WELDMATIC 6 0 0

MODEL NO. CP6

CAT. 7 5 2 4 / 6

6 / 8 0

FROM SERIAL NO. 6 0 3 5

THE INFORMATION CONTAINED I N THE FOLDER I S SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUP4 OPERATING EFFICIENCY.

PLEASE ENSURE THAT T H I S FOLDER I S KEPT I N A SAFE PLACE FOR READY REFERENCE WHEN REQUIREI?.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEIi NO. AND SERIAL NO. OF THE MACHINE AND THE PART NO. OF THE ITEM REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT I N UNNECESSARY DELAYS I N SUPPLYING THE CORRECT PARTS.

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

Melbourne 4 2 9 4 7 6 6 Newcastle 6 1 1 6 6 8 Sydney 5 3 4 2 1 4 4 A d e l a i d e 3 5 2 3 0 2 2 B r i s b a n e 4 4 1 3 9 1 P e r t h 3 6 1 7 0 8 8 L a u n c e s t o n 3 1 7 0 0 4 Darwin 81 6 4 2 7 & 8 4 3 0 7 6

OPERATING AND MAINTENANCE INSTRUCTIONS - WELDMATIC 600 (CP6)

- INTRODUCTION

GENERAL

T h i s m a n u a l h a s b e e n p r e p a r e d e s p e c i a l l y for use i n familiar- i z i n g p e r s o n n e l w i t h t h e d e s i g n , i n s t a l l a t i o n , o p e r a t i o n , m a i n t e n a n c e , a n d t r o u b l e s h o o t i n g of t h i s equipment. A l l inform- a t i o n p r e s e n t e d h e r e i n s h o u l d be g i v e n c a r e f u l c o n s i d e r a t i o n t o a s s u r e optimum performance of t h i s equipment.

RECEIVING/HANDLING.

Prior t o i n s t a l l i n g t h i s e q u i p m e n t , c l e a n all p a c k i n g material from. a r o u n d t h e u n i t a n d c a r e f u l l y i n s p e c t f o r a n y damage t h a t may have occu r red du r ing sh ipmen t . Any claims for loses or damage t h a t m.ay h a v e o c c u r r e d i n t r a n s i t must be f i l e d b y t h e p u r c h a s e r w i t h W e l d i n g I n d u s t r i e s of A u s t r a l i a P t y . L t d . or a u t h o r i s e d a g e n t i m m e d i a t e l y (refer t o EQUIPMENT WARRANTY card e n c l o s e d w i t h O p e r a t i n g I n s t r u c t i o n M a n u a l ) .

When r e q u e s t i n g irrbbrmation c o n c e r n i n g t h i s e q u i p m e n t , it i s e s s e n t i a l t o s u p p l y correct Model i d e n t i f i c a t i o n a n d m a c h i n e s e r i a l number.

SAFETY. Before the equ ipmen t i s p u t i n t o o p e r a t i o n , t h e SAFETY PRACTICES s e c t i o n a t t h e back of t h i s manual MUST BE READ COMPLETELY. T h i s w i l l k e l p avoid p o s s i b l e i n j u r y d u e t o misuse o r imprope r w e l d i n g a p p l i c a t i o n s .

"

CONTENTS PAGE NO.

G e n e r a l D e s c r i p t i o n l

S e t t i n g u p f o r O p e r a t i o n 2 - 3

W e l d i n g O p e r a t i o n I n s t r u c t i o n s 4

M a i n t e n a n c e I n s t r u c t i o n s 5 - 6

Welding Data - Table "C" 7 - Par t s L i s t CP6-02 I s s u e 4 8

- Assembly Drawing CP6-02 Issue 2 9

C i rcu i t D iag rams - CP6-C9 10

Mobile K i t Assem.bly - S a f e t y Pract ices

Guarantee Card

STANDARD UNIT The construction of the standard package plant has been designed fo r i n s t a l l a t ion and operating i n a wide variety of applications, such as high production factories and general fabrication shops.

