WIA TIGARC 140DC MC86-0 Bedienungsanleitung

WELDING

INDUSTRIES

AUSTRALIA

DIVISION

WELDING

INDUSTRIES

LTD

ACN

004

547’

Head

Office

and

International Sales

Allan

Street,

Melrose

Park

South

Australia,

5039

Telephone

(08)

8276

6494

Facsimile

(08)

82766327

OWNERS MANUAL

TIGARC 140DC

MODEL

NO.

MC86-0, REV.

10195

QUALITY WELDING

PRODUCTS,

SYSTEMS

AND SERVICE

Page

TIGARC

140DC

MANUAL

Theinformationcontained

thismanualissetouttoenableyou to properly

maintain your new equipment and ensure that you obtain maximum operating efficiency.

Please ensure that this information is kept

a safe place for ready reference when

required at any future time.

When requesting spare parts, please quote the serial number of the machine and if

possible, the partnumberof the itemrequired.

All

relevantnumbersareshown in this

manual. Failure to supply this informationmayresult

unnecessarydelays in supplying

the correct parts.

SAFETY

Before this equipmentisputintooperation,theSAFEPRACTICESsectionat the

back of the manual must be read completely. This will help to avoid possible injury due to

misuse or improper welding applications.

PLASTIC

HANDLE

machine by hand only.

manner.

Please note that the handle fitted

the TIGARC 140DC is intended for carrying the

NOT

usethishandleforsuspendingormountingthemachine

anyother

CONTENTS

SECTION PAGE

...........................

Receiving

......................................................

2,,

.........................

Specifications..

..............................................

3..

.........................

Connection To Mains

....................................

4..

.........................

Operation

......................................................

5..

.........................

Maintenance

..................................................

...........................

Fault Finding

.................................................

7..

.........................

Service Information

........................................

8...

........................

Parts

Lists

.....................................................

.IO

9..

.........................

Safe Practices.

...............................................

FIGURE PAGE

...........................

GTAW Welding

..............................................

...........................

Connections For GTAW

.................................

3...

........................

Connections

For

MMAW

..............................

..7

...........................

MMAW Welding

.............................................

...........................

Circuit Diagram

.............................................

...........................

Power Source Assembly

...............................

6..

.........................

GTAW Torch And Accessories

.....................

.l2

TEGARC

140DC

MANUAL

Page

RECEIVING

Checktheequipment received against the shipping invoice to makesure the

shipment is complete andundamaged.

anydamagehas occurred in transit,

please immediatelynotify your supplier.

The TIGARG

140DC

carton contains:

TIGARG140DC WeldingPowerSupply

Sample pack of AUSTARC

12P

and

13s

electrodes

(This)OwnersManual

The genuineWIA AA32 Acccessory Kit contains:

Work leadwith spring ‘Work’clamp

Electrode leadwith electrode holder

Face shield

The genuineWIA AA47-0 AccessoryKit contains:

150

AmpGTAW torch

Torch terminal adaptor

Tungsten electrode,

thoriated

Gas regulator and flowguage

Gashoseassembly,

metre

Heavy duty Worklead with spring ‘Work’ clamp.

Page

TIGARC

14cODC

MANUAL

SPECIFICATIONS

INPUT VOLTAGE

........................................

240 Volts AC

RATED INPUT CURRENT

...........................

12.5

Amps

MAXIMUM

SHORT

CIRCUIT CURRENT

.....

Amps

MAXIMUM KVA REQUIREMENT

................

8.2

kva

SUPPLY FLEXIBLE CABLE RATING

...........

Amps

APPROVALS NUMBER

...............................

MC86/S221

OPEN CIRCUIT VOLTAGE

..........................

44 Volts Max.

RATED OUTPUT CURRENT

GTAW

...............................................

105

A, 14 VDC,

25%

Duty

52.5

12 VDC,

100%

Duty

MMAW

..............................................

