wc-1 weld control box owner’s...

Owner’s ManualProduct: WC-1-110Manual: 091-0249Serial: n/aVoltage Rating: 115 VACRevision: June 1999 Rev AModel Number: n/a

WC-1 Weld Control Box

SAFETY CONSIDERATIONSELECTRIC ARC WELDING EQUIPMENT

CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATIONOR MAINTENANCE OF THIS EQUIPMENT

1-1 INTRODUCTIONThis equipment is intended for ultimateapplication by commercial/industrialusers and for operation by persons trainedand experienced in the use andmaintenance of welding equipment.Operation should not be undertakenwithout adequate training in the use ofsuch equipment. Training is availablefrom many public and private schools orsimilar facilities.

Safe practices in the installation,operation and maintenance of thisequipment requires proper training in theart, a careful study of the informationprovided with the equipment, and the useof common sense. Rules for safe useare generally provided by suppliers ofwelding power sources, compressed gassuppliers, and electrode suppliers.Careful compliance with these rules willpromote safe use of this equipment.

The following Safety Rules cover someof the more generally found situations.READ THEM CAREFULLY. In case ofany doubt, obtain qualified help beforeproceeding.

1-2 GENERAL PRECAUTIONSA. Burn PreventionELECTRIC ARC WELDINGPRODUCES HIGH INTENSITY HEATAND ULTRAVIOLET RADIANTENERGY WHICH MAY CAUSESERIOUS AND PERMANENT EYEDAMAGE AND WHICH MAY DAMAGEANY EXPOSED SKIN AREAS.

Wear helmet with safety goggles orglasses with side shields underneath,appropriate filter lenses or plates(protected by clear cover glass). This isa must for welding or cutting (andchipping) to protect the eyes from radiantenergy and flying metal. Replace coverglass when broken, pitted, or spattered.

Medical first aid and eye treatment. Firstaid facilities and a qualified first aidperson should be available for each shiftunless medical facilities are close by forimmediate treatment of flash burns of theeyes and skin burns.

Wear protective clothing - leather (orasbestos) gauntlet gloves, hat, and highsafety-toe shoes. Button shirt collar andpocket flaps, and wear cuffless trousersto avoid entry of sparks and slag.

Avoid oily or greasy clothing. A sparkmay ignite them.

Flammable hair preparations should notbe used by persons intending to weld orcut.

Hot metal such as electrode stubs and workpieces should never be handled withoutgloves.

Ear plugs should be worn when working onoverhead or in a confined space. A hardhat should be worn when others workoverhead.

B. Toxic Fume PreventionWARNING: The use of this product mayresult in exposure to chemicals known tothe State of California to cause cancer andbirth defects or other reproductive harm.

Adequate ventilation. Severe discomfort,illness or death can result from fumes,vapors, heat, or oxygen enrichment ordepletion that welding (or cutting) mayproduce. Prevent them with adequateventilation. NEVER ventilate with oxygen.

Lead-, cadmium-, zinc-, mercury-,beryllium-bearing and similar materials,when welded or cut, may produce harmfulconcentrations of toxic fumes. Adequatelocal exhaust ventilation must be used, oreach person in the area, as well as theoperator, must wear an air-suppliedrespirator. For beryllium, both must beused.

Metals coated with or containing materialsthat emit toxic fumes should not be heatedunless coating is removed form the worksurface, the area is well ventilated, or theoperator wears an air-supplied respirator.

Work in a confined space only while it isbeing ventilated and, if necessary, whilewearing an air-supplied respirator.

Gas leaks in a confined space should beavoided. Leaked gas in large quantities canchange oxygen concentration dangerously.Do not bring gas cylinders into a confinedspace.

Leaving confined space, shut OFF gassupply at source to prevent possibleaccumulation of gases in the space ifdownstream valves have been accidentallyopened or left open. Check to be sure thatthe space is safe before reentering it.

Vapors from chlorinated solvents can bedecomposed by the heat of the arc (orflame) to form PHOSGENE, a highly toxicgas, and other lung and eye irritatingproducts. The ultraviolet (radiant) energyof the arc can also decomposetrichloroethylene and perchloroethylenevapors to form phosgene. DO NOT WELDor cut where solvent vapors can be drawninto the welding or cutting atmosphere orwhere the radiant energy can penetrate toatmospheres containing even minuteamounts of trichloroethylene orperchloroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are:combustibles reached by the arc, flame,flying sparks, hot slag, or heatedmaterial, misuse of compressed gasesand cylinders, and short circuits.

BE AWARE THAT flying sparks or fallingslag can pass through cracks, alongpipes, through windows or doors, andthrough wall or floor openings, out of sightof the goggled operator. Sparks can flymany feet.

To prevent fires and explosion:

Keep equipment clean and operable, freeof oil, grease, and (in electrical parts) ofmetallic particles that can cause shortcircuits.

If combustibles are in area, do NOT weldor cut. Move the work if practicable, toan area free of combustibles. Avoid paintspray rooms, dip tanks, storage areas,ventilators. If the work cannot be moved,move combustibles at least 35 feet away,out of reach of sparks and heat; or protectagainst ignition with suitable and snug-fitting, fire-resistant covers or shields.

Walls touching combustibles on oppositesides should not be welded on (or cut).Walls, ceilings, and floor near workshould be protected by heat-resistantcovers or shields.

