Vortex VRDX13-1 User manual

L
WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIES LTB
ACN Q04 547 4 l1
Head Office and International Sales
5 Allan Street, Melrose Park
South Australia, 5039
Telephone [phone] Facsimile [phone]
OWNERS MANUAL
VORTEX DX13
MODEL VRDXl3-l
06/96
QUALITY WELDING PRODUCTS, SYSTEMS AND S&RVlCE
8/ 7;;:

Page 2 VORTEX DX1 3 OWNERS MANUAL
The informationcontained in thismanual is setouttoenable you to properly
Please ensure that this information is kept in a safe place for ready reference when
maintain your new equipmentand ensure that youobtain maximumoperating efficiency.
requiredat anyfuture time.
When requestingspareparts, please quotethemodel and serial numberofthe
machine andpartnumberoftheitem required. Allrelevant numbers areshown
in lists
contained in this manual. Failure to supply Phis informationmay result
in unnecessary
delays insupplying the correct parts.
SAFETY
Before this equipment is put into operation,the SAFE PRACTICES section at the
back
of the manual must be read completely. This will help to avoid possible injury due to
misuse or improper welding applications.
CONTENTS
Section Page
l ....................... Introduction. ....................................................... .3
2.. ..................... Receiving ........................................................... .4
3.. ..................... Specifications .................................................... .4
4.. ..................... Power SourceControls.. ................................... ..5
5 ....................... Connectionto ElectricalMainsPower Supply .... 6
8.. ..................... General Maintenance ........................................ .9
9 ....................... Fault Finding, No Welding Current ..................... 9
1 Q.. ................... Parts List ............................................................ 11
1
4 ..................... Service Information ........................................... .l2
12.. ................... Safe Practices ................................................... .l3
6.. ..................... MMAWWelding ................................................ .6
7 ....................... GTAW Welding .................................................. 8
FIGURES
Figure Page
1
........................... Power SourceControls .................................. 5
2. .......................... Connections for MMAW ................................ .6
3,. ......................... Strikingthe Arc.. ............................................ .7
4.. ......................... Cable and Hose Connectionsfor GTAW ....... 8
5 ........................... Vortex DX1 3 Parts Qiagram ........................... 10
6. ........................ ..Vortex DX1 3 Circuit Diagram ........................ .l2
L

L
VORTEX DX13 OWNERS MANUAL Paae 3
1. INTRODUCTION
"AW
ManualMetalArc Welding is a process where anarc is struckbetween a flux-coated
consumabtes electrode and the work piece. The arc and the weld pod are both shielded
by gassesgenerated by the flux coatingof the electrode.
The VORTEX
DX1'3 has beendesigned to be used with 2.Qmm,2.5mmand 3.2mm
diameter electrodes.The smaller are usedwhen welding at lower currents, such as sheet
metalapplications.Increasingtheelectrodediameterpermitshigherweldingcurrentsto
be selected.
WIA manufactures a wide range of mild steel and special purpose electrodes which
cater for homeworkshop, rural, and industrial requirements.SomepopularAUSTARC
electrodes are listed below.
The correctly selected AUSTARC electrode used in
conjunction with your new VORTEX
DX13 will influence the quality of the weld, and the
stability of the arc.
Austarc IZP, Classification E41 12.
A popular general purpose electrodeusedwith ease in all positions, vertical up
ordown. The smoothforcefularemakes it an ideal electrode for
all general
mild steel applications.
Austarc 13S, Classification E41 13.
A smooth running electrodewith a soft arc, particularly suited to light
sheetmetal and smooth mitrefillet welds.
Austarc 16TC, Classification E4816.
A lowhydrogen electrode with good arc stability and out-of-positionwelding
characteristics. This electrode is ideal formedium carbon steels, or steels of
unknownanalysis.
Unicord
A hightensile (50tsi), chromiumnickel electrode specially formulated forjoining
all alloy steelsand irons, and fortool and die maintenance.
GTAW
Gas Tungsten Arc Welding is a welding process where the arc is struck between a
non-consumabletungsten electrode and the work piece. A ceramic nozzle surrounds the
tungsten electrode and directs a flow of inert gas, usually Argon, over the electrode and
the weld zone.
If filler metal is required, it is handfed into the welding arc. The DC current
of the VORTEX
DX13 is suitable for welding most ferrous and non-ferrous metals, but is
not suitablefor welding Aluminiumfor which anAC machine isrequired.

