Page 1
WELDING
A
DIVISION
INDUSTRIES
OF
WELDING
ACN
004
547’
OF
AUSTRALIA
INDUSTRIES
l
l
l
LTD
Head
Telephone
Office
5
Allan
(08)
8276
OWNERS MANUAL
MODEL
and
International Sales
Street,
South
Australia,
6494
TIGARC 140DC
NO.
MC86-0, REV.
10195
Melrose
5039
Facsimile
Park
(08)
8276 6327
E
QUALITY WELDING
PRODUCTS,
SYSTEMS
AND SERVICE
4
5
ZL
d
Page 2
Page
2
TIGARC
140DC
MANUAL
The information contained
in
this manual is set out to enable you to properly
maintain your new equipment and ensure that you obtain maximum operating efficiency.
Please ensure that this information is kept
in
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
All
possible, the part number of the item required.
manual. Failure to supply this information may result
relevant numbers are shown in this
in
unnecessary delays in supplying
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.
PLASTIC
HANDLE
Please note that the handle fitted
to
the TIGARC 140DC is intended for carrying the
machine by hand only.
DO
NOT
use this handle for suspending or mounting the machine
in
any other
manner.
CONTENTS
SECTION PAGE
1
...........................
2,,
.........................
3..
.........................
4..
.........................
5..
.........................
6
...........................
7..
.........................
8...
........................
9..
.........................
Receiving
Specifications..
Connection To Mains
Operation
Maintenance
Fault Finding
Service Information
Parts
Safe Practices.
......................................................
..............................................
....................................
......................................................
..................................................
.................................................
........................................
Lists
.....................................................
...............................................
.3
.4
.5
.5
.8
.8
9
.IO
13
FIGURE PAGE
1
...........................
GTAW Welding
..............................................
5
...........................
2
3...
........................
4
...........................
5
...........................
6
...........................
.........................
6..
Connections For GTAW
Connections
MMAW Welding
Circuit Diagram
For
MMAW
.............................................
.............................................
Power Source Assembly
GTAW Torch And Accessories
.................................
..............................
...............................
.....................
6
..7
8
.9
11
.l2
Page 3
I
i
I
I
TEGARC
1.
RECEIVING
140DC
MANUAL
Check the equipment received against the shipping invoice to make sure the
If
shipment is complete and undamaged.
any damage has occurred in transit,
please immediately notify your supplier.
The TIGARG
W
TIGARG 140DC Welding Power Supply
D
Sample pack of AUSTARC
W
(This) Owners Manual
140DC
carton contains:
12P
and
13s
electrodes
The genuine WIA AA32 Acccessory Kit contains:
D
Work lead with spring ‘Work’ clamp
W
Electrode lead with electrode holder
D
Face shield
The genuine WIA AA47-0 Accessory Kit contains:
D
150
Amp GTAW torch
W
Torch terminal adaptor
E
Tungsten electrode,
D
Gas regulator and flowguage
W
Gas hose assembly, 2 metre
o
Heavy duty Work lead with spring ‘Work’ clamp.
2%
thoriated
Page
3
Page 4
Page
2.
4
SPECIFICATIONS
TIGARC
14cODC
MANUAL
INPUT VOLTAGE
RATED INPUT CURRENT
MAXIMUM
MAXIMUM KVA REQUIREMENT
SUPPLY FLEXIBLE CABLE RATING
APPROVALS NUMBER
OPEN CIRCUIT VOLTAGE
RATED OUTPUT CURRENT
WELDING
ELECTRODE RANGE
SHORT
GTAW
MMAW
CURRENT RANGE
........................................
...........................
CIRCUIT CURRENT
................
...............................
..........................
...............................................
..............................................
.....................
..................................
240 Volts AC
12.5
.....
34
8.2
...........
15
MC86/S221
44 Volts Max.
52.5
50
5
2.0
50
Amps
Amps
kva
Amps
105
A, 14 VDC,
A,
12 VDC,
IO0
A,
24
VDC,
A, 22 VDC,
to
120
Amps
to 3.2mm diameter
Hz
25%
Duty
100%
25%
Duty
IOQ%
Duty
Duty
MASS
DIMENSIONS
Duty
Cycle
5
minutes
..........................................................
..............................................
is
defined
in
any
5
minute
in
Australian Standard AS1966.1
period,
expressed
as
27
Kg
H
365mm(incl. handle),
W 240mm,
a
percentage.
B
370mm
as
the ratio
of
arcing time
to
Page 5
TIGAR6
3.
