WIA VORTEX AD15VRADl5-0 Bedienungsanleitung

WELDING INDUSTRIES

AUSTRALIA

DIVISION

WELDING INDUSTRIES

LIMITED

ACN

004

547

Ill

Head

Office and InternationalSales

Allan

Street, Melrose Park

South Australia, 5039

Telephone (08) 8276 6494 Facsimile

(08)

8276 6327

OWNERS

MANUAL

VORTEX

AD15

MODELS VRADl5-0

VRADIS-1

08/96

QUALITY

WELDlNG

PRODUCTS, SYSTEMS AND

SERVICE

Page

VORTEX

AD15

OWNERS

MANUAL

The informationcontained

thismanual has beenprepared to enableyou

properlymaintain your newequipmentand ensure that you obtain maximum

operating efficiency

Pleaseensurethatthisinformation

kept

safeplacefor ready reference

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

machineand partnumber

the item required

All

relevant numbers are shown

lists

contained

this manual

Failure

supply this information may result

unnecessary delays

suppling the correct parts

when requiredat any future

time

SAFETY

Before this equipment is putinto operation. the Safe Practices section atthe

back of

this

manual must be read completely

This will help to avoid possible injury

due to misuse

improper welding applications

CONTENTS

Sec

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

Introduction

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

Sec

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

Receiving

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

Sec

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

Speclflcatlons

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

Sec

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

power Source Controls

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

Sec

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

Connection

Mains Power

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

Sec

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

MMAWOperation

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

Sec

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

GTAW Operation

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

Sec

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

General Maintenance

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

Sec

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

Fault Finding

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

Sec

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

Service Information

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

Sec

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

Parts Lists

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

Sec

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

Remote Foot

Control

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

Sec

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

Remote Pulsing Control

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

Sec

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

Safe PracticesInformation

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

...

FIGURES

Fig

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

Power SourceControls

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

Fig

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

Connections

for

MMAW

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

Fig

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

Striking the Arc

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

Fig

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

Connections for GTAW

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

Fig

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

Circuit Diagram 1

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

Fig

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

Circuit Diagram

3Q>

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

Fig

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

Parts Diagram

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

Fig

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

Remote

Foot

Control

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

Fig

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

Pulsing ControlFunctions

..................... 16

Fig

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

Remote Pulsing Control

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

VORTEX

AD15

OWNERS

MANUAL

Page

INTRODUCTION

MANUAL

METAL

ARC

WELDING (MMAW)

MMAW

weldingprocesswhere

arcis struck betweenaflux-coated

consumable electrode andthe workpiece. The arc and theweld poolareboth

shielded by gases generated

the

flux coating of theelectrode.

The VORTEX AD15 hasbeen designed tobe usedwith2.0mm to4.0mm

diameter electrodes. Thesmallersizesareusedwhen welding at lowercurrents,

such as sheet-metal applications.Increasing the electrode diameterpermitshigher

welding currentsto beselected.

”

WIA

markets awide range of mild steel and special purpose electrodes which

caterfor home workshop, rural,andindustrial requirements. Some popular

AUSTARC electrodes are listed below. The correctly selected AUSTARC electrode

used

conjunction withyournewVORTEX AD15 will influence the quality ofthe

weld, andthe stability of the arc.

Austarc

12P,

Classification E41

popular general purpose electrode used with ease in all positions, vertical up

down. The smooth forcefularc makes it an ideal electrode for

all

general mild

steel applications.

Austarc

13S,

Classification

E41

A smooth running electrode with a soft arc, particularly suited to light sheetmetal

and smooth mitre fillet welds.

Austarc 16TC, Classification E481

low

hydrogen electrodewithgood arc stability and out-of-positionwelding

characteristics. This electrode is ideal formedium carbon steels.

Unicord

Classification E31

2-1

Ahigh tensile

(770

MPa),highchromiumnickel electrode specially formulated

for

joining all alloy steels and irons, for tool and die maintenance and steels of

unknown analysis.

GAS

TUNGSTEN

ARC

WELDING

(GTAW)

GTAW

a welding process where the arc is struck between a non-consumable

tungsten electrode andtheworkpiece.Aceramic nozzle surrounds thetungsten

electrode and directs a flow of inert gas, usually Argon, over the electrode and the

weld zone. If filler metal

required, it is hand fed into the weld pool.

