MANLIFACTURED BY WELDING INDUSTRIES OF AUSTRALIA LTD.

HEAD OFFICE AND EXPORT D I V I S I O N 're1 e p t - , ~ n e 0 3 4d5-251.1 2-26 A u s t a r c A v e n u e , T h c m a s t u w n , F a c s i r r t i 1 e 83 465-863.2 V i c . 307'4, A u s t r a l i a "e1 ex A A 3 2 4 9 3 AUSTAHC

EQUI PPIENT MANUFACTURING D I V I S I O N V e l ephclne 88 2?6-&4?4 ii2 Daws Road, Edwardstuwn, F a c s i r r r i 1 e 0 3 278-8383 S . A . S O W , A u s t r a l i a Te l ex AA82&5b AUSTARC

SALES AND SERVICE SRANCHES A d e l a i d e p h 88 276 h888 t 1 X AA82856 fax 88 276 4327 Br i5bane ph 07 844 1 3 7 1 f a x 8 7 844 6229 Launces.tan p h 6183 44 P 8 2 2 far, 883 44 6678

-SAFETY-

WELDMATIC U T I L I T Y MANUAL PAGE 3

-~ INTAUDUGTION

GENERAL

T h i s m a n u a l has been preparecl e s p e c i a l l y f o r use i n f a m i l i a r i s 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 , and t ruub le s h u o , t % n g o f t h i s e q u i p m e n t . A11 i n f u r m a t i o n p r e s e n t e d 17er-ein 51hould b e g i v e n c a r e f u l c o r l t . ; i d e r a t i o n t o a s s u r e o p t i m u m per formance uf t h i s equipmer-It.

RECE L V I NG/HANDL. I NG

P r - i u r tu i ~ s t a l l i r t y t h i s e q u i p m e n t , c l e a n a l l p a c k i n g material f r o m a r o u n d the u n i t a n d c a r e f u l l y i n s p e r t f o r a n y d a m a g e t h a t may have u e c u r r - e d d u r i n g s l - l i p m e n t . R n y c la ims f a r losses or- d a m a g e t h a t may have o c c u r r e d i n s l l i p m e n t m u s t be f i l e d by . t h e p u r c h a s e r w i t h Wplding I n d u s t r i e 5 o f A u s k r a l i a L t d . , o r a u t h o r i z e d agerrt i tnmediately. (Refer- t o EWUIPMENT WARRANTY CARD e n c l o s e d w i t h t h i s Oper.a-t:iI-lg Manual ) . When r e q u e s t i n g i n f a r m a t i o n s o n c e r n i n g t h i s e q u i p m e n t , i t is essen'kial to s u p p l y c u r - r c x t MODEL I D E N T I F I C A T I O N and MACHINE S E R I A L NUMBER.

CUNTENZ. PAGE

GENERAL DESCRIPTIDN . . . . . . . . . . 4 SETTING UP FOR OPERATION . . . . . . . 5 WELDING OPERATION INSTRUCTIONS . . . . 6 MAINTENQNCE INSTRUCTIONS . . . . . . . 8 WELDING DATA TAULE . . . . . . . . . . 9 PARTS L I S T CP1H-02 . . . . . . . . . .l0 ASSEMBLY DRAWING CP1&3--0 , . . , . m .11 CIRCUIT DIAGRAM CP18-!22 . I . . "12 ACCESSURY LEADS . . . . . . . . . . . . l 3 AM3.9:3 MOBILE K I T . , I) , . . . .l4 SAFETY PRACTICES . . . . . . . . . . .15 WFIHRANTY CARD . . . . . . . . . . . . .17

WELDMATIC UTILITY MaNUFIL PAGE 4

STANDARD IJN 1.1- The c o n s t r u r t i s n o f t h e s t a n d a r d p a c k a g e p l a n t has been designed f a r i n 5 t a l l a t i a n a n d o p e r a t i n g i n a w i d e v a r i e t y o f a p p l i c a t i u n s , such as h i g h p r o d u c t i o n f a c t o r - . i e s ar id g e n e r a l f a b r - i c a t i a n s h o p s .