Fire watcher must be standing by withsuitable fire extinguishing equipmentduring and for some time after weldingor cutting if:

1. Appreciable combustibles (includingbuilding construction) are within 35 feet.

2. Appreciable combustibles are furtherthan 35 feet, but can be ignited by sparks.

3. Openings (concealed or visible) infloors or walls within 35 feet may exposecombustibles to sparks.

4. Combustibles adjacent to walls,ceilings, roofs, or metal partitions can beignited by radiant or conducted heat.

Hot work permit should be obtainedbefore operation to ensure supervisor’sapproval that adequate precautions havebeen taken.

After work is done, check that area is freeof sparks, glowing embers, and flames.

An empty container that heldcombustibles, or that can produceflammable or toxic vapors when heated,must never be welded on or cut, unlesscontainer has first been cleaned inaccordance with industry standards.

This includes: a thorough steam orcaustic cleaning (or a solvent of waterwashing, depending on the combustible’ssolubility), followed by purging and

inerting with nitrogen or carbon dioxide,and using protective equipment.

Water-filling just below working level maysubstitute for inerting.

A container with unknown contentsshould be cleaned (see paragraphabove). Do NOT depend on sense ofsmell or sight to determine if it is safe toweld or cut.

Hollow castings or containers must bevented before welding or cutting. Theycan explode.

Explosive atmospheres. NEVER weldor cut where the air may containflammable dust, gas, or liquid vapors(such as gasoline).

D. Compressed Gas EquipmentThe safe handling of compressed gasequipment is detailed in numerousindustry publications. The followinggeneral rules cover many of the mostcommon situations.

1. Pressure RegulatorsRegulator relief valve is designed toprotect only the regulator fromoverpressure; it is not intended to protectany downstream equipment. Providesuch protection with one or more reliefdevices.

Never connect a regulator to a cylindercontaining gas other than that for whichthe regulator was designed.

Remove faulty regulator from serviceimmediately for repair (first close cylindervalve). The following symptoms indicatea faulty regulator:

Leaks - if gas leaks externally.

Excessive Creep - if delivery pressurecontinues to rise with downstream valveclosed.

Faulty Gauge - if gauge pointer does notmove off stop pin when pressurized, norreturns to stop pin after pressure release.

Repair. Do NOT attempt repair. Sendfaulty regulators for repair tomanufacturer’s designated repair center,where special techniques and tools areused by trained personnel.

2. CylindersCylinders must be handled carefully toprevent leaks and damage to their walls,valves, or safety devices:

Avoid electrical circuit contact withcylinders including third rails, electricalwires, or welding circuits. They canproduced short circuit arcs that may leadto a serious accident. (See 1-3C)

ICC or DOT marking must be on eachcylinder. It is an assurance of safetywhen the cylinder is properly handled.

Identifying gas content. Use onlycylinders with name of gas marked onthem; do not rely on color to identify gascontent. Notify supplier if unmarked.NEVER DEFACE or alter name, number,or other markings on a cylinder. It isillegal and hazardous.

Empties: Keep valves closed, replace

caps securely; mark MT; keep themseparate from FULLS, and return promptly.

Prohibited use. Never use a cylinder or itscontents for other than its intended use,NEVER as a support or roller.

Locate or secure cylinders so they cannotbe knocked over.

Passageways and work areas. Keepcylinders clear of areas where they may bestuck.

Transporting cylinders. With a crane, usea secure support such as a platform orcradle. Do NOT lift cylinders off the groundby their valves or caps, or by chains, slings,or magnets.

Do NOT expose cylinders to excessiveheat, sparks, slag, and flame, etc. that maycause rupture. Do not allow contents toexceed 55 degrees C (130 degrees F.) Coolwith water spray where such exposureexists.

Protect cylinders, particularly valves frombumps, falls, falling objects, and weather.Replace caps securely when movingcylinders.

Stuck valve. Do NOT use a hammer orwrench to open a cylinder valve that cannotbe opened by hand. Notify your supplier.

Mixing gases. NEVER try to mix any gasesin a cylinder.

NEVER refill any cylinder.

Cylinder fittings should never be modifiedor exchanged.

3. HoseProhibited use. Never use hose other thanthat designed for the specified gas. Ageneral hose identification rule is: red forfuel gas, green for oxygen, and black forinert gases.

Use ferrules or clamps designed for thehose (not ordinary wire or other substitute)as a binding to connect hoses to fittings.

No copper tubing splices. Use onlystandard brass fittings to splice hose.

Avoid long runs to prevent kinks and abuse.Suspend hose off ground to keep it frombeing run over, stepped on, or otherwisedamaged.

Coil excess hose to prevent kinks andtangles.

Protect hose from damage by sharp edges,and by sparks, slag, and open flame.

Examine hose regularly for leaks, wear, andloose connections. Immerse pressuredhose in water; bubbles indicate leaks

Repair leaky or worn hose by cutting areaout and splicing. Do NOT use tape.

4. Proper ConnectionsClean cylinder valve outlet of impurities thatmay clog orifices and damage seats beforeconnecting regulator. Except for hydrogen,crack valve momentarily, pointing outletaway from people and sources of ignition.Wipe with a clean, lintless cloth.

Match regulator to cylinder. Beforeconnecting, check that the regulator labeland cylinder marking agree, and that the

regulator inlet and cylinder outlet match.NEVER Connect a regulator designed fora particular gas or gases to a cylindercontaining any other gas.