Page 4 VORTEX DX13 OWNERS MANUAL
2. RECEIVING
Check the equipment received against the shipping invoice tomake sure the
shipment is complete andundamaged,Ifanydamagehas occurred in transit, please
immediatelynotifyyour supplier.
The VORTEX DX13 packagecontains:
Vortex DX13 InverterPower Source
ShoulderStrap
(This) OwnersManual
Optionaladditional itemsfor VORTEX DX1 3:
MMAW Welding LeadKit - 5m .................................................... AA53-0/5
H 150Amp TIG Torch Assembly .............................................. BE-l7V-4M-8
E TIG TorchAdaptor ................................................................... CKPCA2-4
TIG TorchTwist Lock Connector .................................................. DIN25T
E Work Lead - 5m .......................................................................... AA53-1/5
ExtensionPrimaryLead, 15Amp - 1Om.. ................................ AM259-0/10
Gas Regulatorand Flowgauge ................................................. HA801-AR
3. SPECIFICATIONS
PrimaryVoltage ........................................ 240 Volts AC, +/- 1 O%, 50/60 Hz
Maximum Primary Demand ............................................................ 23 Amps
Rated InputCurrent
........................................................................ 14Amps
ElectricalEfficiency
.............................................................................. .84%
Welding CurrentRange
........................................................... 5 - 130Amps
Open CircuitVoltage
................................................................ .65 Volts DC
Mass ................................................................................................... 4.8Kg
Rated Output ................................... 130 Amps @ 25Volts, 35% Duty Cycle
Dimensions
........................................... H: 195mm W: 111mm D: 280rnm
This power source is intendedto be connectedto a 15Amp mains poweroutlet.
IMPORTANT NOTICE
WARRANTY MAY BE VOIDED IF EQUIPMENT IS POWERED FROM AN ENGINE
DRIVEN GENERATOR.
This equipment may be damaged if it is powered from a low capacity engine driven
generator. Generators less than l6kva may have inadequate voltage control
in this
application.

4. POWER SOURCE CONTROLS
FIGURE l. POWER SOURCE CONTROLS
l. POWER ONlOFF SWITCH
supply. Rotate the switch clockwise
to energise the power source.
2. CURRENT CONTROL
5 - 130 Amps. Rotate theknob clockwise to increase the output current.
3. MMAW / GTAW MODE SWITCH
When set to theteft, the switchselects welding outputdynamiccharacteristics
tailored for Metal Manual Arc Welding. When settothe right, theswitchselects GTAW
characteristics.
4. POWER ON INDICATOR
mains power is connected to the welder,andthe ON / OFF switch is set to ON.
5. OVER TEMPERATURE INDICATOR
In the QFF position,thisswitchisolatesthepowersource from themainspower
This controlsetstheoutputcurrent level
of the powersourcewithintherange
This yellow
LED is illuminated when the machineis energised, that is when electrical
This red
LED is illuminatedif any internalthermal protectiondevices haveoperated.

Page 6 VORTEXDX13 OWNER§ MANUAL
5. CONNECTION TO ELECTRICAL MAINS POWER SUPPLY
The VORTEX DX1 3 is supptied with a 3 metre, l5Amp Heavy Duty (30/0.25) PVC
mains power supply cable. This cable must only be connected to a correctly installed 15
AmpGPO(General Purpose Outlet). The plug and GPOare both identified by a wide
Earth pin, whichisintendedtopreventthe plug being inserted into a standard 10 Amp
GPO. If it becomes necessary toreplace the mains power supply cable, use only a cable
with equivatent current rating.
The recommendedSupply Fuse rating is
15 Amps.Due to peak current
requirements, theelectrical mains supplyto welding machinesis best protected bya fuse.
If
a circuit breaker is used, it shouldbeof the motor starttype.
If
it is necessary to use an extension power supply cable, ensure that it is rated for a
minimum
of 15Amps. Voltagedrop which will occur over long lengths of cablewill reduce
the maximum welding currentavailablefrom the equipment.
As noted previousy,
it is not recommended that the VORTEX DX13 bepoweredfrom
smallengine-drivengeneratorsets due to the peaksofsupplyvoltagewhichcanoccur
with some equipment
of this type. Excessive voltage peakscan damage the circuits of the
welder.
6. MMAW WELDING
A. CONNECTION FOR MMAW WELDING
It is important to select the electrode polarity in accordance with the manufacturers
recommendations
for that electrode. Mostcommonelectrodes are operatedwiththe
electrode at positive polarity,as illustratedin Figure
2.
FIGURE 2. CONNECTIONS FOR MMAW, ELECTRODE POSITIVE