"WELDMATIC" Plant.; consi5.t: o f t h r e e b a s i c u n i t s : - 1. Curts.trant P a t e r l t i a l R e c t i . f i e r Power Source. 2. Semi--Automat ic Wire Feeder. 3 . Welding Gun and Cable Assembly.

Separ'ate o p e r - a - k i n g a n d m a i n t e n a r l c e i n s t r u c t i o n s a r @ p r o v i d e d f o r t he w i r -e feeder and gun cables.

" 1. POWER SOlJRCE I- FEATURES

T h e standar-d CP r e c t i f i e r power source i s housed i n a d r i p p r o o f e ~ ~ 1 ~ ) s u r . e . L i f t i n g l u g s a r e p r o v i d e d f o r c r a n e t r a n s p o r t a t i o n . F u r u n i t s w i t h wheel meunt ing, four s o l i d t :yred wheels ar-e p r o v i d e d , t l ~ e t w u f r o n t w h e e l s a r -e . ; t e r rab le pe rm i t t i ng easy muvernent i n r e s t r - i c . t r d . f luor- space!. A push bar- i s p r o v i d e d on t h e fI-on2: o f t h e machine and a gas c y l i n d e r c a l - r - i e r w i t h a s u p p o r t br-acke2: a n d c h a i n a t t h e reat-. R s w i v e l m e u n t i n y f o r t h e w i r e f e e d e r is fitted t o .the top o f .the puwer sour-ce. A 110 v o l t p l u g socket i s l o c a t e d on t h e r e a r p a n e l f o r c o n n e c t i a n o f ga5 pruhea t r r - when w e l d i n g w i t h C O 2 y a s s h i e l d . L o c a t e d an t h e f r o n t p a n e l a r e a c o a r s e v o l t a g e s e l e c t i o n s w i t c h ( i n c o r p o r a t i n g pawer ON/OFF), . f i n e v o l t a g e s e l e e t i a n s w i t c h , c o n t r o l f u s e s , w i r e feeder - p lug socke t and r e c t i f i e r power ou tpu t socke ts .

2. C O N S T K U C T m

T h e power- ~,uut -ce is a C o n s t a n t P o t e n t i a l S i l i c o n D i o d e R e c t i f i e r D.C. W ~ l d e r - , w i t h a th ree phase t rans fo rmer and a th ree phase t -eckif ier b r i d g e . Connected in t h e u u t p u t c i r c u i t is an i nduc tance u n i t : p r o v i d i n g t h e " i n d u c t a n c e " or- degree o f s l o p e n e c e s s a r y f o r v a r i o u s w e l d i n g c u r r e n t s . C o o l i n g o f t h e s i l i c o n d i o d e s , .tI-al-ldarrner- windi11gs and i n d u c t a n c e uni-t i s b y a s i n g l e p h a s e a x i a l far). The power source i s pr-ca tec ted a g a i n s t f a n f a i l u r e and ove rheak ing by t h ~ ? r m o ~ t t a t s mtsurlted un diode h e a t s i n k s .

3 . WELDING PROCESS

G a s metal a r c w e l d i n g w i t h i n the c a p a c i t y o f the power source can be c a r r i e d o u t with t h e f o l l u w i n g e q u i p m e n t : -

a ) Semi-autarnat i r w i r e f e e d e r 2 roll. d r i v e Model W17. b ) ~ ~ I I ~ . ~ ' - i ~ ~ ~ . ~ U f l I ~ ~ . ~ ~ w i r e f e e d ~ r 4 r o l l d r i v e Model WlS. c ) Semi-automat ic w i r - u feeder W17 o r W18 f i t t e d w i t h one o f

t l ~ e f o l l o w i n g u p t i w n k i t s : - . A M 1 2 6 Pre and Pos t ga5,. . A M 1 2 7 S o f t s t a r k and c r a t e r fill. A M 9 2 8 S p a t t i m e r ancl c y c l e a r c

, A M 1 4 6 Push and p u l l gun and con t ro l ,

c o n t r o l 1 er. c l ) "Ho1~au. t " spool gun weld ing u n i t Model §P9 w i t h C V 2

4. WELDING CAPACITY

Power Saurce Capaci ty i 5 as . fo l lows:-- 200 bps, 28 V o l t s , 100% Duty C y c l e . 250 A m p s , 28 V o l t s , 60% Duty C y c l e .