CONNECTION
The
PVC
installed
identified by a wide Earth pin, which is intended to prevent the
a
into
supply
140DC
TIGARC
mains power supply cable. This cable must only be connected to a correctly
f5
Amp
standard
cable,
MANUAL
PO
ELECTRICAL
140DC
GPO
10
Amp
use only a cable with equivalent current rating.
is
supplied
(General Purpose Outlet)
GPO
.
If
it
becomes necessary to replace the mains power
MAINS
with a 3 metre,
POWER
15
Amp Heavy Duty
.
The
plug
SUPPLY
and
GPO
plug
being inserted
Page
(30/0.25)
are both
5
by
Fuse
hand.
The recommended Supply
requirements, the Electrical Mains supply to welding machines
a fuse.
for
maximum welding current available from the equipment.
4.
Arc Welding
GAS
between a non-melting tungsten electrode and
molten
shield of inert
the
metal may
A
Circuit Breaker may trip frequently
If
it
is necessary to use an extension power supply cable, ensure that it
a
minimum
of
15
Amps. Voltage drop over long lengths of cable will reduce the
OPERATION
The
TIGARC:
TUNGSTEN
GTAW
edges of the workpiece together without metal being added to the weld, or filler
is a very clean welding method
weld
be
140DC
(GTAW),
metal
and
gas,
usually Argon. The process can be
fed
into the are
has outputs for two arc welding processes:
and Manual Metal Arc Welding
ARC
WELDING
tungsten electrode are protected from Contamination by a
rating
if
in
is
15
Amps. Due to peak current
is
best protected by
used in this application.
Gas
Tungsten
(W.”).
which the welding arc is established
the
workpiece. The welding zone,
used
to fusion weld, ie. melt
is
rated
FtGURE
BUTT
JOINT
JOINT
1.
GAS
TUNGSTEN
ARC
OUTSIDE
JOINT
WELDING.
Page 6
Page
6
PIGARC
140DC
MANUAL
The TIGARC
connected to the GTAW
connection of the welding torch and gas supply.
Tungsten electrodes for
provide the best arc initiation, arc stability and tip shape retention characteristics.
Thoriated electrodes can be recognised by
electrode is ground to a point, with the grinding marks pointing towards the tip. Fqr
welding currents less than
for currents greater than
torch, the tungsten should protrude 12mm from the ceramic gas nozzle.
Before initial use of the welding torch, allow gas to purge the torch and hoses
for
5
minutes at approximately
rate should
To
piece of copper adjacent to the workpiece, then lifted in a smooth movement to
establish an arc length slightly larger than the diameter of the electrode. When the
is
arc
contamination. The electrode can also be contaminated by contact with the filler
rod.
stable, it can be transferred to the workpiece.
Use of a copper striking plate is recommended to avoid electrode
A
be
initiate the arc, the tungsten electrode should be touched preferably onto a
contaminated electrode produces an unstable arc.
140DC
set in the range
is
a
(-)
DC
20
20
amps, the recommended angle is
Direct Current machine, and for GTAW the torch is
output terminal. Figure
GTAW should be
amps, the included angle of the pojnt should be
10
litres/min. For welding purposes,
2-5
litres/min.
1
a
red coded end. The tungsten
2
illustrates the correct
-
2%
Thoriated. This type will
60
.
When set in the
the
30
gas flow
,
GAS
BOTTLE
FIGURE
2.
CONNECTIONS
FOR GTAW.
Page 7
MANUAL
MMAW is a welding process where an arc is struck between a flux-coated
consumable electrode and
shietded
may be used with 2,0mm, 2.5mm, and 3.2mm diameter welding electrodes. The
smaller sizes are used when 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
are shown in Figure
W.I.A. manufactures a wide range of mild steel and special purpose electrodes
which cater for home workshop, rural, and industrial requirements. Some popular
AUSTARC electrodes are listed below. The correctly selected AUSTARC electrode
used in conjunction with the TIGARC
quality weld deposit.
METAL
by
gases generated from the coating
ARC
3
below.
WELDING.
the
workpiece. The arc and the weld pool are both
140D6
of
the electrode. The TIGARC
of
will provide a stable arc and high
140DC
connection
Austarc 12P, Classification
Austarc 13S, Classification AS1553,
Austarc 16TC, Classification
Unicord 312, Classification AS2576, 1330-A3
AS1553,
A
popular general purpose electrode used with ease in
all positions, vertical up or down. The smooth forceful
arc makes it an ideal electrode for all general mild steel
applications. Preferred polarity electrode positive.