IO0

VDC,

25%

Duty

A, 22 VDC,

IOQ%

Duty

WELDING

CURRENT RANGE

.....................

120

Amps

ELECTRODE RANGE

..................................

2.0

to3.2mm diameter

MASS

..........................................................

DIMENSIONS

..............................................

365mm(incl. handle),

W 240mm,

370mm

Duty

Cycle

defined

Australian Standard AS1966.1

the ratio

arcingtime

minutes

any

minute

period,

expressed

percentage.

TIGAR6

140DC

MANUAL

Page

CONNECTION

ELECTRICAL

MAINS

POWER

SUPPLY

The

TIGARC

140DC

supplied

with a 3 metre,

Amp Heavy Duty

(30/0.25)

PVC

mains power supply cable. This cable must only be connected to a correctly

installed

Amp

GPO

(GeneralPurpose Outlet)

The

plug

and

GPO

are both

identified by a wide Earth pin, which is intended to prevent the

plug

being inserted

into

standard

Amp

GPO

becomes necessaryto replacethe mains power

supply

cable,

use only a cable with equivalentcurrent rating.

The recommended Supply

Fuse

rating

Amps.Due to peak current

requirements,the Electrical Mains supply to welding machines

best protected by

a fuse.

Circuit Breaker may trip frequently

used inthis application.

is necessaryto use an extension power supplycable, ensure that it

rated

for

minimum

Amps. Voltage drop over long lengths of cable will reduce the

maximumwelding current availablefrom the equipment.

OPERATION

The

TIGARC:

140DC

has outputs for two arc welding processes:

Gas

Tungsten

Arc Welding

(GTAW),

and Manual MetalArc Welding

(W.”).

GAS

TUNGSTEN

ARC

WELDING

GTAW

is a very clean welding method

which the welding arc is established

between a non-melting tungsten electrode and

the

workpiece. The welding zone,

molten

weld

metal

and

tungsten electrode are protected from Contamination by a

shield of inert

gas,

usuallyArgon. The process can be

used

to fusion weld, ie. melt

the

edges of the workpiece together without metalbeing added to the weld, or filler

metalmay

fed

intothe are

hand.

BUTT

JOINT

OUTSIDE

JOINT

FtGURE

GAS

TUNGSTEN

ARC

WELDING.

Page

PIGARC

140DC

MANUAL

TheTIGARC

140DC

Direct Current machine,and for GTAW the torch is

connected to the GTAW

(-)

output terminal.Figure

illustrates the correct

connection of the welding torch and gas supply.

Tungsten electrodes for

GTAW should be

Thoriated. This type will

provide the best arc initiation, arc stability and tip shape retention characteristics.

Thoriated electrodes can be recognised by

red coded end. The tungsten

electrode is ground to a point, with the grinding marks pointing towards the tip. Fqr

welding currents less than

amps, the included angle of the pojnt should be

for currents greater than

amps, the recommended angle is

When set in the

torch, the tungsten should protrude 12mmfrom the ceramic gas nozzle.

Before initial use of the welding torch, allow gas to purge the torch and hoses

for

minutes at approximately

litres/min. For welding purposes,

the

gas flow

rateshould

set inthe range

2-5

litres/min.

initiate the arc, the tungsten electrode should be touched preferably onto a

pieceofcopper adjacent to the workpiece, thenlifted in a smooth movement to

establish an arc length slightly larger than the diameter of the electrode. When the

arc

stable, it can be transferred to the workpiece.

Useof a copper striking plate is recommended to avoid electrode

contamination. The electrode can also be contaminated by contact with the filler

rod.

contaminatedelectrode producesan unstablearc.

GAS

BOTTLE

FIGURE

CONNECTIONS

FOR GTAW.

MANUAL

METAL

ARC

WELDING.