Tighten connections. When assemblingthreaded connections, clean and smoothseats where necessary. Tighten. Ifconnection leaks, disassemble, clean,and retighten, using properly fittingwrench.

Adapters. Use a CGA adapter (availablefrom your supplier) between cylinder andregulator, if one is required. Use twowrenches to tighten adapter markedRIGHT and LEFT HAND threads.

Regulator outlet (or hose) connectionsmay be identified by right hand threadsfor oxygen and left hand threads (withgrooved hex on nut or shank) for fuel gas.

5. Pressurizing Steps:Drain regulator of residual gas throughsuitable vent before opening cylinder (ormanifold valve) by turning adjustingscrew in (clockwise). Draining preventsexcessive compression heat at highpressure seat by allowing seat to openon pressurization. Leave adjusting screwengaged slightly on single-stageregulators.

Stand to side of regulator while openingcylinder valve.

Open cylinder valve slowly so thatregulator pressure increases slowly.When gauge is pressurized (gaugereaches regulator maximum) leavecylinder valve in following position: foroxygen and inert gases, open fully to sealstem against possible leak; for fuel gas,open to less than one turn to permit quickemergency shut-off.

Use pressure charts (available from yoursupplier) for safe and efficientrecommended pressure settings onregulators.

Check for leaks on first pressurizationand regularly thereafter. Brush with soapsolution. Bubbles indicate leaks. Cleanoff soapy water after test; dried soap iscombustible.

E. User ResponsibilitiesFollow all Safety Rules.

Remove leaky or defective equipmentfrom service immediately for repair.Read and follow user manualinstructions.

F. Leaving Equipment UnattendedClose gas supply at source and draingas.

G. Rope Staging-SupportRope staging-support should not be usedfor welding or cutting operation; rope mayburn.

1-3 ARC WELDINGComply with precautions in 1-1, 1-2, andthis section. Arc Welding, properly done,is a safe process, but a careless operatorinvites trouble. The equipment carrieshigh currents at significant voltages. The

arc is very bright and hot. Sparks fly,fumes rise, ultraviolet and infrared energyradiates, weldments are hot, andcompressed gases may be used. Thewise operator avoids unnecessary risksand protects himself and others fromaccidents.

A. Burn ProtectionComply with precautions in 1-2.

The welding arc is intense and visiblybright. Its radiation can damage eyes,penetrate lightweight clothing, reflectfrom light-colored surfaces, and burn theskin and eyes. Skin burns resembleacute sunburn; those from gas-shieldedarcs are more severe and painful. DON’TGET BURNED; COMPLY WITHPRECAUTIONS.

1. Protective ClothingWear long-sleeve clothing in addition togloves, hat, and shoes. As necessary,use additional protective clothing suchas leather jacket or sleeves, flameproofapron, and fire-resistant leggings. Avoidouter garments of untreated cotton.

Bare skin protection. Wear dark,substantial clothing. Button collar toprotect chest and neck, and buttonpockets to prevent entry of sparks.

2. Eye and Head ProtectionProtect eyes from exposure to arc. Eyesmay be damaged by radiant energy whenexposed to the electric arc, even whennot looking in the direction of the arc.Never look at an electric arc withoutprotection.

Welding helmet or shield containing afilter plate shade no. 12 or denser mustbe used when welding. Place over facebefore striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shieldshould NOT be worn; radiation can bepassed through to cause burns.

Cracked, broken, or loose filter platesmust be replaced IMMEDIATELY.Replace clear cover plate when broken,pitted, or spattered.

Flash goggles with side shields MUSTbe worn under the helmet to give someprotection to the eyes should the helmetnot be lowered over the face before anarc is struck. Looking at an arcmomentarily with unprotected eyes(particularly a high intensity gas-shieldedarc) can cause a retinal burn that mayleave a permanent dark area in the fieldof vision.

3. Protection of Nearby PersonnelEnclose the welding area. For productionwelding, a separate room or enclosedbay is best. In open areas, surround theoperation with low-reflective,noncombustible screens or panels. Allowfor free air circulation, particularly at floorlevel.

Viewing the weld. Provide face shieldsfor all persons who will be looking directlyat the weld.

Others working in area. See that all personsare wearing flash goggles.

Before starting to weld, make sure thatscreen flaps or bay doors are closed.

B. Toxic Fume PreventionComply with precautions in 1-2B.

Generator engine exhaust must be ventedto the outside air. Carbon monoxide cankill.

C. Fire and Explosion PreventionComply with precautions in 1-2C.

Equipment’s rated capacity. Do notoverload arc welding equipment. It mayoverheat cables and cause a fire.

Loose cable connections may overheat orflash and cause afire.

Never strike an arc on a cylinder or otherpressure vessel. It creates a brittle areathat can cause a violent rupture or lead tosuch a rupture later under rough handling.

D. Compressed Gas EquipmentComply with precautions in 1-2D.

E. Shock PreventionExposed electrically hot conductors or otherbare metal in the welding circuit, or inungrounded, electrically-HOT

equipment can fatally shock a personwhose body becomes a conductor. DONOT STAND, SIT, LIE, LEAN ON, ORTOUCH a wet surface when welding withoutsuitable protection.