When set for

(direct current), the

VORTEX

AD1

is suitable

for

welding

most

ferrousand non-ferrous metals. When set for

(alternating current)thesquare

wave output with adjustablefrequencyand polarity balance enables idealwelding

conditions

be obtained for even highly oxidisedaluminium materials.

Page

VORTEX

AD1

OWNERS

MANUAL

RECEIVING

Checkthe equipment receivedagainsttheshipping invoice to makesurethe

shipment

complete and undamaged.

anydamagehas occurred

transit,

please immediatelynotify your supplier.

The VORTEX AD1

package contains:

Vortex AD1

Inverter Power Source

GasHose

(This) Owners Manual

Optional additional items

for

VORTEX AD15

TC693Bernard

200

AmpTIGTorch c/w Torch Switch

VRADl5-20 RemoteFootControl

VRAD15-21 Remote Pulsing Control

AA53-115 Work

LeadAssembly,

metre

HAl01-185 ArgonRegulator andFlowGauge

AA53-015 MMAWWelding Lead Kit,

metre

SPECIFICATIONS

240

Volt Single Phase Package (VRAD15-0):

Primary Voltage

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

240

Volts Ac,

+/-

IO%,

50160

Maximum Primary Demand

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

33.6

Amps

Rated Output

Amp Primary Supply

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

150

Amps,

Volts,

35%

Duty Cycle

15 Amp Primary Supply

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

150Amps,

Volts, 20% Duty Cycle

Volts Three Phase Package (VRADI

5-1

Primary Voltage

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

Volts AC,

+/-

O%,

phase,

50/60

Maximum Primary Demand

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

Amps per Phase

Rated Input Current

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

Amps per Phase

Rated Output

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

150 Amps

26 Volts,

40%

Duty Cycle

Both Models:

Welding Current Range

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

5-1

Amps

Open Circuit Voltage

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

.70

Volts

Electrical Efficiency

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

80%

Dimensions

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

310mm W: 180mm D:

500mm

Mass

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

.23kg

VORTEX

AD15

OWNERS

MANUAL

Page

POWER SOURCECONTROLS

FIGURE

POWER

SOURCE

CONTROLS

POWER

ONlOFF

SWITCH

rotary switch is located on the back panel. In the

OFF

position, the power

source is isolatedfrom the mains power supply. Rotatethe switch clockwise

energise the powersource.

POWER

INDICATOR.

Yellow

LED

(1)

is illuminated when the machine

energised, that is when

electrical mains power is connected

the welder, and the

ONlOFF

switch

ON.

is set

FAULT

INDICATOR.

Red

LED

(2)

is illuminated if any

the following faults have occurred:

Over-

temperature, Over-supply voltage, Under-supply voltage.

MODE INDICATOR.

Red

LED

(3)

illuminated when thewelding

output

is energised.

CURRENT CONTROL.

This control is used

set the output current of the power source within its

output range

150

Amps.

is active only when the LOCALlREMOTE switch

is set for local control.

Page

VORTEX AD15

OWNERS

MANUAL

UOWNSLOPE

CONTROL

(b).

When

GTA

welding, this control can beset to ramp down the output current at

the endof

weld over

period of

0.1

seconds. Downslope is typically used

avoid the formationof end

weld

craters. Rotatethe knob clockwise to

increase the downslope time. Downslopecommences when thetorch switch is

opened.

POSTGAS CONTROL

(c).

This controlcan beset to provide

seconds of shielding gas flow at the end

of a weld.Postgas is used

protect thecooling weld pool from atmospheric

contamination. Rotate the knobclockwise to increasethe postgas time.

FREQUENCY CONTROL.

This control sets the frequency

the AC squarewave welding output in the

range of

200

Hz.

Higher frequenciesmay assist when GTA welding highly

oxidised materials. Frequency control

only operativewhen the AC welding

mode is selected.

BALANCE CONTROL.

This control canbe used

adjust balance betweencleaning action and

penetration when welding aluminium inthe AC welding mode. The control can

be set from

30%

(maximum penetration)

70%

(maximum cleaning).