A
smooth running electrode with a soft arc, particularly
suited to light sheetmetal and smooth mitre fillet welds.
Preferred polarity electrode positive.
AS1553,
A low hydrogen electrode with good arc stability and
out-of-position welding characteristics. This electrode
ideal
analysis. Operate electrode positive.
A
high
electrode specially formulated for joining all alloy steels
and irons, and for tool
electrode positive,
E41
12.
E41
13.
€4816.
for
medium carbon steels, or steels
tensile
(770
is
of
unknown
MPa), high chromium nickel
and
die maintenance. Operate
Page 8
page
striking a match. As the arc initiates,
establish an arc length of approximately 3mm.
8
To
strike the arc, drag the end of the electrode along the workpiece as if
lift
the
electrode slightly away, aiming to
As
TIGARC
140DC
MANUAL
the electrode end is consumed,
feed the electrode into the arc in order to maintain a constant 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 causes an unwieldy
of
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
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
of
Decreasing this rate
it
increasing
will narrow the weld deposit. Always fit1 the crater which tends to form
travel will result in a wider weld deposit, and similarly
poot
of molten weld metal behind the arc.
at the end of a weld deposit, 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 Maintain steady
5.
MAINTENANCE
FIGURE
4.
MANUAL METAL
onstant molten
ONSTANT
ARC
pool
width means
bead width
WELDING.
arc
length
2
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 and any accumulated dust
be removed by the use of dry, low pressure compressed air, or a vacuum cleaner.
6.
FAULT FINDING, NO WELDING CURRENT
Check that Mains Supply is available at the TIGARC 140DC Power Source, i.e.
is
that the fan
running. Check for continuity of the welding current circuit, i.e., work
lead, work clamp and electrode holder.
The TIGARC
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 has been MANUALLY reset. The
overload device cannot be reset immediately after it has tripped. 8efore resetting,
establish and correct the cause of the overload condition. The reset button is
located on the rear panel, just above the Supply Flexible Cable entry.
If
equipment failure
is
suspected, forward the unit to your nearest WIA Sales
and Service Branch, or qualified service agent.
Page 9
TIGARC
7.
SERVtCE
140DC
MANUAL
INFORMATION.
Page
9
The electrical components of the TIGARC
of
the
diagram below. The output
with the
GTAW
output current smoothed
welding transformer
by
a
Primary voltage to the Welding Transformer is controlled
140DC
is
DC
inductance coil,
are shown in the circuit
full-wave bridge rectified,
by
means of a Triac
based phase shift circuit. Adjustment of the front panel potentiometer will vary the
of
open circuit output voltage
ACTWE
NEUTRAL
B"-----
the Welding Transformer.
TERMINAL
/
BLOCK
""""""""
I
CW
RED
"l
RV1
I
OVERLOAD DEVICE
MC84-0/3
AUXlLLlARY
TRANSFORMER TRANSFORMER
CP102-0/16
AUXlLLlARY
RECTIFIER
CP38-31/5
PRlMARY
CURRENT LIMITIN6 RESISTORS
MC82-15/10
FIGURE
5.
TIGARC
WELDING
140DC
CIRCUIT DIAGRAM
-VE
GTAW
-VE
MMAW
+VE
WORK
Page 10
page
current limiting resistors. The current from these components maintains the GTAW
arc during periods when the triac is not conducting. The printed circuit board
assembly provides the appropriate trigger
incorporates specialized components,
Replacement assemblies obtained from
Potentiometer.
retaining pop-rivets. Clean
remaining heat-sink compound. Always apply clean heat-sink compound
new trim prior to assembly.
10
The
TIGARC
Replacing the Triac requires removal
To
correctly
I
Rotate the Current Control potentiometer knob to the minimum current
position, (fully anti-clockwise).
I
Disconnect the red wire from the positive terminal
(CP38-31/5).
U
Connect a
"-ve
MMAW".
I
With the TIGARC energised, but not welding, adjust the potentiometer
on the printed circuit board to obtain 8 voltmeter reading
Reconnect the red wire to the positive terminal of
140BC
adjust
DC
also
the
Voltmeter to the welding output terminals
includes an auxilliary transformer, rectifier, and
pulses
it
is
not intended to be repaired in
WIA
are supplied complete with Priac and
of
the original part by first drilling out the
the
mounting surface to remove swarf
phase-shift range of a replacement circuit board:
TIGARC
to the Triac.
of
140DC
the auxilliary rectifier
"tve
of
the
auxilliary rectifier.
