WIA VORTEX AD15VRADl5-0 User manual

WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIES LIMITED
ACN 004 547 Ill
.-
Head Office and InternationalSales
5 Allan Street, Melrose Park
South Australia, 5039
Telephone [phone] Facsimile
[phone]
OWNERS MANUAL
VORTEX AD15
MODELS VRADl5-0
& VRADIS-1
08/96
QUALITY WELDlNG PRODUCTS, SYSTEMS AND SERVICE

Page 2 VORTEX AD15 OWNERS MANUAL
The informationcontained in thismanual has beenprepared to enableyou to
properlymaintain your newequipmentand ensure that you obtain maximum
operating efficiency
.
Pleaseensurethatthisinformation is kept in a safeplacefor ready reference
When requesting spare parts, please quote the model and serial number of the
. machineand partnumber of the item required . All relevant numbers are shown in
lists contained in this manual . Failure to supply this information may result in
unnecessary delays in 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
or improper welding applications .
CONTENTS
Sec . 1 ............................... Introduction ................................ 3
Sec . 2 ................................ Receiving .................................. 4
Sec
. 3 ............................. Speclflcatlons ............................... 4
Sec
. 4 ...................... power Source Controls ....................... 5
Sec . 5 .................. Connection to Mains Power .................... 7
Sec
. 6 .......................... MMAWOperation ............................ 7
Sec
. 7 .......................... GTAW Operation ............................ 9
Sec . 8 ....................... General Maintenance ......................... 10
Sec . 9 .............................. Fault Finding ............................... 10
Sec
. 1 o ....................... Service Information .......................... 11
Sec
. I I .............................. Parts Lists ................................. 14
Sec
. 12 ...................... Remote Foot Control ......................... 15
Sec
. 13 ................... Remote Pulsing Control ....................... 16
Sec
. 14 ................. Safe PracticesInformation ..................... 17
...
FIGURES
Fig . l ....................... Power SourceControls ....................... 5
Fig . 2 ...................... Connections for MMAW ....................... 7
Fig . 3 ............................. Striking the Arc .............................. 8
Fig . 4 ....................... Connections for GTAW ....................... 9
Fig . 5 .......................... Circuit Diagram 1 Q .......................... 11
Fig
. 6 .......................... Circuit Diagram 3Q> .......................... 12
Fig . 7 .............................. Parts Diagram .............................. 13
Fig . 8 ......................... Remote Foot Control ......................... 15
Fig
. 9 ..................... Pulsing ControlFunctions ..................... 16
Fig . 9 ...................... Remote Pulsing Control ....................... 17

VORTEX AD15 OWNERS MANUAL Page 3
1 : INTRODUCTION
MANUAL METAL ARC WELDING (MMAW)
MMAW is a weldingprocesswhere an arcis struck betweenaflux-coated
consumable electrode andthe workpiece. The arc and theweld poolareboth
shielded by gases generated
by 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
in conjunction withyournewVORTEX AD15 will influence the quality ofthe
weld, andthe stability of the arc.
Austarc 12P, Classification E41 12
A popular general purpose electrode used with ease in all positions, vertical up
or down. The smooth forcefularc makes it an ideal electrode for all general mild
steel applications.
Austarc
13S, Classification E41 13
A smooth running electrode with a soft arc, particularly suited to light sheetmetal
and smooth mitre fillet welds.
Austarc 16TC, Classification E481
6
A low hydrogen electrodewithgood arc stability and out-of-positionwelding
characteristics. This electrode is ideal formedium carbon steels.
Unicord
31 2 Classification E31 2-1 6
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 is 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
is required, it is hand fed into the weld pool.
When set for DC (direct current), the VORTEX AD1 5 is suitable for welding most
ferrousand non-ferrous metals. When set for AC (alternating current)thesquare
wave output with adjustablefrequencyand polarity balance enables idealwelding
conditions
to be obtained for even highly oxidisedaluminium materials.

Page 4 VORTEX AD1 5 OWNERS MANUAL
2. RECEIVING
Checkthe equipment receivedagainsttheshipping invoice to makesurethe
shipment
is complete and undamaged. If anydamagehas occurred in transit,
please immediatelynotify your supplier.
The VORTEX AD1
5 package contains:
Vortex AD1 5 Inverter Power Source
GasHose
w (This) Owners Manual
Optional additional items
for VORTEX AD15
TC693Bernard 200 AmpTIGTorch c/w Torch Switch
w VRADl5-20 RemoteFootControl
VRAD15-21 Remote Pulsing Control
AA53-115 Work LeadAssembly, 5 metre
m HAl01-185 ArgonRegulator andFlowGauge
AA53-015 MMAWWelding Lead Kit, 5 metre
3. SPECIFICATIONS
240 Volt Single Phase Package (VRAD15-0):
Primary Voltage
..................................... 240 Volts Ac, +/- IO%, 50160 Hz
Maximum Primary Demand .................................................... 33.6 Amps
Rated Output
20 Amp Primary Supply ................ 150 Amps, 26 Volts, 35% Duty Cycle
15 Amp Primary Supply
................ 150Amps, 26 Volts, 20% Duty Cycle
41 5 Volts Three Phase Package (VRADI 5-1 ):
Primary Voltage ..................... 41 5 Volts AC, +/- 1 O%, 3 phase, 50/60 Hz
Maximum Primary Demand ........................................ 9 Amps per Phase
Rated Input Current
.................................................... 6 Amps per Phase
Rated Output
............................. 150 Amps @ 26 Volts, 40% Duty Cycle
Both Models:
Welding Current Range ........................................................ 5-1 50 Amps
Open Circuit Voltage
.................................................................. .70 Volts
Electrical Efficiency
.......................................................................... 80%
Dimensions ......................................... H: 310mm W: 180mm D: 500mm
Mass ................................................................................................
.23kg
L