WELDMAPIC UTILITY MANUAL. PAGE 9

- 5 . SUPPLY AND WELDING CABLES

Pnwer- Sources a r e s u i t a b 1 . e for- c o n n e c t i o n t o a 415/440 V o l t 5 0 H z . 3 Phase supp ly .

T h e recommended f u s e s i z e , p r i m a r y c a b l g s i z e and we ld ing cable size .a re as f o l l o w s : -

a ) Fuse - 1 5 a m p b ) P r i m a r y Cable - 4 c o r e 3 2 / 0 . 2 0 T . R . 8 . c ) Weld iny Cab le - 7 9 2 / 0 . 2 @ T.R.S.

A . SHIELDING GASES

a) Welding Grade C O 2 f o r a l l m i l d and a 1 l . o y 5teel w e l d i n g i n t l ~ i c k n e s s e s r a n g i n g f r om l m r n upwards.

b ) Clrgen/CQ2 o r Argen /Oxygrn m ix tu res f e r a l l a p p l i c a t i o n s on low cu r - r -en ts r e y u i r i n y minimum o f s p l a t t e r on shee.lr. steel and f o r s t a i n l e 5 , s 5teel w e l d i n y .

c ) nrqorr/Uxygen and A r y o n / C O 2 m i x t u r e s f o r p r i m e w e l d i n g uf s t a i n l e s s s . k e ~ ? l

d ) Rrycan ( p u r e ) f o r - a l l a lumin ium we ld ing .

7. SETTING UP UNIT FOR OPERATION

a) Grr le ra l Assembly o f Packaged Plant

The power swur-c(? i s sl - i iypud on i ts s k i d base. Wheels.,, handle, , bottle c a r r i e r and b w t t l e c r a d l e s h o u l d be assembled a5 shown i n d raw ing 8Ml93. W17 Wi re Feuder- is f i t t e d to the t o p o f power' suu rce in the special s w i v e l rrmunt 01-1 the mach ine . F i t t h e W14-It, pivot p i n assembly to ttje w i r e feeder arld ensure f i b r e th rus t washer i s 01.) the p i n before l o c a t i n g i n t he swive l rmun. I : iny. Check that w i r e f e e d e r i s f r e e t o s w i v e l in a l l d i r - e c t i o n s , if necessary apl~1.y a s m a l l amount o f y r - a p h i t e yr-ease t o s h a f t .

13) C u r ~ ~ ~ e c t ~ t i u r ~ t u Mains Supp ly

NOTE: T h i % wur-I< shuuld o n l y be c a r r i e d o u t b y a q u a l i f i e d e lec t t - i r i a r \ .

T h e power siuurce i.; d e s i g n e d f o r connec.l:ior-l t o 415/440 Volt 50 I i z . 3 Phase s u p p l y a n d t h e s u p p l y v o l t a g e 5 t lou ld be a s c e r t a i n e d b e f o r e c o n n e r t i n g t t l e n ~ a c l ~ i n e . Rcress t o s u p p l y e o n n e c t . i o n terminals i n cnactli.1-1e may be g a i n v d by remov ing left hand s i d e par le l . Use a f l e x i b l e 4 cor-^! p r i m a r y cable for- p o r t a b l e m a c h i n e s and e l a m p c a b l e t o ensure t h a t thur -e i s 1-10 s t r a in 01.1 c a b l e c ~ r l r ~ e c t i o n s . The e a r t h (o r - g round) connectimn ( y r e e n / y e l 1 0 l . r ) m u s t be s e c u r e l y f a s k e n e d t o the ' u a r t h ' t e r m i n a l o n t h e m a c h i n e a d j a c e n t t o t he s u p p l y c o n n e c t i o n . terminals. C h a r l y e l i r > k o n t e r m i n a l b l o c k to 440 v o l t p o s i t i o n if rnac;Iline is coclnected ta 440 V o l t s u p p l y .