VORTEX DX13 OWNERS MANUAL Page 7
B. MMAW OPERATION
Be certain that you are wearing suitable protectiveclothing, gloves etc. and that you
are working
in a non-hazardous area. If necessary, refer again to the SAFE PRACTICES
section ofthis manual.
Connectthe Work Clamp to theworkpiece. Place thedesiredelectrode
in the
ElectrodeHolder.Select an appropriateweldingcurrentfortheelectrodediameterby
settingthe knob on the machinefront panel.
WIA AUSTARC electrodeswill give the best
results.
To strike the arc, drag the end of the electrode along the work piece as if striking a
match.
As the arc initiates, lift theelectrode slightly away,aiming to establish anarc
length of approximately3mm.
As the electrode end is consumed, feed theelectrode into thearc in order to
maintain arc length.
As a general rule, 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 cause an
unwieldy flow
of metal with aroughweld appearanceand reduced penetration.An arc too
short leads
to a narrow weld depositand"stuttery" arc characteristics, andthe electrode is
liable to freeze onto thework piece.
As the solidified weid deposit forms, movethe end of the electrode slowly along the
weld path, aimingto maintaina pool of molten weld metal behind the arc. Decreasingthis
rate of travel
will result in a wider weld deposit, and similarly increasing it will narrow the
weld deposit.
Always fill the crater which tends to form
at the end of a weld deposit, by pausing
momentarily before withdrawingthe electrode to break the arc. Unfilledcraters are a point
of weakness, and canlead to weld cracking.
.
FIGURE 3. STRIKING THE ARC
4

Page 8 , VORTEX OX13 OWNERS MANUAL
7. GTAW WELDING
A. CONNECTION FOR GTAW WELDING
For GTAW,the torch is connected electrode negative.Figure 3 illustratesthe correct
connection ofthe welding torch and gas supply.Welding grade Argon isthe shielding gas
most commonlyusedfor
DC GTAWwelding.
Before initial use of the welding torch,
allow gas to purge the torch and hoses for 5
minutes at approximately 10 litres/min. For welding purposes, the gas flow rate should be
set
in the range 2 - 5 litres/min.
Tungsten electrodes for
DC GTAW shouldbe 1 - 2% Thoriated.Thistype will
providethe best arc initiation, arc stability and tip shape retentioncharacteristics.
Thoriated electrodes canbe recognisedby
a red coded end. The tungstenelectrode is
ground to
a point, with the grinding marks pointing towards the tip. For welding currents
less than 28 amps, the includedangle of the point should be 3Q",fOrcurrents greaterthan
20 amps,therecommended angle is 60". When set in thetorch,thetungstenshould
protrudeQmm fromthe ceramic gas
noule.
FIGURE 4. CABLE AND HOSE CONNECTIQNS FOR GTAW

VORTEX DX13 OWNERS MANUAL Page 9
B. GTAW OPEFIBTION
To initiate thearc,thetungstenelectrodeshould be touchedontotheworkpiece,
then lifted in
a smoothmovementto establish an arclength slightly largerthanthe
diameter
of the electrode.When the arc is stable, it can betransferred to the work piece.
Use
of acopper striking plate is recommended to avoid electrode contamination.
The electrode can also
be contaminatedbycontact with the filler rod. A Contaminated
electrodeproduces an unstable arc.
8. GENERAL MAINTENANCE
Check thatmainssupply is availabte atthe VORTEX DX13 power source,ie.that the
fan is running and the
POWER ON LED is lit. Check for continuity of the welding current
circuit, ie. work lead, workclamp and electrode holder.
The
VORTEX DX13weldingpowersourceincorporates inbuilt protection devices
which will trip if the unit is overloaded. In this event, the machinewill not deliver welding
current, and the red
LED will beilluminated.Ifthethermal overload protectiondevices
havebeen tripped,leavethe machine energised with the fan running to achievethe
maximumcooling rate.
if equipment failure is suspected,forwardthe unit
to yournearest WIA Salesand
Service branch, or aqualified service agent.
L