As
this circuit
WORK" and
12
volts.
MANUAL
the
field,
and
any
tu
the
RV2
8.
PARTS
TIGARC
ITEM
1
..................
Includes
2
..................
3
..................
4.
5..................SA140-0/1
6
..................
includes
7
..................
8
..................
9..................CP101-0/19
10
11
I2
13
15.
17
18
19
20
21
22
23
24
25
26
LISTS
1408C
.................
.................
.................
.................
.................
................
.................
.................
.................
.................
.................
.................
.................
................
.................
.................
POWER
#.......PART#
MC86-11
6P101-11
CPlOl-11/2
MC86-12
MC86-l3
MC84-i
MC84-16
MCll-41/1
MC66-0/8
CP27-U/15
Wll-O/16
MK6/4
H390W
H285
CP102-0/18
WIP1199
HF200-1/15
MC84-0/3
MC84-0/2
MC84-0/4
MC86-20
CP104-0/2
.W1
CP38-31/5
MC82-15/10
SOURCE
......................
...................
/8
..............
..............
...................
...................
4
...................
................
...................
...............
.................
................
..............
..................
......................
......................
.........................
.............
.....................
..............
.................
.................
.................
...................
................
O2-0/16
..............
................
.............
DESCRIPTION
Printed Circuit Assembly
Potentiometer
Triac
Transformer assembly
Base
Cover
Handle
Terminal Assembly
Terminal Knob
Primary Flex and Plug
Fan
and Motor
Fan
Finger Guard
Potentiometer Knob
Terminal Block
Cup
Terminal and Washer
Earth Tab
.Circuit Board Support
tabel
Foot
Overload Device
Cable Gland
Cable Gland
Inductance Assembly
Rectifier Assembly
Auxilliary Transformer
Diode Bridge
Resistor
Set
Nut
Page 11
TiGARC
140DC
MANUAL
Page
ITEM
25
0
J
1
1
FITTED
I
/
FIGURE
6.
PIGARC
140DC
POWER
ITEMS
FITTED
BACK
SOURCE
12&13
INSIDE
COVER
ASSEMBLY
Page 12
page
12
TIGARC
140DC
MANUAL
GTAW
ITEM
Includes
TORCH
#.............PART
1
.................
1.1
..............
1.2
..............
1.3
..............
1.4
..............
..............
1.5
1.6
..............
2
.................
.................
3
4
.................
5
.................
AND
CK1512VR
300
300HS
3C332
3CB332
387
IOOVK
TUNGTH2.4
CK15P6A
AA4
HA101-185
ACCESSORIES
#.....................DESCRIPTION
................
M
.........................
.......................
.......................
.....................
...........................
.......................
..............
..................
7-0/1
..................
................
GTAW
Medium backcap
Heatshield
Collet
Collet body
Alumina Nozzle
Gas
2.4mm diam. 2% Thoriated Tungsten
Torch Terminal Adaptor
Gas Hose Assembly
Gas
Torch, Rigid
Valve
Regulator and flowgauge
FIGURE
7.
GTAW
TORCH
AND
ACCESSORIES
Page 13
PIGARC
9.
SAFE
These notes are provided in the interests of improving operator safety. They should be considered
only as a basic guide
the Standards Association of Australia, also various State Electricity Authorities, Departments of Labour and
Industry
requirements. WTlA Technical Note TN7-98 also provides a comprehensive guide
welding.
EYE
PROTECTION
with side shields underneath, with appropriate filter lenses protected by clear cover lens. This is a MUST for
welding, cutting, and chipping
lens when broken, pitted, or spattered.
140DC
PRACTICES
or
Mines Department and other Local Health or Safety Inspection Authorities may have additional
NEVER
LOOK
MANUAL
WHEN
to
Safe Working Habits. A full list of Standards pertaining
AT AN ARC WITHOUT
to
protect the eyes from radiant energy and flying metal. Replace the cover
USING
WELDING EQUJPMENT
PROTECTION.
Wear a helmet with safety goggles or glasses
Page
to
industry is available from
to
safe practices in
l3
Recommended shade
Amps
0-100
.............
100-150
150-200
200-300
300400
400-500
500
+
...................................................
TIG
IO
..................
.........
11
..................
.........
12
..................
.........
13
..................
.........
14
..................
............................
”
”
MMAW
9
IO
10-11
11
12
13
”
filter
lens.