CAUTION: B e f o r e i n 5 e r t i n g p r i m a r y c a b l e p l u g i n mains s u p p l y s o c k d , ensure k h a t s w i t c h or1 b o t h p l u g s a c k e t a n c l weld ing mach ine i s .in 'CIFF' position.

WELDMATIC UTILITY MfiNUFIL PFIGE 6

c ) Connectj.c)n uf Cables/Hnses , e t c ,

W i t h u n i t s w i t . c h e d 'OFF' c o n n e c t r o n t r e l c a b l e ( 4 p i n p l u g ) f r om pwwur S Q U ~ C E ? t u wit-, feeder-. Connect gas ho5;e f r o m w i r e f e e d e r t o gas regclls.tal-./-f.aowmE?t.er-, e n s u r i n g a 1 1 c o n n e c t i o n s a r e t i g h t e n e d f i r m l y . I f C O 2 Gas S h i ~ 2 d is buriny used, p l u g heater- i n t o 110 v o l t soczket a t real- t1.f u n i t . N e x t i n s e r t g u n c a b l e i n t o s o c k e t o f w i r e ft?e~Iev- o u t p u t g u i d e Connect "Gas I-luse" and "Gun S w i t c h " l e a d s to r-e.;pt'c'tive s u r k e t s .

d ) W e l d i l l y Cables

A l l G.M.R. w e l d i n g is d o n e w i t h electrode w i r e c o n n e c t e d t o ' 'pc35it: i .ve~~ pu le commonly known as D.C. rever 'se p o l a r i t y (D .C .R .P . 1 t h e r e f o r e con l lec t t h e s h o r t j u m p e r l e a d f r o m " + " socket on machine ,to . t : (?r-minal l u g WI~I yurl c a b l e . The work lead ( " r regat ive" ) shou ld be pl.uyC)ed i c ~ t : ~ t h e ' I . - ' ' scacl<e~k un the mael-line. T h e p l u g s o f t h e w e l d i n g cl:abJ.os 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 e t i o n . T o a v o i d e r r o r , w e l d i r l y s h o u l d n o t be a t t e m p t e d u n t i l a l l connect ions have been secure . T h e w i re feeder - may be i n s t a l l e d remote f rom t:he power source, i n wh ich ca5e o x t e n % i o n l u a d s ~ t s cmnprj.Eiing power c a b l e , g a s hose and c o t ~ t r u l c a b l e (. four cor-e) a r e t - e ~ u i r e d i n a c c o r d a n c e w i t h t h e d r s i r e d l e r l y t h , ~ ~ t a n d a r d l eng th a v a i l a b l e f r o m s t o c k i s 9 met res .

e ) Wire Feeder- a n d G u n Cab le

F i . t a spool a f w i r e to t h e w i r e f e e d e r (5ee rides i n "Wire Feeder Z n s t r u c t l o n M a n u a l " ) T i g h t e n t h e " b r a k e " scr-pw u n t i l a s l i g h t b r a k i n g e f f e c t i5 f e l t when t u r n i n y the w i r e spoo l by hand to p r e v e n t " o v e r - r u n " when w i r e fped stops.. T h e w i r e d r i v e r o l l s and i n l d w i r e g u i d e s h o u l d be 5@1PCt€?d i n accor -dance w i th t he d iamete r arid 'type s f w i r e b e i n g used R e f e r t o cu r ren t w i r -e f eeder manua l f o r c o r r e c t s e l e c t i o r l s f w i r e feecl r .-ollc~ and ir1pu.l: g u i d e s .

0 I 8mm := 0 . 030" O.?rnm = 0.035" 1 %mm = 0 . 45"

The gun c a b l e and gun a r e n o r m a l l y d e l i v e r e d w i t h the c o n t a c t t i p ancl l i n e r s p r i n g f o r w i r e s i z e n o m i n a t e d , b u t c h e c k t h a t b o t h a r e c o r r e r t 5ize f o r w i r e b e i n g used.