To protect against shock:

Keep body and clothing dry. Never work indamp area without adequate insulationagainst electrical shock. Stay on a dryduckboard, or rubber mat when dampnessor sweat cannot be avoided. Sweat, seawater, or moisture between body and anelectrically HOT part - or grounded metal -reduces the body surface electricalresistance, enabling dangerous andpossibly lethal currents to flow through thebody.

1. Grounding the EquipmentWhen installing, connect the frames of eachunit such as welding power source, control,work table, and water circulator to thebuilding ground. Conductors must beadequate to carry ground currents safely.Equipment made electrically HOT by straycurrents may shock, possibly fatally. DoNOT GROUND to electrical conduit, or to apipe carrying ANY gas or a flammable liquidsuch as oil or fuel.

Three-phase connection. Check phaserequirement of equipment before installing.If only three-phase power is available,connect single-phase equipment to only twowires of the three-phase line. Do NOTconnect the equipment ground lead to thethird (live) wire, or the equipment willbecome electrically HOT - a dangerouscondition that can shock, possibly fatally.

Before welding, check ground for continuity.Be sure conductors are touching bare metalof equipment frames at connections.

If a line cord with a ground lead is providedwith the equipment for connection to a

switch box, connect the ground lead tothe grounded switch box. If a three-prongplug is added for connection to agrounded mating receptacle, the groundlead must be connected to the groundprong only. If the line cord comes with athree-prong plug, connect to a groundedmating receptacle. Never remove theground prong from a plug, or use a plugwith a broken ground prong.

2. ConnectorsFully insulated lock-type connectorsshould be used to join welding cablelengths.

3. CablesFrequently inspect cables for wear,cracks, and damage. IMMEDIATELYREPLACE those with excessively wornor damaged insulation to avoid possiblylethal shock from bared cable. Cableswith damaged areas may be taped togive resistance equivalent to originalcable.

Keep cable dry, free of oil and grease,and protected from hot metal and sparks.

4. Terminals and Other Exposed PartsTerminals and other exposed parts ofelectrical units should have insulatingcovers secured before operation.

5. Electrode WireElectrode wire becomes electrically HOTwhen the power switch of gas metal-arcwelding equipment is ON and weldinggun trigger is pressed. Keep hands andbody clear of wire and other HOT parts.

6. Safety DevicesSafety devices such as interlocks andcircuit breakers should not bedisconnected or shunted out.

Before installation, inspection, or serviceof equipment, shut OFF all power, andremove line fuses (or lock or red-tagswitches) to prevent accidental turningON of power. Disconnect all cables fromwelding power source, and pull all 115volts line-cord plugs.

Do not open power circuit or changepolarity while welding. If, in anemergency, it must be disconnected,guard against shock burns or flash fromswitch arcing.

Leaving equipment unattended. Alwaysshut OFF, and disconnect all power toequipment.

Power disconnect switch must beavailable near the welding power source.

THIS PAGE INTENTIONALL BLANK

Table of ContentsIntroduction ............................................................7

Section 1 SPECIFICATIONS ........................................................... 8

Section 2 SUPPORT EQUIPMENT REQUIRED ................................ 8

Section 3 OPTIONAL KIT ............................................................... 8

Section 4 OPTIONAL ACCESSORY ................................................. 8

Section 5 INSTALLATION............................................................... 8

Location ................................................................................................. 8

Contactor Selection ................................................................................. 8

115 VAC Connection ................................................................................ 9

Posa Start Connections .......................................................................... 10

Spool Gun Connections........................................................................... 10

Section 6 OPERATION.................................................................. 10

General ................................................................................................ 10

CC Posa Start Operation ......................................................................... 11

CV Posa Start Operation ......................................................................... 11

Section 7 MAINTENANCE ............................................................. 11

WC-1 Recommended Spare Parts List ...................................................... 12

Section 8 TESTING THE TORCH................................................... 12

Motor Check ......................................................................................... 12

Testing The Potentiometer ...................................................................... 12

Testing The Micro Switch ....................................................................... 12

Section 9 RELAY K2 OPERATION................................................. 12

Section 10 TESTING THE 115 VAC CIRCUITS ............................... 12

Section 11 TESTING THE SPEED CONTROL ................................... 13

Section 12 INTERCONNECTIONS ................................................... 13

Section 13 TROUBLESHOOTING .................................................... 14

Section 14 MAIN P.C. BOARD CONNECTIONS ............................... 15

Section 15 MAIN P.C. BOARD PARTS PLACEMENT ....................... 16

Section 16 FRONT PANEL P.C. BOARD LAYOUT ............................ 18

Section 17 DRAWINGS AND SCHEMATICS .................................... 19

Limited Warranty ................................................................ 24

THIS PAGE INTENTIONALL BLANK

Owner’s Manual - Page 8

IntroductionThis manual details the installation and operation of your WC-1 weld control.

The WC-1 can be used with any constant voltage(CV) or constant current(CC)power source having its own contactor. A secondary contactor is available forthe WC-1, for those power supplies not having a contactor system. CC Posastart "Run-in Speed" is included as a standard feature.

The WC-1 has a 7 pin "W" clocked amphenol connector and is designed foruse with Prince® and Prince® XL Spool guns models 146-XXX and 216-XXX.

In order to assure optimum performance of your WC-1, familiarize yourself withthe contents of this manual and carefully follow all instructions.