"WELDMATIC" Plants consist of three basic u n i t s : -

l, Constant Potential Rectifier Power Source. 2 . Semi-Automatic Wire Feeder. 3 , Welding Gun and Cable Assembly.

Separate operating and maintenance instruct ions are provided for the wire feeder and gun cables.

1. - POWER SOURCE - FEATURES The standard C.P. r e c t i f i e r power source i s housed i n a drip- proof enclosure. L i f t i n g l u g s are provided for crane trans- portation. For u n i t s w i t h wheel mounting four solid rubber tyred wheels are provided: the two front wheels are steerable permitting easy movement i n restricted floor space. A push bar i s provided on the f r o n t of the machine and a gas cylinder ca r r i e r w i t h a support bracket and chain a t the rear . A 110 volt plug socket i s located on the rear panel f o r connection of gas preheater when welding w i t h C 0 2 gas shield. Located on the front panel are a coarse voltage selection switch, fine voltage selection switch, power ON/OFF switch, control fuses, wire feeder p lug socket and r e c t i f i e r power outlet sockets.

2 . CONSTRUCTION

The power source i s a Constant Potential Silicon Diode Rectif- i e r B.C. Welder, w i t h a three phase transformer and a three phase rect i f ier br idge. Connected i n t h e output circuit i s an inductance u n i t providing the "inductance" or degree of slope necessary for various welding currents. Cooling of t h e s i l i - con diodes, transformer windings and inductance u n i t i s by a single phase axial fan. The power source i s protected against fan fa i lure and overheating by thermostats mounted on diode heat sinks.

3 . WELDING PROCESS

Gas metal arc welding w i t h i n the capacity of the power source can be carried o u t w i t h tke following equipment:- a ) Semi-automatic wire feeder model W 1 4 . b ) Semi-automatic wire feeder w i t h spot timer W14-20. c ) "Hobart" spool gun welding u n i t model SP9 w i t h CV2

d) "Mini-mig" push and p u l l gun and control. control ler .

4. WELDING CAPACITY

Power Source Capacity i s as follows:- 600 Amps, 42 vol ts , 100% du ty cycle.

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-2-

5 . SUPPLY AND WELDING CABLES.

Power Sources are s u i t a b l e f o r c o n n e c t i o n t o a 415 v o l t 50 Her t z 3 phase supp ly .

The recommended f u s e s i ze , p r imary cable s i z e a n d w e l d i n g c a b l e s i z e a re as follows:-

a ) Fuse - 50 amp. b) Pr imary Cable - 4 c o r e 77/0.40 T.R.S. c ) Welding Cable - 998/0.30 T.R.S.

6 . SHIELDING GASES.

a ) Welding Grade C 0 2 for a11 mild a n d a l l o y s teel w e l d i n g i n

"

t h i c k n e s s e s r a n g i n g from lmm upwards.

b ) Argon/C02 or Argon/Oxygen m i x t u r e s for a l l a p p l i c a t i o n s o n l o w c u r r e n t s r e q u i r i n g minimum of s p a t t e r o n s h e e t s t e e l and for s t a i n l e s s s teel weld ing .

c ) Argon/Oxygen and Argon/C02 m i x t u r e s for prime q u a l i t y weld- i n g of s t a i n l e s s s tee l .

d ) Argon ( p u r e ) f o r a l l aluminium. welding.