WELDING OPERATION INSTRUCTIONS

Is_, S I NGIs-_F_blNCT_.I !JN CHECK

U n i t is now ready f o r o p e r a t i o n , b u t p r i o r ts commencing welding, the f u l l o w i n g " f u n c t i o n s c h e c k " is recommended:

S w i t c h on power source and check a i r f l o w - See t h a t all w e l d i n g l e a d p l u g s a r e i nse r . ted in t h e c o r r e c t p u l a r i t y sc~clccts - e l e c t r o d e "po.; i t . i .ve", work "neyative" -- Check a1 1 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 " L i c u 1 a r 1 y " w o r k " c l a m p .

Nex t cnsurc .that: all c o n t r o l c a b l e s a n d gas hnses a r e s e c u r e l y c u n r , e e . t e d atid .khat G a 5 H e a t e r ( f e r C O 2 o n l y ) is p l u g g e d i n t o s o c k e t a t r e a r o f power source. S w i t c h nn wir-u f e e d e r - , i n d i c a t o r l i g h t s h o u l d now r,how "Power O n " . Open g a s c y l i n d e r f u l l y and check CotltEn'kEi g a u g e f o r - &ldE?L~Ua'tP gas 5UppI.y

WELDMATIC UTILITY MANUAL PAGE 7

Press "Gas P u r g e " s w i t c h a n d s e t gas f l o w i n a c c o r d a n c e w i t h welding r e q u i r e m e n t s , a t the same t i m e , c h e c k t h a t gas f l o w (8-10 lt./min) i5 adequate f rom the gun nozz le . 5et " W i r e S p e e d " c o n t r o l t a de5.i.r-ed w i r e speed. PrE>ss " w i r e i n c h " s w i t c h and check wi re feed f o r - co r rec t p res rsu re on d r i v e r - n l l s . P r e s s u r e s h o u l d be s u . f f i s i e n t t o p r - e v e n t a n y " s l i p " when feed ing th rough gun and c a b l e .

Nex-l:, close gun s w i t c h momentarily f o r w i r e feed, gas f l o w and w r l d i n g power check. S e t t he vol. t a g e s e l e c t o r s w i t c h e s . i n

arcor-dance w i t h r e q u i r e d vtal t .age (see weldi.ng table) u n i t is now ready f a r w e l d i n g .

l~"""""l.- 9 . SETTING O F WELDING CURRENT 4N-g VOLTRGE.

W e l d i n y 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 t h e ' w i r e s p e e d ' . The e l e c t r o d e w i r - o i 5 .fed a t .the p r - e - s e l e c t e d s p e e d b y d r i v e r o l l s -thr.c~ugfl the gun cable tu Lhe ;arc at t h e constar-It speed, a5 s e t by the ' w i r e speed' ccJntrc- , l . The higher the w i r e speed, the h i g h e r t h e w e l c l i n y c u r r e n t m

The uutput vo l . t aye o f t he power s o u r c e whpn t h e gun s w i t c h is cla5ed, .i5 d i v i d e d i n t o a number uj: s teps by coa r se 5 e l e c t o r and f i n e 5electov. swi tc lhes. T h e ' c o a r s e ' selectur. s w i t c h is a cnfnk,j.r1ed h i g t ~ ~ / l o w r-arlge O N / O F F 5 w i t . c h wcarkiny i n c o n j u n c t i o n w i t h a " f i n e " selector s w i t c h g i v i n g 2 0 vultaye ~ t e p . ; .

T h e f o l l o w i l l g sequence uf w e l d s e t t i n g is recommended:"

a ) C o n s u l t t y p i c a l w e l d s e t t l i n g c h a r t .

b ) S e l e c t w e l d i n y c u r - r e r 1 . t m o s t s u i t e d t o t h e a p p l i c a t i o n b y f o l I o w i n g tthe s e t t i n g s o f w i r e speed a n d v u l t a g e shown on the s e t t i n g e h a r - t . T o " t u n e " e a c h w e l d s e t t i n g , a d j u s t w i r e speed o r ) l y

c ) I f v o l t a g e i s t o o l o w f o r - t h e a p p l i c a t i o n w i r e " s t u b b i n g " will o c c u r , p a r t . i c u l a r l y a t s t a r k c a f weld and weld con tour will be ve ry convex. I f t-11~ vul.t:age is t oo h i g h , m e t a l , t r a n s f e r will be e r r a t i c w i , t h excess spa t te r - .