AC/DC MODE SELECTION SWITCH.

AC output mode is selectedwhen set tothe lower position,

mode when set

the upper position.

IO.

TORCH SWITCH MODE SELECTOR.

When set

the upper position, twostep torch switch mode is selected. The

torch switch is closed

commence welding and released to endwelding.

When set to the lower position, fourstep switch mode

selected. The torch

switch is closed toinitiate manual pre-gas, released toinitiatewelding, closed

commence downslopetime

(5),

and released

commence post-gas time

(6).

MMAWIGTAW MODE SWITCH.

Set to the upper position

for

GTA welding, and to thelower position for MMA

Welding.

12.

ARC START MODE SWITCH.

When set to the upper position, this switch selects

arc starting mode. When

set to the lower position, lift arc mode is selected.

and

lift

arc starting modes

apply only

GTA welding.

13.

LOCAL REMOTE SWITCH.

When set

the upper position, theoutput welding current

adjusted by the

front panel currentcontrol. The switch must be set to the lower position when a

foot control

remote pulsing controlis

be used.

14.

REMOTE CONTROL CONNECTOR.

Optional devices suchasthefootcurrent control and remote pulsing controlare

attached to the machinevia this connector.

VORTEX

AD15

OWNERS

MANUAL

Page

CONNECTION

ELECTRICAL MAINS

POWER

SUF'PLY

The VORTEX AD15 is supplied fitted with a

metre mains power supply cable.

is necessary

replace the mains power supplycable, use cable withthe correct

current rating.

An appropriate mains plug should be fitted by a qualified electrician. In

the

case

the single phase.-model VRDXI

5-0,

Amp single phase plug is required.

used ona

Amp supply, the output duty cycle of the machine must be derated

as detailed

Section

of this manual.

The capacity

the mains wiring and poweroutlet supplying a welder is selected

according

the rated inputcurrent

themachine.The circuit breakeror fuse

however must tolerate the periods

maximum demand which occur during arcing.

Forthisreason,Australianstandards allow thefuse

circuit breakersupplyinga

welder toberatedat upto twice therated input current of thewelder,(AS3000,

clause

2.4.3.4).

If the equipment is used withan extension primary supply cable, ensure that it is

correctly rated. Voltage drop which will occur over long lengths of cable will reduce

the capacity of the welder.

MMAW

WELDING

FRONT

PANEL

SETTINGS.

Set switch

(Ref. Figure

)

the lower position for

MMAW.

DC welding

current will provide excellent arc stability, however any tendency

arc blow can be

minimised bythe use

AC.

The

selection switch

should be set to the lower

(HF

Off)

position.

OUTPUT

POLARITY.

For DC operation,most

MMAW

electrodes are operated electrodepositive

(+),

however in all cases refer to the manufactures' recommendations

for

the electrode

in use. Electrode positive connection

illustrated in the figure below.

FIGURE

CONNECTIONS

FOR

"MAW

ELECTRODE

POSITIVE

Page

VORTEX

AD15

OWNERS

MANUAL

ARC

INITIATION.

setting the Current control

(4)

on the machine front panel.

Select an appropriateweldingcurrent

suittheelectrodediameter

use by

strike the arc, drag the end

the electrode alongthe workpiece as if striking

match.

the arc initiates, lift the electrode slightly away, aiming

establish an

arc length of approximately

3mm.

the electrode is consumed, feed the electrode

into the arc

maintain

-a

constant arc length. As a general rule, the arc should be

held as short as possible, consistent with stable burn

off

and good weld appearance.

Anarcwhich is toolongcauses an unwieldyflow of metalwith

roughweld

appearanceandreducedpenetration.Anarc

too

short leads to

narrowweld

deposit and "stuttery" arc characteristic, andthe 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

maintain a stable pool of molten weld metal behind the arc.

Decreasingthisrate of travelwillresult

a wider welddeposit, and similarly

increasing it will narrowthe weld deposit.

Alwaysfill the craterwhichtends

form at the end of awelddeposit

pausing momentarily before withdrawing the electrode. Unfilled craters are a point of

weakness and may leadto fatigue weld cracking.