7 . §ETTING UP UNIT FOR OPERATION.

a ) - Genera l Assembly of Packaqed P l a n t (Refer Drawing AM1.16)

The Rectifier Welder i s sh ipped w i t h t h e sk ids or w h e e l s unbol- ted. B o l t on t h e w h e e l assemblies w i t h t h e steerable ( swive l ) w h e e l s n e a r e s t t h e f r o n t p a n e l a n d p u s h bar. If a "Mini-Boom" wire f eede r moun t ing i s s u p p l i e d , locate t h e v e r t i c a l boom p o s t i n t h e special swive l mount a t t h e rear of the machine . Locate t h e Wire F e e d e r o n t h e s w i v e l m o u n t , e n s u r i n g t h a t t h e fibre t h r u s t w a s h e r i s on t h e pivot p i n . Check t h a t t h e "Wire Feeder" i s free t o s w i v e l i n a l l d i r e c t i o n s . If n e c e s s a r y a p p l y a small am.ount of g r a p h i t e grease t o shaf t .

b) Connect ion t o Mains Supply. Note: T h i s work s h o u l d o n l y be done by a q u a l i f i e d e l e c t r i c i a n . The power source i s des igned fo r c o n n e c t i o n t o 415 v o l t , 50 hertz, 3 phase s u p p l y and the s u p p l y v o l t a g e s h o u l d be ascert- a i n e d before c o n n e c t i n g t h e m a c h i n e . Access t o supply connec- t i o n terminals i n machine may be g a i n e d b y d o o r i n r i g h t h a n d side p a n e l . U s e a f l e x i b l e 4 core p r imary cable for p o r t a b l e machines and clamp cable t o e n s u r e t h a t there i s n o s t r a i n o n cable connec t ions . The ear th (or g r o u n d ) c o n n e c t i o n ( g r e e n / ye l low) mus t be s e c u r e l y f a s t e n e d t o t h e ' e a r th ' t e rmina l on t h e m a c h i n e a d j a c e n t t o t h e s u p p l y c o n n e c t i o n t e r m i n a l s .

CAUTION Before i n s e r t i n g p r i m a r y cable p l u g i n m a i n s s u p p l y socket: e n s u r e t h a t s w i t c h on both p l u g socket and weld ing machine i s i n 'OFF' p o s i t i o n .

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c ) " CONNECTION OF CABLES/HOSES, ETC. W i t h u n i t s w i t c h e d 'OFF' c o n n e c t c o n t r o l cable ( 6 p i n p l u g ) from power s o u r c e t o wire feeder. Connect gas hose from wire feeder t o gas r e g u l a t o r / f l o w m e t e r , e n s u r i n g a l l c o n n e c t i o n s are t i g h t e n e d f i r m l y . If C 0 2 Gas S h i e l d i s b e i n g u s e d , p l u g heater i n t o 110 v o l t socket a t r ea r of u n i t . Next i n s e r t gun cable i n t o socket o f wire feeder o u t p u t g u i d e a n d r e t a i n i n p l a c e w i t h set screw p r o v i d e d . Set screw s h o u l d n o t be t i g h t e n e d so as t o p reven t gun cable f rom swive l l ing . Connect " G a s Hose" and "Gun Switch" leads t o r e s p e c t i v e s o c k e t s .

d ) WELDING CABLES.

A l l G.M.A. w e l d i n g i s done w i t h e l e c t r o d e w i r e c o n n e c t e d t o " p o s i t i v e " pole comrn.only known as D.C. r e v e r s e p o l a r i t y (D .C .R .P . ) t h e r e f o r e , c o n n e c t t h e s h o r t j u m p e r lead from ' I + ' '

socket on machine t o t e r m i n a l l u g o n g u n cable. The work l e a d ( " n e g a t i v e " ) s h o u l d be p l u g g e d i n t o t h e ' I - ' ' socke t on t h e mach ine . The p lugs o f t he we ld ing cables must be f u l l y i n s e r t e d i n t h e sockets, t o p r e v e n t a c c i d e n t a l d i s c o n n e c t i o n . T o avo id error, w e l d i n g s h o u l d n o t be attempted u n t i l a l l c o n n e c t i o n s have been secured . The wire f e e d e r may be i n s t a l l e d remote from t h e power s o u r c e , i n which case, e x t e n s i o n lead sets compr i s ing power cable, gas hose a n d c o n t r o l cable ( f o u r core) a r e r e q u i r e d i n a c c o r d a n c e w i t h t h e desired l e n g t h . S t a n d a r d l e n g t h ava i l - able from stock i s 9 m.etres.

