WIA TIGARC 150DC 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)

82766494Facsimile (08)8276

6327

OWNERS

MANUAL

TIGARC 150DC

MODEL

NO. MC86-2,

REV.

220V/240VVERSION

10195

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE

Page

TJGARC

150DC

MANUAL

Theinformationcontained in thismanual is setouttoenableyoutoproperly

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,thepartnumberoftheitemrequired.Allrelevantnumbersareshown in this

manual.Failuretosupplythisinformationmayresult in unnecessarydelays in supplying

the correct parts.

SAFETY

Before this equipment is putintooperation,theSAFEPRACTICESsectionatthe

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

misuse

improper welding applications.

PLASTIC HANDLE

machine by hand only.

manner.

Please note that the handlefitted to the TIGARC 140DC is intended for carrying the

NOT

usethishandleforsuspendingormountingthemachine in anyother

CONTENTS

SECTION

PAGE

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

Receiving

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

2..

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

Specifications..

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

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

Connection To Mains

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

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

Operation

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

5..

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

Maintenance.

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

..8

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

Fault Finding

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

7..

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

Service Information

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

..9

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

Parts Lists

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

9..

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

Safe Practices.

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

.l3

FIGURE PAGE

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

GTAW Welding

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

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

Connections For GTAW

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

3..

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

Connections For MMAW

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

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

MMAW Welding

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

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

Circuit Diagram

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

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

Power

Source Assembly

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

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

GTAW Torch And Accessories

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

.l2

TiGARC

150DC

MANUAL

Page

RECEIVING

Check the equipment received against

the

shipping invoice

makesure the

shipment is complete and undamaged.

any

damage

has

occurred

transit,

please

immediately

notify

your

supplier.

The

TIGARC

150DC

carton contains:

TIGARC

150DC

Weldin

Power

Supply

Sample

pack

AUSTA

12P

and

13s

electrodes

(This)Owners

Manuaf

The genuine

WIA

AA32

AcccessoryKit contains:

Worklead with sprin ‘Work’ clamp

Electrode

lead

with

ectrode holder

Face

shield

The genuineW1A

AA47-0

AccessoryKit contains:

150

Amp

GTAW torch

Torch terminaladaptor

Tungstenelectrode,

thoriated

Gas

regulator

and

ffowguage

Gas

hose

assembly,

metre

Heavyduty

Work

lead with spring ‘Work’ clamp.

SPECfFlCATIONS

INPUT

VOLTAGE

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

220/240

Volts

50/60

RATED

iNPUT

CURRENT

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

Amps@220V,

12.5

Amps@24BV

MAXIMUM

SHORT

CIRCUIT

CURRENT

.....

Amps@220V.

Amps@240V

MAXIMUM KVA

REQUIREMENT

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

8.2

kva

SUPPLY

FLEXIBLE

CA5L.E RATJNG

...........

Amps

OPEN

CIRCUIT

VOLTAGE

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

Volts

Max.

RATED

OUTPUT

CURRENT

GTAW

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

VDC,

25%

Duty

52.5

Vac,

180%

Duty

MMAW..

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

100

VDC,

25%

Duty

VDC,

100%

Duty

WELDING

CURRENT

RANGE

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

120

Amps

ELECTRODE

RANGE

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

2.0

3.2mm

diameter

MAS$

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

DIMENSIONS

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

365mm(inci.

handle),

240mm,

370mm

Duty

Cycle

defined

Australian Standard

AS1966.1

the ratio

arcing

time

minutes

any

minute

period, expressed

percentage.

TIGARC

150DC

MANUAL

Page

CONNECTION

ELECTRICAL MAINS

POWER

SUPPLY

The WELDARC140 can be set for a supply voltage of either 220 or 240 volts

AC.

adjust the supply voltage tapping, remove the machine cover, and

terminate the white wire in the appropriately marked connection point. The

machine isfactory set for 240 volts.

TherecommendedSupplyFuse rating

Amps.Due to peak current

requirements,the mainssupply towelding machines

best protected bya fuse. A

Circuit Breaker may trip frequently

used inthis application.

Themachine is supplied with

metre,

AmpHeavy Duty

(30/0.25)

PVC

mainspowersupply cable. If it becomesnecessary to replace the mainspower

supply cable,useonly

cablewith equivalentcurrent rating.

OPERATION

GAS

TUNGSTEN

ARC

WELDING

GTAW is

very clean welding method inwhich the welding arc is established

between a non-meltingtungsten 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

used

fusion weld, ie. melt

the edges oftheworkpiece together without metalbeingadded tothe weld, or filler

metalmay befed into

the

arc by hand.

BUTT

JOINT

LAP

JOINT

30°

FILLET

JOINT

FIGURE

GAS

TUNGSTEN

ARC

WELDtNG.