Paae IO VORTEX DX13 OWNERS MANUAL
FIGURES. VORTEX DX13 PARTS DIAGRAM

VORTEX DX13 OWNERS MANUAL
10. PARTS LISTS
Item # Part #l
Description
001. .................. MC66-0/8 .....................
Supply Cable & Plug(l 5 Amp)
002
................... VR08.20.050 ................ Cable Clamp
003
................... VR08.20.051 ................
Nut forCableClamp
Q04
................... WR03.05.268 ................
Technical Specification Plate
005 ................... VR01.05.215 ................
Back Panel
006 ................... VR14.7’0.014 ................ Cooling Fan
007 ................... VR2l.06.002 ................ Strap Handle
008
................... V801.11.045 ................
Strap Retainer
009
................... VR03.07.031 ................ Sheet Metal Cover
01
0 ................... VR15.14.198 ................
Driver PCB
811 ................... VR08.25.053 ................
Fuse
012
................... VR15.18.006 ................
FET Assembly PCB
Q13
................... WR06.37.072 ................
Left Plastic Panel
014.
.................. VRQ6.37.071 ................
Right PlasticPanel
015
................... VR09.09.020 ................
Relay
016. .................. VR14.10.150 ................
Diode Bridge (Component of Item Q1 2)
017.. ................. VR15.18.002 ................ Output Rectifier PCB
018...
................ VRI2.03.030 ................
Filter Capacitor Board
019
................... VR01.02.033 ................
LowerCover
020 ................... VR21.03.003 ................
RubberFoot
021 ................... VR05.04.206 ................
Primary inductor
022
................... VR05.02.008 ................
MainTransformer
Q23
................... VR01.11.050 ................
Inductor Transformer Support
024..
................. VR49.02.797 ................
RibbonCable Assembly
025
................... WR11.20.053 ................ Shunt
026..
................. VR09.01.001 ................
Switch
027
................... VRB1.04.247 ................
Front Panel
028 ................... VR15.22.035 ................
FrontControl Panel PCB and Assembly
029..
................. VI310.13.001 ................ Output Socket
030.. ................. VR09.11.Q09 ................ Switch Knob
031
................... VR09.11.207 ................ Potentiometer Knob
832
................... VR09.07.004 ................
Thermal Cut-out
033..
................. WR11.14.1 00 ................
Resistor 25W
034.
.................. VROl.14.170 ................
Filter BoardSupport
835 ................... VR14.70.016 ................
Filter PCB

Pacre l2 VORTEX DX13 OWNERS MANUAL
l l. SERVICE INFORMATION
The electrical components of the equipmentare shown in the circuit diagram below.
The
VORTEX DX13 is an inverter type design, where the mains supply is first rectified,
filtered then choppedto
a highfrequency before beingapplied to the welding transformer.
The outputof this transformer
is rectifiedto form thewelding output of the machine.
VR14.70.016 VR15.18.006 VR15.18.002
r--.---1 L l l
VR15.18.002
l
+;
I +*
I
+;
I +*
p222pr P23
/-L I;l
T c2
I
CE
I I
PZl?
J
P25 P26 P27
'-T"f"""
345
CN5
4' J
p--
TJJ4
T
VR15.22.035
J1 -J2 ' ' J3 J4
FIGURE 6. VORTEX DX13 CIRCUIT DIAGRAM

VORTEX DX13 OWNERS MANUAL Page l3
12. SAFE PRACTICES
These notes are provided in the interests of improvingoperator safety. They should
be considered only as a basic guide toSafeWorking Habits. A full list ofStandards
pertaining to industry is available from the Standards Association of Australia, also
various State Electricity Authorities, DepartmentsofLabourand Industry or Mines
Departmentandother Local Health or Safety InspectionAuthorities mayhave additional
requirements.WTlA Technical Note
TN7-98 also providesa comprehensivwguide to safe
practices
in welding.
EYE PROTECTION
NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a full face helmet, with
an appropriateshade filter lensprotected
by clear cover glass.This is a MUST for any arc
process
to protectthe eyes from radiant energy and flying sparks etc.. Replace the cover
glasswhen it
is broken,pitted,or spattered.
Recommendedshade filter lens.
Amps IT16 MMAW MlG Pulsed MlG
0-100 ................. 10 .............. 9 ................ 10 .............. 12-13
100-150 ............. 11 .............. IO .............. IO .............. 12-13
’150-200 ............. 12 .............. 10-11 ......... 11-12 ......... 42-13
200-300 ............. 13 .............. 11 .............. 12-13 ......... 12-13
300-400 ............. 14 .............. l2 .............. 13 .............. ’14
400-500 ............................... 13 ..............
14 .............. 14
500 + ................................................. ” -I
14 .............. 14
BURN PROTECTION.
The welding arc is intense and visibly bright. Its radiation can damageeyes,
penetrate lightweight clothing, reflect from light-coloured surfaces, and burn the skin and
eyes. Burns resulting from gas-shielded arcs resemble acute sunburn, but canbe more
severeand painful.
Wear protectiveclothing
- leatheror heat resistant gloves, hat,and safety-toeboots.
Button shirt collar and pocket flaps, andwear cuffless trousers to avoid entry of sparks
and slag.
Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode
stubsand workpiecesshould never
be handledwithout gloves.
Ear plugs should bewornwhen welding
in overhead positions or in a confined
space.A hardhat should beworn when othersareworking overhead.
Flammablehair preparationsshouldnot
be used by personsintendingto weld or cut.