3 ) W I R E FEEDER AND GUN CABLE.

F i t a spool of w i r e t o t h e w i r e feeder (see n o t e s i n "Wire F e e d e r I n s t r u c t i o n M a n u a l " ) . T i g h t e n t h e "brake" screw u n t i l a s l i g h t b r a k i n g e f fec t i s f e l t when t u r n i n g t h e wire spool by hand t o p reven t "ove r - run" when wire f e e d stops. The wire d r i v e r o l l s and i n l e t wi re g u i d e s h o u l d be selected i n a c c o r d a n c e w i t h t h e diameter a n d t y p e of w i r e be ing u sed . Refer t o c u r r e n t wire feeder manual for correct s e l e c t i o n of wire feed rolls a n d i n p u t g u i d e s .

0.8mm. = 0.030" 1.6m = 1/16" 0.9mm = 0 .035" 2 . 4 m = 3/32" 1 . 2 m m = 0.045" 3.2m = 1/8"

The gun cable and gun are norma l ly d e l i v e r e d w i t h t h e c o n t a c t t i p and l i n e r s p r i n g fo r w i r e s i z e nominated , bu t check t h a t bo th are correct s i z e f o r wire b e i n g u s e d .

8.

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WELDING OPERATION INSTRUCTIONS

SINGLE FUNCTION CHECK

Uni t i s now ready for o p e r a t i o n , b u t prior t o commen i n a , t h e f o l l o w i n s " f u n c t i o n s c h e c k ' ' i s recommended,

c i n g weld- swi tch on

poGer source and check a i r f low. See t h a t a l l w e l d i n g l e a d p l u g s are i n s e r t e d i n t h e correct p o l a r i t y sockets - electrode " p o s i t i v e " , work " n e g a t i v e " . Check a l l w e l d i n g c o n n e c t i o n s a n d p l u g s f o r t i g h t n e s s p a r t i c u l a r l y " w o r k " clamp.

Next e n s u r e t h a t a l l c o n t r o l cables and gas h o s e s a re s e c u r e l y c o n n e c t e d a n d t h a t Gas Heater ( f o r C 0 2 o n l y ) i s p l u g g e d i n t o s o c k e t a t rear of power source . Swi tch on wi re feeder, i n d i c - a tor l i g h t s h o u l d now show "Power On". Open Gas c y l i n d e r f u l l y and check conten ts gauge for adequa te gas supp ly .

Press "Gas Purge" switch and set g a s f l o w i n a c c o r d a n c e w i t h w e l d i n g r e q u i r e m e n t s , a t t h e same time c h e c k t h a t gas flow i s adequa te from gun nozzle , Set "wire s p e e d " c o n t r o l t o desired wire speed. Press "wire inch" swi t ch and check wire f e e d for correct p r e s s u r e o n d r i v e rolls . P r e s s u r e s h o u l d be s u f f i c i e n t t o p r e v e n t a n y ' ' s l i p " when f eed ing t h rough gun and cab le .

Next , close gun switch momentar i ly for wire feed, gas f l o w and we ld ing power check. Se t t h e v o l t a g e selector s w i t c h e s i n accordance w i t h required v o l t a g e (see weld ing t a b l e ) , u n i t i s now r e a d y fo r we ld ing .

The w e l d i n g c u r r e n t i s d e t e r m i n e d a u t o m a t i c a l l y b y "Wire Speed". T h e e l e c t r o d e wire i s f e d a t t h e p r e - s e l e c t e d speed b y t h e d r i v e r o l l s t h r o u g h t h e g u n cable t o t h e arc a t a c o n s t a n t speed, unchanged except when r e se t b y t h e "Wire Speed" c o n t r o l . The h i g h e r t h e wire speed, t h e h i g h e r t h e w e l d i n g c u r r e n t , as w i l l be i n d i c a t e d b y t h e ammeter. The o u t p u t v o l t a g e of t h e power s o u r c e , i n d i c a t e d b y t h e v o l t m e t e r when t h e gun swi tch i s closed, i s d i v i d e d i n t o a number of steps by Coarse Selector and F ine Selector swi t ches .