This manual will not only guide you in installing your WC-1, but will also be ahandy reference for optional items and replacement parts.


Section 1 SPECIFICATIONSPower Input ....................................................................... 115 VAC 50/60 Hz.

Weight ......................................................................................... 6 3/4 pounds

Shipping Weight ................................................................................ 8 pounds

For Use with Torch Numbers ................................................ 146-XXX, 216-XXX

Section 2 SUPPORT EQUIPMENT REQUIREDC. V. or C.C. power source of sufficient capacity for your needs.

Regulated gas supply and hoses.

Properly sized power lead from power source to ground.

Section 3 OPTIONAL KITCV POSA START ADAPTOR KIT005-0339Used only when having arc starting problems with a CV power source.

Section 4 OPTIONAL ACCESSORYSECONDARY CONTACTOR BOX001-3066Used in conjunction with the WC-1 on power sources that do not have acontactor system. Mounts on top of the WC-1 and is rated at 200 amps, 100%duty cycle.

Section 5 INSTALLATION

Location

The WC-1 should be secured to the power supply or another suitable locationswhere it can be secured to protect it from damage. Lead lengths andaccessibility to a 115 VAC 50/60 Hz power source must also be consideredwhen installing the control. Refer to specifications for dimensional information.

Contactor Selection

The WC-1 is shipped from the factory in the closing contacts position. A sixfoot contactor/Posa Start sense cable is supplies with the unit to which theblack and white wires supply the contactor signal.

NOTE:Refer to the power supply owner's manual for location of

and type of contactor signal required.

WARNING:Disconnect the WC-1 from all power sources before changing contactor.

If a 115 VAC signal is required, remove the four screws from both sides on thecontrol box, and remove cover. Locate black and white wire on #3 and #4 ofterminal strip J6. Move black wire to #4 and white wire to #3 of terminal stripJ5. The unit will now supply 115 VAC on the black (hot) and white (neutral)wires.


WARNING:In the 115 VAC Contactor Mode, the contactor leads willbe "LIVE" with 115 VAC whenever the trigger is pulled.

Leads should be protected to prevent accidentalcontact and labeled 115 VAC.

115 VAC Connection

Connect the supplied 6' power cord to a 115 VAC 50/60 Hz outlet.

The cord is connected to the PC Board on terminal strip J5 #1 (neutral) and #2(hot) and Ground to the WC-1 chassis.

WHITEWHITEWHITEWHITEWHITE

BLACKBLACKBLACKBLACKBLACK

ClosingClosingClosingClosingClosingContactsContactsContactsContactsContacts

ConnectionConnectionConnectionConnectionConnection WHITEWHITEWHITEWHITEWHITE


4444433333222221111144444333332222211111

J6J6J6J6J6 J5J5J5J5J5 FRONTFRONTFRONTFRONTFRONT

115 VAC115 VAC115 VAC115 VAC115 VACContactorContactorContactorContactorContactor

ConnectionConnectionConnectionConnectionConnection

WHITEWHITEWHITEWHITEWHITE


GREENGREENGREENGREENGREEN

115 VAC115 VAC115 VAC115 VAC115 VACINPUTINPUTINPUTINPUTINPUT

J6J6J6J6J6 J5J5J5J5J54444433333222221111144444333332222211111


Posa Start Connections

When using a constant current power supply, the Posa Start sensing leadsmust be connected to the power source. Place the red wire on the powersupply positive terminal and the green wire on the power supply negativeterminal. When using a constant voltage power supply, the sensing leadsneed not be connected, and the Posa Start should be turned off. The PosaStart Sense Leads are internally connected to the P.C. Board on terminal stripJ6 terminal 1 (red) and terminal 2 (green).

Spool Gun Connections

Connect the gun control cable amphenol plug to the WC-1, and secure.

Attach the power cable lug from the gun to the positive terminal of the powersupply, and the negative terminal of the power supply to work ground.

Connect gas hose to regulator/flowmeter on gas supply.

Section 6 OPERATION

General

The WC-1 is designed to interface the Prince® XL Spool Gun to most DCConstant Current, Constant Voltage, and pulsed power supplies.

The Posa Start feature allows the WC-1 to be used in combination withconstant current DC welding power sources of open circuit voltage in excess of55 volts.

NOTE:Reverse polarity MUST be used)

CAUTION:Do not operate a WC-1 on a power source having a high frequency

starting circuit before making sure that the high frequencyportion of the power source is turned off. Failure to take this

precaution will cause permanent damage to the posa start circuitry.

The Posa Start Run-in Speed Control, located on the front panel, providesadjustment for slow wire run-in. Once the arc has been established, the wirefeed speed is automatically changed from the slow run-in speed to the weldingspeed set on the torch potentiometer.

WORK

J5J64444433333222221111144444333332222211111

+ WELDRED

GREEN


CC Posa Start Operation

Attach the WC-1 to a CC power source according to the installationinstructions.

Insure power supply high frequency switch is in the “OFF” position, and powersupply is set to DC reverse polarity.

The power supply contactor should be set to “Remote” or “Tig” and theamperage control set to “Panel” or “Standard” depending on power supply.

Turn the WC-1 power switch to the “ON” position and the Posa Start switch tothe “OFF” position.

Adjust power source to desired amperage for your weld condition.