MMAWis a welding process where an arc is struck between a flux-coated

consumable electrode and

the

workpiece. The arc and the weld pool are both

shietded

gases generatedfrom the coating

the electrode.The TIGARC

140DC

maybeused with 2,0mm,2.5mm, and 3.2mmdiameter welding electrodes. The

smallersizesareusedwhen welding at lower currents, such as sheet-metal

applications. tncreasing the electrode diameter permits higher welding currents to

be setected,

When using a DC (Direct Current) welding machine such as the TIGARC

140BC, it is important to select the electrode polarity in accordance with the

manufacturers’ recommendations for that electrode. Both methods

connection

are shown inFigure

below.

W.I.A.manufacturesa wide range of mild steel and special purpose electrodes

which cater for home workshop, rural, and industrial requirements.Somepopular

AUSTARC electrodes are listed below. The correctly selected AUSTARC electrode

used in conjunctionwith the TIGARC

140D6

will provide a stable arc and high

quality weld deposit.

Austarc 12P, Classification

AS1553,

E41

12.

popular generalpurpose electrode used with ease in

all positions, vertical up or down. The smooth forceful

arcmakes it an ideal electrode for all general mild steel

applications. Preferredpolarity electrode positive.

Austarc 13S,Classification AS1553,

E41

13.

smooth running electrode with

soft arc, particularly

suited to light sheetmetal and smooth mitre fillet welds.

Preferred polarity electrode positive.

Austarc 16TC, Classification

AS1553,

€4816.

A low hydrogen electrode withgood arc stability and

out-of-positionwelding characteristics. This electrode

ideal

for

medium carbon steels,orsteels

unknown

analysis. Operateelectrode positive.

Unicord312, Classification AS2576, 1330-A3

high

tensile

(770

MPa), high chromium nickel

electrode specially formulated for joining all alloy steels

and irons, and for tool

and

die maintenance. Operate

electrode positive,

page

TIGARC

140DC

MANUAL

strike the arc, drag the end of the electrode along the workpiece as if

strikinga match. As the arc initiates,

lift

the

electrode slightly away, aiming to

establish an arc length of approximately 3mm.

the electrode end is consumed,

feed the electrode into thearc in order to maintain a constant arc length. As a

generalrule, 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 causes an unwieldy

flow

metal with a rough weld apFearance and reduced penetration. An arc too

short leads to a narrow weld deposit and "stuttery" arc characteristic, and the

electrode is liable

freeze onto the workpiece.

As the solidified weld deposit forms, move the end of the electrode slowly

along the weld path, aiming to maintaina

poot

of moltenweld metal behind the arc.

Decreasing this rate

travel will result in a wider weld deposit, and similarly

increasing

will narrow the weld deposit. Always fit1 the crater which tends to form

at the endof a weld deposit, by pausing momentarily before withdrawing the

electrode to break the arc. Unfilled craters are a point of weakness, and can lead

toweld cracking.

onstantmolten

pool

widthmeans

ONSTANT

beadwidth

StrikingthearcMaintainsteady

arc

length

FIGURE

MANUAL METAL

ARC

WELDING.

MAINTENANCE

Care should be taken to prevent excessive build-up of dust and dirt within the

welding power source. It isrecommendedthat at regular intervals,according to the

prevailing conditions, the machine covers be removed and any accumulated dust

be removedby the use of dry, low pressurecompressedair, or avacuum cleaner.

FAULT FINDING, NOWELDING CURRENT

Check that Mains Supply is available at the TIGARC 140DC Power Source, i.e.

that the fan

running. Check for continuity of the welding current circuit, i.e., work

lead,work clamp and electrode holder.

TheTIGARC

140DC

welding power source incorporates an inbuilt protection

device which will trip if the unit is overloaded. In this event the machine will not

deliver welding current until the overload device hasbeenMANUALLYreset.The

overload device cannot be reset immediately after it has tripped. 8efore resetting,

establish and correct the causeof the overload condition. Thereset button is

located on the rear panel,just above the Supply Flexible Cableentry.

equipment failure

suspected, forward the unit to yournearest WIASales

and ServiceBranch, or qualified serviceagent.