The CP6 has Coarse Vol t age and F i n e V o l t a g e S w i t c h e s , e a c h w i t h s i x steps, g i v i n g 36 vol tage s e t t i n g s f o r t h e m a c h i n e . T h e i n d u c t a n c e t e r m i n a l sockets are numbered ''1 - 4". No.1 socket shou ld n o t be u s e d f o r w e l d i n g c u r r e n t s over 300 amps. Depend- i n g o n t h e t y p e of w e l d i n g c o n d i t i o n s , v a r i o u s i n d u c t a n c e v a l u e s are r e q u i r e d . T h e t y p i c a l weld s e t t i n g c h a r t i n d i c a t e s t h e recommended s o c k e t s f o r v a r i o u s w e l d i n g c o n d i t i o n s . A s a g e n e r a l r u l e , l o w w e l d i n g c u r r e n t s r e q u i r e i n d u c t a n c e N o . 1 o r 2 . For a lumin ium and t ubu la r f l ux co red wires, i n d u c t a n c e s o c k e t No. 2 i s u s e d e x c l u s i v e l y .

- 5 -

The following sequence of weld se t t ing i s recommended:-

a ) Consult typical weld set t ing char t . b ) Select welding current most suited t o the application by following the settings of wire speed and voltage shown on the set t ing char t . T o "tune" each weld sett ing, adjust wire speed only. c) I f vol tage i s too low for the application, wire "stubbing" w i l l occur , par t icu lar ly a t s ta r t of weld and weld contour w i l l be very convex. If the voltage i s too high, metal t ransfer w i l l be e r r a t i c w i t h excess spatter. d ) With welding current and voltage matched the resu l t w i l l be an optimum tuned welding condition w i t h a smooth spatter- f ree arc .

10. SAFETY DEVICES

I n the event of the power source becoming overheated the ther- mostats on the diode heat sinks w i l l operate preventing further welding. The thermostats w i l l automatically reset and w i t h the cooling fan operating t h i s w i l l take approximately 10 min- utes. A check should be made to ascertain the reason for the over-heating such as fan not operating or air flow restricted. Fuses provided for a l l c i rcu i t s a re as fo l lows and are indicated on the front panel:-

Fuse E l - 3 amps (Delayed action) Fuse E2 - 3 amps ( 'l ' I 1 Fuse E 3 - 5 amps ( ' I ' I 1 Fuse E4 - 5 amps ( ' I ' I 1

11 . E N T ENANC E

a ) Power Source Apart from the fan the rect i f ier has no rotary components. To achieve complete dissipation of heat from the active com- ponents, the rectifier should be thoroughly blown off w i t h d ry compressed a i r a f t e r 6 months' operation. Cleaning should be car r ied ou t a t shor te r in te rva ls i f d u s t accumulation i s considerable.

Prior t o cleaning, remove the u n i t cover by detachment of lugs and the f ixing screws. Thus a11 the components of the power source w i l l bs accessible.

b ) The wire feed motor/gearbox i s pre-packed w i t h grease and needs no other lubrication. Change the grease after approx- im.ately 14 ,000 service hours. (see Wire Feeder Instruction Manual . The dr ive ro l le rs and the inner w i r e guides should be kept clean. If necessary, blow of f the inside of t h e wire feeder w i t h compressed a i r .

-6-

c ) Gun and C a g Remove any spatter w h i c h might adhere t o t h e n o z z l e bore so t h a t t h e s h i e l d i n g g a s o u t f l o w i s n o t impeded. The c o n d i t i o n of t h e c o n t a c t t u b e s s h o u l d be r e g u l a r l y c h e c k e d . Damaged and /o r bu rn t tubes are an impediment t o t r o u b l e - f r e e w e l d i n g o p e r a t i o n a n d s h o u l d be r e p l a c e d i m m e d i a t e l y .