MIG
...................
.................
............
.................
.................
.................
10
10
11-12
12-13
13
14
14
Pulsed
.................
.................
............
............
.................
.................
.................
12-13
12-13
12-13
12-13
14
14
14
MIG
BURN PROTECTION.
The welding arc
clothing, reflect from light-coloured surfaces, and burn the skin and eyes. Burns resulting from gas-shielded
arcs resemble acute sunburn, but can be more severe and painful.
Wear protective clothing
collar and pocket flaps, and wear cuffless trousers
Avoid oily or greasy clothing.
pieces should never be handled without gloves.
Ear plugs should be worn when welding in overhead positions or in a confined space. A hard hat
should be worn when others are working overhead.
Flammable hair preparations shoutd not be used by persons intending
TOXIC
vapours, heat, or oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen.
produce harmful concentrations of toxic fumes, Adequate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be
used.
removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.
respirator.
FUMES.
Adequate ventilation with air is essential. Severe discomfort, illness or death can result
Lead, cadmium, zinc, mercury, and beryllium bearing and similar materials when welded or cut may
Metals coated with or containing materials that emit fumes should not be heated unless coating is
Work in a confined space only while it is being ventilated and, if necessary, while wearing air-supplied
is
intense and visibly bright.
-
leather or heat resistant gloves, hat, and safety-toe boots. Button shirt
A
spark may ignite them.
Its
radiation can damage eyes, penetrate lightweight
to
avoid entry of sparks and slag.
Hot
metal such as electrode stubs and work
to
weld or cut.
from
fumes,
Page 14
page
14 TIGARC 140DC
MANUAL
Work in a confined space only while it is being ventilated and, if necessary, while wearing air-
supplied respirator.
Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form
PHOSGENE,
a highly toxic gas, and lung and eye irritating products. The ultra-violet (radiant)
energy of the arc can also decompose trichlorethylene and perchlorethylene vapors to form
Do
phosgene.
not weld or cut where solvent vapors can be drawn into the welding or cutting
atmosphere or where the radiant energy can penetrate to atmospheres containing even minute
amounts of trichlorethylene or percholorethylene.
FIRE AND
EXPLOSION PREVENTION.
Be aware that flying sparks or falling slag can pass through cracks, along pipes, through
windows or doors, and through wall or floor openings, out of sight of the operator. Sparks and slag
10
can travel up to
metres from the arc.
Keep equipment clean and operable, free of oil, grease, and (in electrical parts) af metallic
particles that can cause short circuits.
If combustibles are present in the work area, do
NOT
weld or cut. Move the work if practicable,
to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the
work can not be moved, move combustibles at least
10
metres away out of reach of sparks and heat;
or protect against ignition with suitable and snug-fitting fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on or cut. Walls, ceilings,
and floor near work should be protected by heat-resistant covers or shields.
A
person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment
during and for some time after welding or cutting if;
D
Combustibles (including building construction) are within
m
Combustibles are further than
D
Openings (concealed or visible) in floors or walls within
10
metres but can be ignited
10
metres.
by
sparks.
10
metres may expose
combustibles to sparks.
D
Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by
radiant or conducted heat.
After work is done, check that area is free of sparks, glowing embers, and flames.
An tank or drum which has contained combustibles can produce flammable vapors when
heated. Such a container must never be wetded on or cut, unless
described in
AS.
1674-1 974,
the S.A.A. Cutting and Welding Safety Code. This includes a thorough
it
has first been cleaned as
steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility),
followed by purging and inerting with nitrogen
recommended in
AS.1674-1974.
Water-filling just below working level may substitute for inerting.
or
carbon dioxide, and using protective equipment as
Hollow castings or containers must be vented before welding or cutting. They can explode.
Never weld or cut where the air may contain flammable dust, gas, or liquid vapours.
SHOCK
PREVENTION.
Exposed conductors or other bare metal in the welding circuit, or ungrounded electrically alive
equipment can fatally shock a person whose body becomes a conductor. Ensure that the machine is
correctly connected and earthed. If unsure have machine installed by a qualified electrician. On
mobile or portable equipment, regularly inspect condition of trailing power leads and connecting
plugs. Repair or replace damaged leads.
Fully insulated electrode holders should be used.
Bo
not use holders with protruding screws.
Fully insulated lock-type connectors should be used to join welding cable lengths.
Terminals and other exposed parts of electrical units should have insulated knobs or covers
secured before operation.
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