The

TIGARC

150DC

a DirectCurrentmachine,

and

for

GTAW

the torchis

connected

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

point, withthe grinding marks pointing

towards

the tip. Fqr

welding currents less than

amps,

the

included angle

the pojnt should

for currents greater than

amps, the recommendedangle

When set inthe

torch, the tungsten shouldprotrude

12mm

from the ceramic gasnozzle.

Before initial use

the welding torch, allow gas to purge the torch and

hoses

for

minutesatapproximately

litres/min. Forweldingpurposes,thegasflow

rateshould

set

inthe range

2-5

litres/min.

initiatethe arc, the tungsten electrode

should

touched preferably onto

piece

copperadjacent to theworkpiece, then lifted in

smoothmovement

establish

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

arc isstable,

can

transferred

the workpiece.

Use

copper

striking plate

recommended

avoid electrode

contamination.

The

electrode can

also

be contaminated

contact with

the

filler

rod.

contaminatedelectrode producesan unstable arc.

GAS

0OTTLE

RESULATOR

GTAW

(

CONNECTION

WORK

(

)

CONNECTION

FIGURE

CONNECTIONS

FOR

GTAW.

TlGARC

150DC

MANUAL

Page

7’

MMAW

welding processwhere

areisstruck between

flux-coated

consumable electrode

and

the workpiece.The arc and the weld pool are both

shielded

ases

generated from

the

coating

the electrode. The

TIGARC

150DC

may

use

with 2.0mm,2.5mm, and

3.2mm

diameterweldingelectrodes.The

smallersizesareusedwhen welding atlowercurrents, such

sheet-metal

applications. tncreasing the electrode drameter permits higher welding currents to

be selected.

When

using

(DirectCurrent) welding machinesuch

the

TIGARC

150DC,

important to selectthe electrode polarity

accordance with the

rnanufaeturers’ recommendationsfor that electrode. Both methods of connection

are shown inFigure

below.

Austarc

12P,

Classification

AS1553,

E41

i2.

populargeneralpurposeelectrodeused with ease

all

positions, vertical up

down.

The

smooth forceful

arc makes

ideal

electrode

for

all general mild

steel

applications. Preferredpolarityelectrode positive.

Austarc

13S,

ClassificationAS1553,

E41

13.

smooth running electrode with

soft

arc, particularly

suited to light sheetmetal

and

smooth mitre fillet welds,

Preferred polarityelectrode positive.

Austarc

16K,

Classification

AS1553,

E4816.

IOW

hydrogen

electrode with

good

arc stability and

out-of-positionwelding characteristics.

This

electrode

ideal for medium carbon steels,orsteels

unknown

analysis. Operateelectrodepositive.

Unicord

312,

Classification

AS2576,

1330-A3

high

tensile

(770

MPa),

high

chromium nickel

alectrade specially formulated for joining

all

alloy steels

and

irons, and fortoot and

die

maintenance.Operate

electrode positive.

ELECTROUENEGATIVE ELECTRODE

POSITIVE

FIGURE

3.CONNECTIONS

FOR

MMAW.

Page

TIGARC

f50DC

MANUAL

To strike thearc,dragthe end of the electrode

along

theworkpiece as

striking

match.

thearcinitiates,

lift

the electrode slightly

away,

aiming to

establish an arc length of approximately

3mm.

the electrode

end

is consumed,

feedtheelectrode into

the

arc in arder to maintain

constant arclength.

generalrule,the arc shouldbe held

short

possiblewhile

still

giving stable

burn off and

good

weld a pearance. An arc which

too long causes an.unwieldly

flow

of metal with a roug

weld appearance and reduced penetration.

arc too

short leads to

narrow

weld

deposit and"stuttery" arccharacteristic,andthe

electrode

liableto freeze onto the workpiece.

the solidified welddeposit forms, move the

end

of the electrodeslowly

along the weld path, aimingto maintaina

pool

of moltenwetd metal behind the arc,

Decreasing this rate

travel willresult in

wider

weld

deposit,andsimilarly

increasing

will narrow the weld deposit.

Always

fill the crater which tendsto form

the end of a welddeposit, by

pausing

momentarily before withdrawing

the

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

to weld cracking.

Striking the arc Maintainsteadyarc kngth

FIGURE

MANUAL

METAL

ARC WELDING.

MAINTENANCE

Care

should

taken to prevent excessive build-up

dust

and

dirt within the

welding

power source.

recommendedthat at regular intervals,according to the

prevailing conditions, the machine covers

removed and any accumulated dust

removed

the use of

dry,

low

pressure compressedair, or

vacuum

cleaner.