FIGURE

STRIKING

THE

ARC

VORTEX

AD15

OWNERS

MANUAL

Page

GTAW

WELDING

FRONT

PANEL

SETTINGS.

Set switch

(Ref. Figure

the upper position for GTAW. Switch

is set for

either AC or

output mode dependant on the material

be welded. AC is used

for

alumimium, DCfor

all

other ferrous andnon-ferrous metals.

The use

high frequency

(HF)

arc initiation is optional when

output mode is

selected, however

is necessarywhen AC mode is in use. Setswitch

required. When

is not

use, the arc is initiated by

touch-start techniqueas

described below.

OUTPUT POLARITY.

Forboth

and AC output modes, the torch andwork leads

must

connectedas illustrated inFigure

that is with the

Work

leadconnected to the

positive

(+)

output terminal. Before initial use, allow shielding gas

purge the torch

and hoses for

minutes prior

welding.

The gas flow rate for welding should be

set

the range

2-5

litredmin.

For

GTAW, the tungsten electrode shouldbe

1-2%

Thoriatedtype.This

will providethe best arcinitiation, arc stability and tipshape retention characteristics.

Thoriated electrodes can be recognised by

redtip.

The electrode should be ground

a point, with the grinding markspointing

towards the tip.

For

welding currents less than

amps, the included angle of the

point shouldbe

degrees, for currents greater than 20 amps, the recommended

angle

degrees. Whenfixed in the torch, the electrode should protrude

6mm

from

the

ceramic gas nozzle.

For

GTAW, the tungsten electrodes should be either Pure

Zirconiated.

Pure tungsten electrodes can be recognised by a green tip, Zirconiated by

brown

tip. The tungsten electrode should be ground

a flat end, and will develop a balled

end during welding.

GAS

HOSE

FRO11

BOTTLE

REAR

MACHINE

FIGURE

CABLE AND HOSE-CONNECTIONS

FOR GTAW

Page

VORTEX

AD15

OWNERS

MANUAL

GTAW

ARC

INITIATION, TOUCHSTARTTECHNIQUE.

Lightly touch the tungstenelectrodeontothe workpiece, then

asmooth

movement, lift the torch

initiate anarc slightly longer thanthediameter ofthe

electrode. Once the arc

stable,

normal working arclength can beestablished.

copper striking plate is recommended

minimise electrode contamination.

contaminated electrode will produce an unstable arc, and must be reground before

further use.

GTAW ARC INITIATION,

TECHNIQUE.

Rest an edge

the open endof the ceramic gasnozzle onthe workpiece, with

the tip

the electrode approximately 6mm from the work.

initiate the arc, close

thetorch switch. If themainarcdoesnot transfer,thetorchmayberotated

decreasethe electrode

workdistance.

avoid contamination, caremustbe

taken not

touch the electrode ontothe work.

Following arc initiation, thetorchshouldberotated

anormaloperating

position.

GENERAL

MAINTENANCE

Before removing the-:machinecover,

ENSURE

fhat the unif is disconnectedfrom

the mainspower supply, When-fhe--unit

energised

LETHAL

VOLTAGES

are

present

the electrical components enclosed.

Care should be taken to prevent excessive build-up

dust and dirt within the

welding power source.

is recommended that at regular intervals, according

the

prevailing conditions, the machine covers be removed andany accumulated dust be

removed by the use

dry, low pressure compressedair.

Inspect the visible componentsforanysigns of overheating

other damage.

Report any observed problems to qualified servicepersonnel.

FAULT

FINDING

WELDING

CURRENT

Check that mains supply is available at the Power Source, ie. that the fan

runningand the

POWER

Led is

lit.

Checkfor continuity of the weldingcurrent

circuit, ie. work lead, work clamp and electrode holder.

Check that the electrode and work leads are correctlyconnected for the welding

process in use,.

The welding power source incorporates inbuilt protection devices which will tripif

the unit is overloaded.

this event, the machine will notdeliver welding current, and

the redfault indicator LED

(Ref. Figure

will be illuminated. Inthis instance, leave

the machineenergised with the fan running

achieve themaximum cooling rate.

equipment failureissuspected,forwardtheunit

your nearest

WIA

Sales

and ServiceBranch or qualified service agent.

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