T r o u b l e - f r e e o p e r a t i o n depends t o a l a r g e e x t e n t o n t h e good c o n d i t i o n a n d c l e a n l i n e s s of t h e i n n e r wire l i n e r (See I n s t r - u c t i o n s o n Gun Cables) .

1 2 . WELDING OPERATION

Never observe t h e arc w i t h u n p r o t e c t e d e y e s . I t i s of impor- t a n c e t h a t t h e welder wear p r o t e c t i v e c l o t h i n g p r o v i d i n g s u f f i c i e n t s a f e t y .

13. STOPPAGES AND THEIR ELIMINATION

The machine should be checked on ly by a f u l l y sk i l led electr- i c i a n .

If t h e u n i t s t o p s w o r k i n g , f i r s t de te rmine whe the r s toppages are i n i t i a t e d b y t h e mains ( f o r i n s t a n c e , b u r n t f u s e ) or by t h e s u p p l y cable ( l o o s e c o n n e c t i o n , cable break) o r b y t h e u n i t p r o p e r .

If t h e t h r e e t e r m i n a l s L1, L2 and L 3 on t h e p r i m a r y t e r m i n a l board are c o r r e c t l y c o n n e c t e d t o the mains (voltmeter reading) t h e c a u s e o f t h e s t o p p a g e m u s t be s o u g h t i n t h e u n i t i t s e l f .

The w i r i n g d i a g r a m o n t h e n e x t p a g e s w i l l f a c i l i t a t e t h e l o c a t i o n of t h e de fec t .

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WELDING DATA - TYPICAL VALUES

S h i e l d i n g Gas i s weld ing Grade C 0 2 used w i t h a G a s P r e h e a t e r . C o n t a c t T i p 1 . 5 m i n s i d e of Gas Nozzle. Wire "S t i ck Out" 6 - 9m.m up to 2 0 0 amps. 1 2 - 19mm over 2 0 0 amps. These Tables a r e a g u i d e o n l y f o r i n i t i a l m a c h i n e s e t t i n g a n d f i n e r ad jus tmen t s may be necessary t o a c h i e v e optimum welding c h a r a c t e r i s t i c s f o r t h e a p p l i c a t i o n . Recommended machine s e t t i n g method i s t o se t Vo l t age Switches, Inductance and Gas Flow a s p e r T a b l e t h e n a d j u s t wire speed t o o b t a i n recommended c u r r e n t .

:ect- f ie r

JP6

Wire S i z e Gas

0 . 9 m ( S o l i d Wire)

1.2m. ( S o l i d Wire)

10 Li t . /Min

( f o r v e r t i c a l Down)

1 5 Li t . /Min

1.6mm 15/17 (Fluxo- Li t . /Min . f i l )

2 .0m. ( F l u x o f i l )

2 . 4mrn ( F l u x o f i l )

Wire Speed Metres Per Min.

3.9 6 . 3

2.2 3 . 2 4.4

5.7 5.8

7.6

9.0 10.0

5.1 6.4

5.5 6.6

Coarse -

2 2

2 3 3

3 3

4

5 5

5 5

5 6

4 1 190 4 2 2 0 0

2 3 250

2 2 330 3 2 360

4 2 380 5 2 450

6 2 500 1 2 550

Vol t

18 2 1

20 2 1 2 2

23.5 2 6

27

31 3 2

33 3 4

3 4 35

NOTE: Wire speed i s shown i n m e t r e s / m i n u t e a n d a r e n o t d i a l c a l i b r a t i o n s e t t i n g s .

- I TEP NO. -

2

2 . 1

2 . 2

2 . 3

3

3 . 1

4 4 . 1 4 . 2

5

S

9

1 8

2 1

2 2

2 4

2 5

26

2 6 . 1

2 7

2 8

2 9

30

3 2

33

3 4

3 7

3 8

3 9

40

3 7 . 1

3 7 . 2

8 D R A W I N G NO. CP6-02 - SPARE PARTS L I S T I S S U E 5 .

PART NO.