TIGARC

140DC

MANUAL

Page

SERVtCE

INFORMATION.

The electrical components of the TIGARC

140DC

are shown in the circuit

diagram below. The output

the

welding transformer

full-wave bridge rectified,

with the

GTAW

output current smoothed

inductance coil,

Primary voltage to the Welding Transformer is controlled

means of a Triac

based phase shift circuit. Adjustment of the front panel potentiometer will vary the

open circuit output voltage

the WeldingTransformer.

ACTWE

B"-----

NEUTRAL

AUXlLLlARY

TERMINAL

BLOCK

""""""""

RV1

CW RED

PRlMARY

OVERLOAD DEVICE

WELDING

MC84-0/3

TRANSFORMER TRANSFORMER

CP102-0/16

-VE

GTAW

AUXlLLlARY

RECTIFIER -VE

MMAW

CP38-31/5

+VE

WORK

CURRENT LIMITIN6 RESISTORS

MC82-15/10

FIGURE

TIGARC

140DC

CIRCUIT DIAGRAM

page

TIGARC

140DC

MANUAL

The

TIGARC

140BC

also

includesan auxilliary transformer, rectifier, and

current limiting resistors.The current fromthese components maintainsthe GTAW

arc duringperiods when the triacisnotconducting. The printedcircuitboard

assembly provides the appropriate trigger

pulses

to the Triac.

thiscircuit

incorporatesspecialized components,

not intendedto be repaired in

the

field,

Replacement assemblies obtained from

WIA

are supplied complete with Priac and

Potentiometer.

Replacing the Triac requires removal

the original partby first drilling out the

retainingpop-rivets. Clean

the

mounting surface to removeswarf

and

any

remaining heat-sink compound. Alwaysapply clean heat-sink compound

the

new trimprior toassembly.

correctly

adjust

the

phase-shiftrange of

replacement circuit board:

Rotate the Current Control potentiometer knobto the minimum current

Disconnectthe red wire from the positiveterminal

the auxilliary rectifier

Connect a

Voltmeter to the welding output terminals

"tve

WORK" and

"-ve

MMAW".

With theTIGARC energised, but not welding, adjust the potentiometer

RV2

on the printed circuit boardto obtain

voltmeter reading

volts.

Reconnect the redwire tothe positiveterminal of

the

auxilliaryrectifier.

position,(fully anti-clockwise).

(CP38-31/5).

PARTS

LISTS

TIGARC

1408C

POWER

SOURCE

ITEM

#.......PART#

......................

DESCRIPTION

..................

MC86-11

...................

PrintedCircuitAssembly

6P101-11

..............

Potentiometer

Includes

CPlOl-11/2

..............

Triac

..................

MC86-12

...................

Transformer assembly

5..................SA140-0/1

................

Handle

..................

MC86-l3

...................

Base

.................

MC84-i

...................

Cover

..................

MC84-16

...................

TerminalAssembly

..................

MC66-0/8

.................

Primary Flex and Plug

..................

CP27-U/15

................

Fan

and Motor

9..................CP101-0/19

..............

Fan

Finger Guard

.................

Wll-O/16

..................

PotentiometerKnob

.................

MK6/4

......................

Terminal Block

.................

H390W

......................

Cup

Terminal andWasher

.................

H285

.........................

EarthTab

15.

................

CP102-0/18

.............

.CircuitBoard Support

.................

WIP1199

.....................

tabel

Set

.................

HF200-1/15

..............

Foot

.................

MC84-0/3

.................

OverloadDevice

.................

MC84-0/2

.................

Cable Gland

.................

MC84-0/4

.................

Cable Gland

Nut

.................

MC86-20

...................

InductanceAssembly

.................

CP104-0/2

................

RectifierAssembly

.................

MC82-15/10

.............

Resistor

includes

MCll-41/1

...............

Terminal Knob

................

.W1

O2-0/16

..............

AuxilliaryTransformer

.................

CP38-31/5

................

Diode Bridge

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