VORTEX AD15 OWNERS MANUAL Page 5
4. POWER SOURCECONTROLS
FIGURE 1. POWER SOURCE CONTROLS
POWER ONlOFF SWITCH
A rotary switch is located on the back panel. In the OFF position, the power
source is isolatedfrom the mains power supply. Rotatethe switch clockwise
to
energise the powersource.
l. POWER ON INDICATOR.
Yellow LED (1) is illuminated when the machine is energised, that is when
electrical mains power is connected
to the welder, and the ONlOFF switch
to ON.
is set
2. FAULT INDICATOR.
Red LED (2) is illuminated if any of the following faults have occurred: Over-
temperature, Over-supply voltage, Under-supply voltage.
3. MODE INDICATOR.
Red LED (3) is illuminated when thewelding output is energised.
4. CURRENT CONTROL.
This control is used to set the output current of the power source within its
output range
of 2 - 150 Amps. tt is active only when the LOCALlREMOTE switch
(1 3) is set for local control.

Page 6 VORTEX AD15 OWNERS MANUAL
5. UOWNSLOPE CONTROL (b).
When GTA welding, this control can beset to ramp down the output current at
the endof
a weld over a period of 0.1 - 10 seconds. Downslope is typically used
to avoid the formationof end of weld craters. Rotatethe knob clockwise to
increase the downslope time. Downslopecommences when thetorch switch is
opened.
6. POSTGAS CONTROL (c).
This controlcan beset to provide 5 - 30 seconds of shielding gas flow at the end
of a weld.Postgas is used
to protect thecooling weld pool from atmospheric
contamination. Rotate the knobclockwise to increasethe postgas time.
7. FREQUENCY CONTROL.
This control sets the frequency of the AC squarewave welding output in the
range of
50 - 200 Hz. Higher frequenciesmay assist when GTA welding highly
oxidised materials. Frequency control
is only operativewhen the AC welding
mode is selected.
8. BALANCE CONTROL.
This control canbe used to adjust balance betweencleaning action and
penetration when welding aluminium inthe AC welding mode. The control can
be set from
30% (maximum penetration) to 70% (maximum cleaning).
9. AC/DC MODE SELECTION SWITCH.
AC output mode is selectedwhen set tothe lower position, DC mode when set
to the upper position.
IO. TORCH SWITCH MODE SELECTOR.
When set to the upper position, twostep torch switch mode is selected. The
torch switch is closed
to commence welding and released to endwelding.
When set to the lower position, fourstep switch mode
is selected. The torch
switch is closed toinitiate manual pre-gas, released toinitiatewelding, closed
to
commence downslopetime (5), and released to commence post-gas time (6).
l l. 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 HF arc starting mode. When
set to the lower position, lift arc mode is selected.
HF and lift arc starting modes
apply only
to GTA welding.
13. LOCAL REMOTE SWITCH.
When set to the upper position, theoutput welding current is adjusted by the
front panel currentcontrol. The switch must be set to the lower position when a
foot control
or remote pulsing controlis to 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 7
5. CONNECTION TO ELECTRICAL MAINS POWER SUF'PLY
The VORTEX AD15 is supplied fitted with a 3 metre mains power supply cable.
If it is necessary to 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
of the single phase.-model VRDXI 5-0, a 15 or 20 Amp single phase plug is required.
If used ona 15 Amp supply, the output duty cycle of the machine must be derated
as detailed
in Section 3 of this manual.
The capacity of the mains wiring and poweroutlet supplying a welder is selected
according
to the rated inputcurrent of themachine.The circuit breakeror fuse
however must tolerate the periods
of maximum demand which occur during arcing.
Forthisreason,Australianstandards allow thefuse
or 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.
6. MMAW WELDING
A) FRONT PANEL SETTINGS.
Set switch
11 (Ref. Figure 1 ) to the lower position for MMAW. DC welding
current will provide excellent arc stability, however any tendency
to arc blow can be
minimised bythe use
of AC.
The HF selection switch 12 should be set to the lower (HF Off) position.
B) 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
is illustrated in the figure below.
FIGURE 2: CONNECTIONS FOR "MAW - ELECTRODE POSITIVE