d ) With w e l d i n g c u r - r e n t a n d v o l t a g e m a t c h e d , t h e r e s u l t will be an o p t i m u m t u n e d w e l d i n y c o n d i t i o n w i t h a smooth a rc w i . t : h minimum s.pd4-l:er- f o r m e d I

WELDMATIC UTILITY MONUAL PAGE 9

K€LD 1 NE DATA TflE-lE

TYPICAL WELD SETTING CHART WELDING CURRENT (Amps)

I 30 40 50 60 70 80 90 100 120 140 160 180 200 220 24C

0 4 m m COARSE VOLTS 1 l 1 1 1 1 2 2 2 2 2 2 2

WIRE FINEVOLTS 3 3 3 4 6 10 1 2 3 8 8 10 10 I D

WIRE SPEED CO 26 DIAL SETTING 1.3 1.4 2.0 2-4 2.5 3.1 3-9 4.5 4.8 5.9 6.7 10

0.9rnm COARSE VOLTS 1 1 1 1 1 1 2 2 2 2 6 2 I WIRE FINE VOLTS 4 4 4 6 7 8 1 3 3 4 2 1 0

WIRE SPEED CO 26 DIAL SETTING 1.2 mm COARSE VOLTS

WIRE FINE VOLTS

1.3 1.5 1.7 109 2.2 2.4 3.0 3.9 4.6 6.4

1 1 1 1 1 2 2 2 2 2 7 7 7 7 9 1 3 5 8 1 0

SETTINGS GIVEN FOR C02 SHIELDING GAS -FLOW RATE 8-tOLITRES/MlNUTE. USE THIS CHART AS A PRELIMINARY SETTING GUIDE. TO'TUNE' EACH WELD SETTING, ADJUST WIRE

SPEED ONLY. FOR FURTHER DETAILS, INCLUDlNG USE OF ARGON MIXED GAS REFER MANUAI

I f mixed gasr5 are t o b e u s e d , t h e a b o v e c h a r t w i l l s t i l l p r o v i d e a u s e f u l s e t t i n g g u i d e , h o w e v e r f a r uptimum r e s u l t s , v o l t a g e a d j u s t m e n t may be n c e e s s a r y - i n g e n e r a l the v o l t a g e s e t t i n g w i l l need to be r -educcd . Recammended g a s f l o w r a t e f o r m i x e d gases is 10 - 15 l i L r - e s / m i n t l - k e .

WELBMATIC U T I L I T Y MANUAL PAGE 10

PARS

CP33-50 CP1,8"12 cf315-14 cFJ33-0/4 CP29-0/7 CP35,-16 CP15-13/2 C P 1 5 - 1 3 / 3 CP3"9/8 CP15-0/7 CP18-0/8 w1-22 W1-23 CPZ 5-0 / 18 CP25-0/19 CP15-0/14 CP18"14 CPSS-15 CP15-27 CP 3-5-28 WIN44 MC=14-1/14 AM 1 b 08029F CP18-0/22 CP53-23 WIN122 CPl5-30

DESCRIPTION

BASE FRAME ASSEMRLY TRANSFORMER ASSEMBLY INDUCTRNCE ASSEMBLY FAN EILADE 250" DIAMETER FAN MOTOK RECTIF IER ASSEMBLY DIODE (SEMIKRON S K R 2 4 0 / 0 4 ) DIUDE (SEMIKRON SKN240/04) THERMOSTAT HEATER PLUG SOCKET WELDING CONTACTOR INDICATOR LIGHT FUSE HOLDER F I N E SELECTCIA SWITCH GOI1RSE SELECTOR SWITCH CONT'ROL PLUG FRONT PANEL BACK PANEL TOP COVER SIDE PANELS TYPE NB./SERIOL NO. PLATE TERMINAL STRIP QUTPUT TERM I NALS 1/2"W. EYE NUT LOOM ASSEMBLY A I R FLOW FINS TERMINAL CONNECTION NAMEPL PIVOT I iOUNTING FOR W17

ATE

L

l1

W

c

6

(d

W

c jk

c

0

0 0

J

0

0

c.