Press gun trigger and adjust wire feed speed at gun to match current setting.If approximate wire feed speed is not known, it is better to start with excesswire feed rather than too little, in order to prevent possible damage to thecontact tip.

Turn Posa Start switch to the “ON” position. Press torch trigger and, usingRun-in Speed Control, adjust wire feed speed to approximately 10% of thewelding wire speed.

Strike an arc; if the wire stubs out, reduce wire feed rate at gun, or increaseamperage setting on power source.

NOTE:Because the Posa Start Run-in Speed always remains a percentage

of the actual welding wire feed rate, the Posa Start run-in speedwill always slow down or speed up proportional to any adjustment you

now make at the gun. Therefore, if you slow down the welding wirefeed speed, you will have to increase the Run-in Speed setting.

CV Posa Start Operation(005-0339 kit must be installed)

Attach WC-1 to CV power source according to the installation instructions.

Turn the WC-1 to the “ON” position and the Posa Start to the “OFF” position.

Adjust power source to desired voltage for your weld condition.

Depress gun trigger and adjust wire feed speed at gun to match voltagesetting. If approximate wire feed is not known, it is better to start with excesswire feed rather than too little, in order to prevent a “burn-back”.

Strike an arc, and adjust wire feed rate at gun until correct condition isachieved.

Section 7 MAINTENANCEMaintenance of the torch will normally consist of a general cleaning of the wireguide system, including tubes, drive rolls, and liners at regular intervals.Remove spatter build-up from inside of nozzles with a hardwood stick.

The only parts of the spool gun that are subject to normal wear are the contacttips, gas cups, front and rear liners, wire guides, drive and idler rolls. A supplyof these parts should be maintained on hand.

If repairs do become necessary, any part can easily be replaced by a qualifiedshop maintenance person.


Your WC-1 is designed to provide years of reliable service. Normal wear andcomponent failure may require occasional service.

The number of units in operation and the importance of minimal "down time"will determine to what extent spare parts should be stocked on hand. Thefollowing list comprises the most commonly replaced parts on the WC-1.

WC-1 Recommended Spare Parts List

QTY P/N DESCRIPTION1 003-1636 Main P.C. Board1 003-1644 Front Panel Board

Section 8 TESTING THE TORCH

Motor Check

Remove the amphenol connector from the WC-1.

Using the torch amphenol, check the resistance across pins “A” and “B”(motor leads). The resistance across the motor should be between 5-10ohms.

If an open circuit or short exist, check the motor leads and motorindependently.

Testing The Potentiometer

Using the torch amphenol, check the resistance across pin “D” (wiper) and pin“C”. The resistance should vary from 0 - 5K ohms.

Check the resistance across pin “D” (wiper) and pin “G”. The resistanceshould vary from 5K - 0 ohms.

Testing The Micro Switch

Using the torch amphenol, check for continuity across pins “E” and “F” whenthe trigger is pressed.

Section 9 RELAY K2 OPERATIONWhen the torch trigger is pressed, 24VAC is sent to the coil of relay K2. WhenK2 is energized, 115VAC is sent to the 115VAC contactor. Relay K2 is alsoresponsible for sending 24VAC to the speed control circuit and shorting thetorch motor leads together when the trigger is released for the dynamic brakingsystem. K2 also provides the closing contactor signal.

Section 10 TESTING THE 115 VAC CIRCUITSThe 115 VAC circuit is protected by fuse F3. If either continually blows,remove J5-3,4 (115 VAC Contactor) from the P.C. Board. Replace fuse, andretrigger system.

Section 11 TESTING THE SPEED CONTROL

NOTE:The torch should be tested first and the amphenol must be

connected to the WC-1 to perform this test.


Place a voltmeter across diode D10 and press torch trigger. A reading of 0 -24VDC should be observed, as the potentiometer is varied.

Section 12 INTERCONNECTIONSPrince® XL Spool Gun 216-xxx connected to a WC-1Weld Control Box 001-3062

Gas Hose

COUPLER - AW-430-RHM.K. P/N 753-3377

Weld Control Box

Electrical Cable

CUSTOMERSUPPLIED

Contactor Leads

WC-1CONSTANT CURRENTPOSA START SENSINGLEADS. NOT NEEDED

WITH CONSTANTVOLTAGE SUPPLIES

Ground Lead

+ _

Power Cable

CONSTANT VOLTAGEOR

CONSTANT CURRENTPOWER SUPPLY

NOTE:The Posa Start feature permits the WC-1 tobe used in combination with any Constant

Current DC power source with an opencircuit voltage in excess of 55 volts.

115 VAC Plug

RED

GREEN

D10

+ _

VDC

24.0


Section 13 TROUBLESHOOTING

TROUBLE CAUSE REMEDY

No wire feed at torch

F3 fuse in WC-1 blown. Check 115VAC circuit. Replace fuse.

F1 fuse in WC-1 blown.Check motor leads for shorts, then replacewith 4A fuse.

Micro-switch defective/not beingactivated. Broken electrical cable.

Replace switch. Check switch foroperation. Check micro switch wires forcontinuity.

Relay K2 inoperative. Check/Replace relay K2.

Loose P.C. board connectors. Check connectors.

Bad potentiometer. Check potentiometer with meter.

Bad torch motor. Check/replace motor.

Broken electrical cableCheck motor and potentiometer wires forcontinuity.

Bad speed control/PCB. Check/Replace P.C. board.