Page 8 VORTEX AD15 OWNERS MANUAL
C) ARC INITIATION.
setting the Current control (4) on the machine front panel.
Select an appropriateweldingcurrent
to suittheelectrodediameter in use by
To strike the arc, drag the end of the electrode alongthe workpiece as if striking
a match. As the arc initiates, lift the electrode slightly away, aiming to establish an
arc length of approximately
3mm. As the electrode is consumed, feed the electrode
into the arc
to 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
a roughweld
appearanceandreducedpenetration.Anarc
too short leads to a narrowweld
deposit and "stuttery" arc characteristic, andthe electrode is liable
to freeze onto the
workpiece.
As the solidified weld deposit forms, move the end of the electrode slowly along
the weld path, aiming
to maintain a stable pool of molten weld metal behind the arc.
Decreasingthisrate of travelwillresult
in a wider welddeposit, and similarly
increasing it will narrowthe weld deposit.
Alwaysfill the craterwhichtends
to form at the end of awelddeposit by
pausing momentarily before withdrawing the electrode. Unfilled craters are a point of
weakness and may leadto fatigue weld cracking.
FIGURE 3: STRIKING THE ARC

VORTEX AD15 OWNERS MANUAL Page 9
7. GTAW WELDING
A) FRONT PANEL SETTINGS.
Set switch 11 (Ref. Figure 1) to the upper position for GTAW. Switch 9 is set for
either AC or
DC output mode dependant on the material to be welded. AC is used
for alumimium, DCfor all other ferrous andnon-ferrous metals.
The use of high frequency (HF) arc initiation is optional when DC output mode is
selected, however
HF is necessarywhen AC mode is in use. Setswitch 12 as
required. When
HF is not in use, the arc is initiated by a touch-start techniqueas
described below.
B) OUTPUT POLARITY.
Forboth DC and AC output modes, the torch andwork leads must be
connectedas illustrated inFigure
4, that is with the Work leadconnected to the
positive
(+) output terminal. Before initial use, allow shielding gas to purge the torch
and hoses for
5 minutes prior to welding. , The gas flow rate for welding should be
set
in the range 2-5 litredmin.
For DC GTAW, the tungsten electrode shouldbe a 1-2% Thoriatedtype.This
will providethe best arcinitiation, arc stability and tipshape retention characteristics.
Thoriated electrodes can be recognised by
a redtip.
The electrode should be ground
to a point, with the grinding markspointing
towards the tip.
For welding currents less than 20 amps, the included angle of the
point shouldbe
30 degrees, for currents greater than 20 amps, the recommended
angle
is 60 degrees. Whenfixed in the torch, the electrode should protrude 6mm
from the ceramic gas nozzle.
For AC GTAW, the tungsten electrodes should be either Pure or Zirconiated.
Pure tungsten electrodes can be recognised by a green tip, Zirconiated by
a brown
tip. The tungsten electrode should be ground
to a flat end, and will develop a balled
end during welding.
GAS HOSE FRO11 BOTTLE TO
IN REAR OF MACHINE
FIGURE 4: CABLE AND HOSE-CONNECTIONS FOR GTAW

Page IO VORTEX AD15 OWNERS MANUAL
C) GTAW ARC INITIATION, TOUCHSTARTTECHNIQUE.
Lightly touch the tungstenelectrodeontothe workpiece, then in asmooth
movement, lift the torch
to initiate anarc slightly longer thanthediameter ofthe
electrode. Once the arc
is stable, a normal working arclength can beestablished. A
copper striking plate is recommended to minimise electrode contamination. A
contaminated electrode will produce an unstable arc, and must be reground before
further use.
D) GTAW ARC INITIATION, HF TECHNIQUE.
Rest an edge of the open endof the ceramic gasnozzle onthe workpiece, with
the tip
of the electrode approximately 6mm from the work. To initiate the arc, close
thetorch switch. If themainarcdoesnot transfer,thetorchmayberotated
to
decreasethe electrode to workdistance. To avoid contamination, caremustbe
taken not
to touch the electrode ontothe work.
.-
Following arc initiation, thetorchshouldberotated to anormaloperating
position.
8. GENERAL MAINTENANCE
Before removing the-:machinecover, ENSURE fhat the unif is disconnectedfrom
the mainspower supply, When-fhe--unit
is energised LETHAL VOLTAGES are
present
on the electrical components enclosed.
Care should be taken to prevent excessive build-up of dust and dirt within the
welding power source.
It is recommended that at regular intervals, according to the
prevailing conditions, the machine covers be removed andany accumulated dust be
removed by the use
of dry, low pressure compressedair.
Inspect the visible componentsforanysigns of overheating
or other damage.
Report any observed problems to qualified servicepersonnel.
9. FAULT FINDING
NO WELDING CURRENT
Check that mains supply is available at the Power Source, ie. that the fan is
runningand the POWER ON 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.
In this event, the machine will notdeliver welding current, and
the redfault indicator LED
2 (Ref. Figure l) will be illuminated. Inthis instance, leave
the machineenergised with the fan running
to achieve themaximum cooling rate.
If equipment failureissuspected,forwardtheunit to your nearest WIA Sales
and ServiceBranch or qualified service agent.