SAN UAL
TOXIC FUME PREVENTION.
Adequate ventilation with air is essential. Severe discomfort, illness or death can
resultfromfumes,vapours,heat,oroxygen depletion thatweldingor cutting may
produce.
NEVER ventilatewith oxygen.
Lead,cadmium, zinc, mercury,andberyllium bearing and similarmaterialswhen
weldedor cut may produce harmful concentrations of toxic fumes.Adequate
local exhaust
ventilationmust be used, or each person
in the area as well as the operator must wearan
air-supplied respirator. For beryllium,bothmust be
used.
Metalscoatedwith or containing materialsthatemitfumesshould not be heated
unless coating is removed fromtheworksurface,the area
is wellventilated, or the
operator wearsan air-suppliedrespirator.
Work in aconfined space only while it is being ventilated and, if necessary, while
wearing air-supplied respirator.
Vapoursfrom chlorinated solvents can be decomposed by the heatof the arc (or
flame) to form
PHOSGENE, a highly toxic gas, and lung and eye irritating products. The
ultra-violet(radiant)energyofthe arc can also decomposetrichlorethylene and
perchlorethylenevapours to formphosgene.
Do notweldorcutwheresolventvapours
can be drawn into thewelding or cutting atmosphereor where the radiantenergy can
penetratetoatmospherescontaining even minuteamounts of trichlorethyleneor
percholorethylene.
FIRE AND EXPLOSION PREVENTION.
Be awarethat flying sparksor falling slag canpass through cracks, along pipes,
through windowsor doors, and through wall
or floor openings, outof sight of the operator.
Sparks and stag cantravei up to
10 metres from the arc.
Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of
metallic particlesthat cancauseshort circuits.
If combustibles are present in the work area,
do NOT weld or cut. Move the work if
practicable, to an area free
sf combustibles. Avoid paint spray rooms, dip tanks, storage
areas,ventilators, If the
work cannotbemoved,movecombustibles at least 10 metres
away out
of reach of sparks and heat; or protect against ignition with suitable and snug-
fitting fire-resistantcovers or shields.
Walls touchingcombustibles on opposite sides should not be welded on or cut.
Walls, ceilings, and floornearworkshould be protected byheat-resistantcoversor
shields.

VORTEX DX1 3 OWNERS MANUAL. Page 15
A person acting asFire Watcher must be standing by with suitable fire extinguishing
Combustibles(including buildingconstruction) are within IO metres.
E Combustiblesarefurther than 10 metres but canbe ignitedby sparks.
E Openings(concealedor visible) infloors or walls within 10metres may expose
Combustibles adjacentto walls, ceilings, roofs,or metal partitionscan beignited by
equipment during andfor some time after welding orcutting if;
combustibles to sparks.
radiantor conducted heat.
After work is done, check that area
is free of sparks, glowing embers,andflames.
Any tank or drum which has contained combustibles can produce flammable vapours
when heated. Such a container must never be welded on car cut, unless
it has first been
cleanedas described inAS.1674-1974, the
S.A.A. Cutting andWelding Safety Code. This
includes a thorough steam
or caustic cleaning (or a solvent or water washing, depending
on the combustible's solubility), followed bypurging and inerting with nitrogen or carbon
dioxide, and using protective equipment as recommended in
AS. 1674-1974. Water-filling
just belowworking level may substitute forinerting.
Holtowcastingsorcontainers mustbevented before welding or cutting. They can
explode. Never weld
or cutwheretheair may contain flammabledust,gas,or liquid
vapours.
SHOCK PREVENTION.
Exposed conductorsorother bare metal in the weldingcircuit,or ungrounded
electrically alive equipment canfatally shock
a person whosebody becomes a conductor.
Ensure that the machine is correctlyconnected and earthed.
If unsure have machine
installed by a qualified electrician.On mobile or portable equipment, regularly inspect
conditionof trailing power leadsand connecting plugs. Repairor replacedamaged leads.
Fully insulatedelectrode holders should be used.
Bo not use holderswith protruding
screws. Fully insulatedlock-type connectors shouldbe
used tojoin welding cable lengths.
Terminals and other exposedparts
of electrical units should have insulated knobs or
covers securedbeforeoperation.