primary current and the connect-
ion links on the primary coil terminal block
are
arranged to suit
the voltage that the machine
is
being connected
to.
(see
terminal
connection printed
on
back cover.
)
To
connect the machine
it
is
necessary to
remove
the back panel.
The cable entry
is
located in
the
back
at
the bottom behind the
terminal block. The terminal block
is
situated
on
the left hand
side
of
the
transformer
and the
brass
earth
screw
directly
below
it.
PORTABLE
MOUNTING
ASSEMBLY
(when used)
-
Refer
to
drawing No.
MC76-40
Attach the
axle
by means
of
two
%"W
hex head
set
screws
to
the
two holes provided in the
rear
of the skids.
Assemble
the wheels onto the lubricated shaft.
Fit
the washers
then tap the ratchet caps on the ends
of
axle.
To
fit the handle, remove the
4
-
%"
hex head
set
screws
in
the
top panel and attach
the
handle
as
shown
on
drawing nu.nbcr
MC76-.40.
POWER
FACTOR
CORRECTION
Space
is
provided within the
case
for power factor
correction
cap-
acitors if required to
be
fitted.
I_
RECOMMENDED
WELDING
CABLE
For
both electrode and work cables use
1121/0.20
flexible welding
cable.
If
the combined length
of
both
cables
exceeds
20
metres,
it
is
recommended that
703/0.30
flexible welding cable be
used
to
avoid excessive voltage drops..
Only genuine
W.I.A.
welding lead plug connectors, part nu.mber
AA36
should be used with this machine.
DRAWING NOMC77-0
_l"l_l
""
___-
U
c
+=
W
ISSUE
NO1
1"""
DRAIqING
NO.
MC77-0
PARTS
LIST ISSUE
1.
-
I
NO.
1
..
1.1
1.2
l.
3
2
3
4
5
6
7
8
9
LO
-
11.
l
12
13
14
15
16
16.1
17
L8
19
PART
NO.
MC76-11
MC~
6-
2
3
MC76-12
MC76-13
MC76-31.
MC76-33
MC76-34
MC76-35
AA35
MC76-25
W76-26
YC14-1/14
YC20-0/25
IIC14-0/10
IIC14-0/11
vlC76-24
3C76-0/13
VIN44
U36
.IC77-0/17
4C77-0/18
4C30-01/17
1C35-0/10
DESCRIPTION
"
TRANSFORMER ASSEIBLY
PIVOT BEARING ASSEMBLY
PRIMARY COIL ASSEMBLY
SECONDARY COIL ASSEMBLY
BASE
F-
ASSEMBLY
FRONT PANEL
BACK PANEL
COVER
OUTPUT TERMINAL ASSEPBLY
LOCKING HANDLE
WASHER
FOR
LOCKING HANDLE
TERMINAL STRIP
TERMINAL BLOCK
MALE PLASTIC BUSH
FEMALE PLASTIC BlJSH
LOCKING QUADRANT
INTERNAL CONNECTING LEADS
SERIAL No./TYPE
No.
NAMEPLATE
OUTPUT TERMINAL PLUG
FAN
MOTOR
FAN
BLA.DE
PRIMARY SUPPLY
CABLE
ON/OFF
SWITCH
(WHEN FITTED)
INDICATOR LIGHT
(
"
"
1
(
)
DRAWING
No
MC76-40
ISSUE
NO1
TO
FIT
WHEELS
AND
HANDLE
-ASSEMJ3LY
Attach the
axle
by
means
of
two
$"W
hex head
set
screws
to
the
two
holes provided in the
rear
of
the skids.
Assemble
the wheels
onto
the lubricated shaft. Fit the washers then tap the ratchet
caps
on
the ends
of
axle.
To
fit
the handle, remove
the
4
-
%"W.
hex
head
set
screws
in the top panel and attach
as
shown.
.-
.-
SAFE
PRACTICES
IN
USING
WELDING
AND
CUTTING
EQUIPMEKT
!.
t
/