1

0

7”

W

S

I I I

. . I 4-

I

0 El

I

, 1 1

t

I

Q-

r

8

I o

0

I 13

"l I

-

W v, 0 I Ln Q W

0

INSTRUCTIONS FOR FITTING AM193 MOBILE KIT

1 ) L i f t Power Source on to Mob i l e K i t Frame 1 . Use c r a n e o r f o r k l i f t w i t h c h a i n s and hooks and i n s e r t h o o k s t h r o u g h eye n u t s on t op cover o f Power Saurce. ( I f crane or f o r k l i f t is n o t a u a i l a b l e t h e Power Source may be c a r e f u l l y s l i d o n t o f rame +rom t h e b a c k o f t h e f r a m e ) .

2) L i n e - u p h o l e s i n s i d e beams a f f r a m e w i t h t h e s l o t s i n t h e s i d e s o f t h e Power Source base.

3) I n s e r t a l l f o u r 3/#"W x 1 " s c r e w s 3 t h r o u g h t h e f o u r h o l e s a n d . s l o t s .

4 ) Thread on a1 1 f o u r 3/8"W Hex " N r l o c " n u t s 4 . (The a p p o s i t e side of t h e n u t t o t h e n y l o n r i n g t h r e a d s o n t o t h e c,crews f i r - s t ) . 5) T i g h t e n all four n u t s ( y o u will need s p a n n e r s f o r b o t h the sc rew and t he n u t ) .

6 ) Remove screws 7 , s p r i n g w a s h e r s 6 and f l a t washers 5 f r o m back pane l o f power sou rce .

7 > F i t b o t t l e c r a d l e 2 ( n o t e t h a t t h e c h a i n s l o t s are uppermos t ) .

8) R e f i t sc rews and washers and t hen t i gh ten .

NOTE: DO NOT fiTTEMPT TO L IFT POWER SOURCE AND MOBILE K I T ASSEMBLY MITH GAS BOTTLE I N PLACE. REMOVE GAS BOTTLE BEFORE LIFTING ASSEMBLY.

Am 193-41

SAFE PRACTICES I N U S I N G WELDING EQUIPMENT

produced by Welding I n d u s t r i e s of Australia P t y . L t d . i n t h e i n t e r e s t s of improving operator safety. These notes should be cons idered on ly as a b a s i c guide to Safe Working Habits. A f u l l l ist of S tandards per ta in ing to indus t ry is ava i l ab le from h e Standards .Association of Aus t ra l ia , a l so var ious State Electr ic i ty Authori t ies , Departments of Labour and Indus t ry or Mines Depart- ment and other Local Health or Safety Inspection Authorit ies may have additional requirements.

1. A nea t unc lu t te red work area makes f o r s a f e working hab i t s .

2 . Burn Prevention

The welding arc is in t ense and v i s ib ly b r igh t . Its rad ia t ion can damage eyes , pene t r a t e l i gh twe igh t c lo th ing , r e f l ec t from light-coloured surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful .

Wear p ro tec t ive c lo th ing - l e a t h e r (or asbestos) gaunt le t g loves, hat , and safe ty- toe boots. Button shirt c o l l a r and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.

NEVER LOOK AT AN ARC WITHOUT PROTEXTION.

Wear helmet with safety goggles or glasses w i t h side shields underneath, appropriate f i l t e r l e n s e s o r plates (protected by c lear cover g lass ) . This is a MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and f lying metal . Replace cover glass when broken, p i t ted,or spa t te red .

A v o i d o i l y o r greasy c lothing. A spark may i g n i t e them. Hot metal such as e l ec t rode stubs and workpieces should never he handled without gloves.

Ear plugs should be worn when welding i n overhead posit ions or i n a confined space: A hard hat should be worn when o t h e r s work overhead.