FAULT

FINDING,

WELDING

CURRENT

Check that Mains Supply

available at the

T1GARC

150DC

Power

Source,

i.e.

that the fan isrunning. Check forcontinuity of the welding current circuit,

i.e.,

work

lead, work

clamp

andelectrode holder.

The

TIGARC

15ODC

welding powersource incorporates

inbuilt protection

device which will

trip

the

unit is overloaded. In this event themachine will not

deliver

Welding

current until the overload device has been

MANUMY

reset.

The

overload

device cannot

reset immediately after

has tripped. Before resetting,

establish and correct

the

cause

the overload condition. Thereset buttonis

located on

the

rear panel, justabovethe

Supply

Flexible Cable entry.

equipment failure

suspected, forward the unit to yournearest

WIA

Sales

and

Service Branch, orquaiifiedservice agent.

TIGARC

150DC

MANUAL

Page

SERVICE

INFORMATION.

The electrical components

the

TIGARC

150DC

areshown

the

circuit

diagram below. The output of the welding transformer

full-wave bridge rectified,

with the

GTAW

output current

smoothed

inductancecoil.

Primary voltage to the Welding Transformer is controlled by means

Triac

based phase shift circuit. Adjustment

the front panel potentiometerwill vary

the

open

circuit output

voltage

theWeldingTransformer.

ACTIVE

NEUTRAL

AUXILLIARY

TRANSFORMER

CPlO2-0116

AUXILLIARY

RECTIFIER

l- l

L-J

'il"""""

BTA40-6008

MC86-11

OVERLOADDEVICE

PRIMARY

MC84-013

PRlMARY

-VE

GTAW

INDUCTANCE

MC86-20

SECONDARY

MAIN

RECTIFIER

CPlO4-012

+VE

CURRENTLIMITINGRESISTORS

~~82-15110

FIGURE

TfGARC

150DC

CIRCUIT

DIAGRAM

page

TIGARC

J50DC

MANUAL

The

TIGARC

150DC

also includes an auxilliary transformer, rectifier,and

current limiting resistors.The current from these components maintainsthe GTAW

are during periods when the triac

not conducting.

The

printedcircuitboard

assembly provides

the

appropriate trigger pulses to

the

Triac. AS

this

circuit

incorporates specialized components,

is not intendedto be repaired in the field.

Replacement assemblies obtained from WIA are supplied complete with Triac

and

Potentiometer.

Replacingthe Triac requires removal of the original part by first drilling out the

retaining pop-rivets. Clean the mounting surface to removeswarf and any

remaining heat-sink compound.Always apply clean heat-sink compound to the

new triac prior toassembly.

To correctlyadjustthe phase-shift rangeof a replacementcircuit board:

Rotate the Current Control potentiometer knob to

the

minimum current

Disconnect the red wire from

the

positive terminal

the auxilliary rectifier

Connecta

Voltmeter to the welding output terminals

"+VB

WORK"

and

"-veMMAW".

With the PIGARC energised, but not welding, adjust the potentiometer

RV2

on the printed circuit boardto obtain

voltmeter reading of

volts.

Reconnectthe redwire to the positive terminal of the auxilliaryrectifier.

position, (fully anti-clockwise).

(CP38-31/5).

PARTS

LISTS

TlGARC

150DC

POWER

SOURCE

ITEM

-#........PART#

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

DESeRIFSPION

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

MC864

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

PrintedCircuitAssembly

CP101-11/8

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

Potentiometer

CPlO1-11/2

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

Triac

Includes

2..................MC86-23...................Transformer

Assembly (220J240V)

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

MC84-14

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

Cover

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

MC84-16

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

TerminalAssembly

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

MC86-13

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

Base

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

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

Handle

Includes

MCI1-41/1

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

TerminalKnob

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

MC66-Q/8

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

Primary Flex and

Plug

8..................CP27-0/15

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

Fan

and Motor

9..................CP101-0/17

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

Fan Finger Guard

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

1-0/16

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

PotentiometerKnob

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

MK6/4

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

TerminalBlock

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

H390W

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

CupTerminaland Washer

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

H285

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

EarthTab

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

CP102-0/18

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

Circuit Board Support

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

WIN199

labe^ labe^ be^

Set

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

HF200-1

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

Foot

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

MC84-0

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

OverloadDevice

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

MC&4-0/4

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

CableGland Nut

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

CP102-0/16

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

AuxilliaryTransformer

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

MC82-15/10

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

Resistor

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

MC84-24

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

Heatsinkto

suit

220/240V

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

MC84-0/2

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

CableGland

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

MC86-20

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

InductanceAssembly

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

CP104-0/2

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

RectifierAssembly

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

eP38-31/5

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

Diode

Bridge

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