CP6-5

CP6-5/2

CP6-5 /3

CP3-9/8

CP6-8 ,

CP6-19

CP6-2

C P 6 - 7 / 1

CP6-7/2

CP25-0/7

CP3-0/4

14235-0/6

CP15-0/7

CP5-25

CP5-0/19

AM1 6

CP15-0 /14

TC262

TC262N

CP3-0 /47

CP6-0 /35

w1-22

CP6-0 /47

CP5-0 /13

CP5-0 /14

CP5-0 /15

W1-23

C P 2 2 - 3 / 1 3

CP6-20

C P 6 - 2 1

K10

K11

DESCRIPTION

RECTIFIER ASSEMBLY

DIODE

DIODE ( R )

THE R?.!lOS TAT

TRANSFORMER ASSEMBLY

PRIMARY/SECONDARY COIL

INDUCTANCE ASSEMBLY

LEFT HAND INDUCTANCE COIL

RIGHT HAND INDUCTANCE COIL

CONTROL TRANSFORMER

FAN BLADE

FAN MOTOR

GAS HEATER PLUG SOCKET

RECTIFIER PROTECTION ASSEMBLY

WELDING CONTACTOR

OUTPUT TERMINALS

CONTROL PLUG

GAS NIPPLE

GAS NIPPLE NUT

VOLTMETER 0-60V.

AMPETER 0-800A.

INDICATOR LIGHT

A P N T E R SHUNT 0-800A

POWER ONYOFF SWITCH

COARSE VOLTAGE SWITCH

FINE VOLTAGE SWITCH

FUSE HOLDER

STAND OFF INSULATOR

RESISTOR

SERIES RESISTOR

3AG. 3 A DELAY FUSE

3AG. 5 A DELAY FUSE

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SAFE PRACTICES IN UStNG WELDING EQUIPMENT

These notes are provided in the interests of improving operator safety. They should be considered only as a basic guide to Safe Working Habits. A full list of Standards pertaining to industry is available from the Standards Association of Australia, also various State Electricity Authorities, Departments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements.

EYE PROTECTION NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or glasses

with side shields underneath, with appropriate filter lenses protected by clear cover glass. This is a MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal. Replace the cover glass when broken, pitted, or spattered.

WELDING CURRENT SHADE NUMBER

Below 30 Amps ....................................... 6 30 - 75 Amps ......................................... 8

75 - 200 Amps ....................................... 10 200 - 400 Amps ...................................... 12

Above 400 Amps ..................................... 14

BURN PROTECTION. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight

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 - leather or heat resistant gloves, hat, and safety-toe boots. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and stag.

Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and workpieces 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 should not be used by persons intending to weld or cut.

TOXIC FUME PREVENTION. Adequate ventilation with air is essential. Severe discomfort, illness or death can result from

fumes, vapors, heat, of oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen.

Lead, cadmium, zinc, mercury, and beryllium bearing and similar materials when welded or cut may 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.

Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.

Work in a confined space only while i t is being ventilated and, i f 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 phosgene. Do 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 can travel up to 10 metres from the arc.

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of 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-fltting 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;

R Combustibles (including building construction) are within 10 metres. m Combustibles are further than 10 metres but can be ignited by sparks. R Openings (concealed or visible) In floors or walls within 10 metres may expose combustibles

m Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or

After work is done, check that area is free of sparks, glowing embers, and flames.

to sparks.

conducted heat.

An tank or drum which has contained combustibles can produce flammable vapors when heated. Such a container must never be welded on or cut, unless It has first been cleaned as described in AS. 1674-1 974, the S.A.A. Cutting and Welding Safety Code. This includes a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility), followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AS.1674-1974. Water-filling just below working level may substitute for inerting.

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. Do 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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