Wire feeds, butwelding wire is notenergized.

Loose or no cable connections.Relay K2 not sending contactorsignal.

Check all power connections.Check/replace relay K2.

Contactor control cable loose or inwrong position.

Check power supply owners manual forlocation and type of contactor signalrequired, i.e., closing contacts or 115VAC.

Welding power source. Check power source for operation.

Wire feeds erratically.

Excessive spool drag pressure. Decrease spool drag pressure.

Dirty or worn liners. Blow out or replace liners.

Incorrect pressure on drive rolls. Adjust pressure at both feeder and torch.

Idler roll stuck.Check for lock washer under idler roll, orreplace if damaged.

Wrong size contact tip. See contact tip table.

Wire feeds onespeed only.

Bad potentiometer. Check with meter.

Broken electrical cable.Check potentiometer wires for continuity orshort.

Bad speed control. Check/replace P.C. board.

Wire walks out ofdrive rolls

Idler roll upside-down. Place groove in idler roll towards top.

Rear wire guide missing. Replace wire guide.


Section 14 MAIN P.C. BOARD CONNECTIONS

J3

J2

J8 J7

J5J6

FRONT PANEL

not used

FRONT PANEL

not used

TRANSFORMER

115VAC CONTACTOR OUT

115VAC CONTACTOR OUT

115VAC INPUT

115VAC INPUT

GROUND

CLOSING CONTACTS OUT

CLOSING CONTACTS OUT

(-) WORK GROUND - GREEN

(+) WELD VOLTS - RED

J4

4444433333222221111144444333332222211111

jumperJ1

115 vac only


Section 15 MAIN P.C. BOARD PARTS PLACEMENT

COMPONETS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY.

R5 R4

JP1J1J1J1J1J1

K1R2 D2 R3

D3R1

D4

D5

R6C4

J2C3 Q1

D1

RV1

C1

C5

D6

RV2

D8

RV3

R7

R8

R9

C7

R11

Q4

Q3 R12

R13

R10

C8 C9

D9D7

RV6RV6RV6RV6RV6

K2

F1

F2

F3

J8

Q5C6

RV5

JP3JP2

J9

J10

J11

RV4

D10

Q2

C2

3 41 2 4321

J5J6

J3

J4J7

C10

24 vac supply - 4A

115 vac input - 2A


MAIN P.C. BOARD PARTS LIST (P/N 003-1636)

COMPONENT # P/N DESCRIPTION

K1 157-0144 RELAY, 5V 5000HM 200MAR2, R3 115-0154 RESISTOR, carbon .25 watt 6.8K ohmR4, R5 115-0042 RESISTOR, carbon .50 watt 6.8K ohm

R12, R13 115-0120 RESISTOR, carbon .25 watt 100 ohmR6 115-0122 RESISTOR, carbon .25 watt 150 ohmR7 115-0144 RESISTOR, carbon .25 watt 10K ohmR8 115-0138 RESISTOR, carbon .25 watt 3.3K ohmR9 115-0129 RESISTOR, carbon .25 watt 560 ohmR10 115-0136 RESISTOR, carbon .25 watt 2.2K ohmR11 115-0141 RESISTOR, carbon .25 watt 5.6K ohm

D1, D3 124-0002 DIODE, 1 amp 800 voltsD6-D10 124-0003 DIODE, 2.5 amps 1KV

D4 124-0011 DIODE, zener 1 watt 10 voltsQ2 122-0011 TRANSISTOR, NPN 500MA 250 voltsQ3 122-0004 TRANSISTOR, PNP 1 amp 50 voltsQ4 122-0013 TRANSISTOR, unijunction 30 voltsQ5 125-0028 THYRISTOR, 8 amps 400 volts

C1, C5, C8, C9 101-0016 CAPACITOR, ceramic .01uf 600VDCC2 101-0013 CAPACITOR, Poly .047uf 200VDC

C4, C6 104-0002 CAPACITOR, tantalum 10uf 20VDCC7 101-0021 CAPACITOR, ceramic .047uf 50VDC

RV1, RV5, RV6 124-0026 VARISTOR, 130 volts 10 ampsRV2, RV4 124-0028 VARISTOR, 56 volts 8 amps

J1 153-0866 TERMINAL, header 2 pinJ2 153-0885 TERMINAL, header 26 pinJ3 153-0713 TERMINAL, header 4 pin

J5, J6 186-0057 TERMINAL, strip 4 pinJ8 153-0850 CONNECTOR, 6 pin

Fuse Holder 152-0008 FUSE HOLDER, PC mountF3 151-0001 FUSE, AGC 2A 250VK2 157-0022 RELAY, 24VAC 4PDT

K2 Socket 173-0026 SOCKET, relay 14 pinF1 151-0043 FUSE, 3AG 4A, 250VD5 124-0093 DIODE, zener, 1 watt, 5-1volts


Section 16 FRONT PANEL P.C. BOARD LAYOUT

FRONT PANEL P.C. BOARDPARTS LIST

003-1644

COMPONENT # P/N DESCRIPTION

R2 119-0020 POTENTIOMETER, 100k ohmR3 115-0037 RESISTOR, Carbon 2.7k ohm, 1/2wattD1 124-0045 LED, greenJ1A 153-0845 HEADER, 4 pin 90 degreeJ2 153-0876 HEADER, 26 pin 90 degreeJ3 153-0860 HEADER, 8 pin 90 degree

SW1 159-3587 SWITCH, DPDT, p.c. mountSW3 159-3586 SWITCH, SPDT, p.c. mount

R2 (bracket) 435-0901 BRACKET, p.c. mount

COMPONENTS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY


Section 17 DRAWINGS

AND

SCHEMATICS

Ow

ner’s Manual - P

age 21

No. Qty. Part No. Description

1 1 438-0026 Base

2 1 003-1636 PCB, Main w/Posa Start 115V

3 4 342-0410 Spacer tacking #6-32 x 0.534 LG

4 4 336-0005 Screw, PH. FIL. #6-32 x 3/8

5 1 405-0716 Decal, Block Diagram WC-1 115V

6 1 003-1644 PCB, Panel w/Posa Start

7

8 1 301-0023 Grommet pnl., mtg., LED

9 1 401-0012 Knob 1.00 Dia.

10 1 003-1645 Cable, board to board

11 1 003-1646 Cable, power board to board

12 1 003-1642 Cable, board to torch "W"

13 1 003-0773 Transformer 115V Assy.

14 3 325-0135 Screw, PH. FIL> #6-32 x 1/2

15 7 333-0023 Washer, X star #6

16 2 341-0005 Nut Hex #6-32

17 4 331-0002 Washer flat #6

18 1 411-0157 Clamp, cable strain rel.

19 1 003-0796 Power cable

20 1 003-1302 Cable, contact assy.

21 1 438-0025 Cover

22 8 336-0026 Screw, St T/A #6-32 x 3/8 LG.

23 1 003-1639 Jumper bypass assy.

24 1 405-0647 Decal, front WC-1

25 1 405-0709 Decal, rear WC-1 115V

26 2 345-0008 Nut, self locking #6-32

27 1 405-0725 Decal, terminal block

28 2 327-0110 Screw, ST-F #6-32 x 3/8 LG.

29 1 003-1301 Cable, Posa Start assy.

30 2 331-0019 Washer flat #4

FORM :LW-9MKDATE :January 1, 2000

LIMITED WARRANTY - MK Products,Inc.,Irvine,Californiawarrants that all new and unused equipment furnished by MKProducts is free from defect in workmanship and material asof the time and place of delivery by MK Products. No warrantyis made by MK Products with respect to trade accessories orother items manufactured by others. Such trade accessoriesand other items are sold subject to the warranties of theirrespective manufacturers, if any.

MK Products’ warranty does not apply to components havingnormal useful life of less than one (1) year, such as relaypoints, wire conduit, tungsten, and welding torch parts thatcome in contact with the welding wire, including gas cups, gascup insulators, and contact tips where failure does not resultfrom defect in workmanship or material.

In the case of MK Products’ breach of warranty or any otherduty with respect to the quality of any goods, the exclusiveremedies therefore shall be at MK Products’ option:

(1) repair(2) replacement(3) where authorized in writing by MK Products, the reasonablecost of repair or replacement at our Irvine, California plant; or(4) payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goodsat customer’s risk and expense. Upon receipt of notice ofapparent defect or failure, MK Products shall instruct theclaimant on the warranty claim procedures to be followed.

As a matter of general policy only, MK Products may honor anoriginal user’s warranty claims on warranted equipment in theevent of failure resulting from a defect within the followingperiods from the date of delivery of equipment to the originaluser:

1. Torches and Weldheads ......................... 1 year2. All Other Equipment .............................. 3 years3. Repairs ................................................... 90 days

Classification of any item into the foregoing categories shall beat the sole discretion of MK Products. Notification of any failuremust be made in writing within 30 days of such failure.

A copy of the invoice showing the date of sale must accompanyproducts returned for warranty repair or replacement.

All equipment returned to MK Products for service must beproperly packaged to guard against damage from shipping.MK Products will not be responsible for any damages resultingfrom shipping.

Normal surface transportation charges (both ways) for productsreturned for warranty repair or replacement will be borne byMK Products, except for products sold to foreign markets.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPLIED WARRANTY, GUARANTY, ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT WHICH, BUT FORTHIS PROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE, OR COURSEOF DEALING, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR OF FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENTFURNISHED BY MK PRODUCTS, IS EXCLUDED ANDDISCLAIMED BY MK PRODUCTS.

EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTSIN WRITING, MK PRODUCTS ARE INTENDED FORULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIALUSERS AND FOR OPERATION BY PERSONS TRAINEDAND EXPERIENCED IN THE USE AND MAINTENANCE OFWELDING EQUIPMENT AND NOT FOR CONSUMERS ORCONSUMER USE. MK PRODUCTS WARRANTIES DO NOTEXTEND TO, AND NO RE-SELLER IS AUTHORIZED TOEXTEND MK PRODUCTS ’ WARRANTIES TO ANYCONSUMER.

Effective January 1, 2000This warranty supersedes all previous MK Products warranties and is

exclusive, with no other guarantees or warranties expressed or implied.

16882 Armstrong Ave.Irvine, CA 92606Tel (949)863-1234Fax (949)[email protected]

MK PRODUCTS, INC.16882 ARMSTRONG AVE.IRVINE,CALIFORNIA 92606

TEL (949) 863-1234 FAX (949) 474-1428

wc-1 weld control box owner’s...

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