Flammable ha i r p repa ra t ions shou ld no t be used by persons intending t o weld o r cut.

3. Toxic Fume Prevention

Adequate v e n t i l a t i o n i s e s sen t i a l . Seve re d i scomfor t , i l l nes s or death can r e s u l t from fumes, vapors, heat, or oxygen enrichment o r dep le t ion t ha t we ld ing (or c u t t i n g ) may produce. Prevent them with adequate vent i la t ion. NEVER ven t i l a t e w i th oxygen.

Lead, cadium, zinc, mercury, and beryll ium bearing and similar materials when welded (or c u t ) may produce harmful concentrations of toxic fumes. Adequate loca l exhaus t ven t i l a t ion must be used, or each person i n t h e area as well as t h e operator m u s t wear an a i r - suppl ied respirator. For beryll ium, both m u s t be used. Metals coa ted wi th o r conta in ing materials that emit fumes should not be heated unless coa t ing is removed from the work s u r f a c e , t h e area is well v e n t i l a t e d , o r t h e o p e r a t o r wears an a i r - suppl ied resp i ra tor .

Work i n a confined space only while it is being ventilated and, if necessary, while wearing a i r -suppl ied respirator .

Vapors frpm chlorinated solvents can be decomposed by the hea t o f t he arc (o r flame) t o form PHOSGENE, a h ighly tox ic gas , and lung and eye i r r i t a t i n g products. The u l t ra -v io le t ( rad ian t ) energy of the arc can a lso decompose t r ichlorethylene and perchlorethylene vapors to form phosgene. DO no t WELD o r c u t where solvent vapors can be drawn i n t o t h e welding o r c u t t i n g atmosphere o r where the radiant energy can penetrate t o atmospheres containing even minute amounts of t r ich lore thylene o r percholore thylene .

4 . Fire and Explosion Prevention

Causes of f i re and explosion are:- Combustibles reached by t h e a r c , flame, f l y - ing sparks , hot s lag, or heated materialI misuse of compressed gases and c y l i n - ders; and short c i r c u i t s .

Be aware that f ly ing spa rks o r f a l l i ng s l ag can pas s t h rough cracks, along pipes, through windows or d0or8, and through wall or floor openings, o u t of s i g h t of the goggled operator. Spark8 and slag cm fly 10 metres.

!ID prevent f ires and explosions:- Keep equipment c lean and operable , f ree of o i l , grease, and (in electrical parts) of metallic p a r t i c l e s that can cause short c i r c u i t s .

If combwtibles are in area, do NOT weld or cut . Move t he work if practicable, to an area f r e e of combustibles. A v o i d paint spray moms, d ip t anks , s to rage a reas , ven t i l a to r s . If the work can n o t be mved, nave combustibles a t least l0 metres away out of reach of sparks and heat8 or protect aga ins t i gn i t i on w i th suitable and snug- f i t t i ng fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on (or c u t ) . Walls,ceil ings, and floor near work should be protected by hea t - res i s tan t covers o r sh i e lds . Fire watcher m u s t be 6tanding by with suitable f i r e e x t i n g u i s h i n g equipment during and for some time a f t e r welding or c u t t i n g i f :

(1) combustibles ( inc luding bu i ld ing cons t ruc t ion) are within 10 metres. (11) combustibles are fu r the r t han 10 metres but can be i gn i t ed by sparks. (111) openings (concealed or v i s i b l e ) Fn f l o o r s or wal ls within 10 metres

( 1 V ) combustibles ad jacen t to walls, c e i l i n g s , roofs, or metal par t i t ions may expose combustibles to sparks.

can be i g n i t e d by r a d i a n t or conducted heat.

A f t e r work is done, check that area is free of sparks, glowing embers, and flames.

An empty con ta ine r that he ld &mbustibles, o r can produce flamable vapors when heated, must never be welded on or cut, unless conta iner has f i r s t been c leaned as described iri AS.1674-1974, t h e S.A.A. Cutting and Welding Safe ty Code. This inc ludes : a thorough steam or caustic c leaning (or a so lvent or water washing, depending on the combust ib le ' s so lubi l i ty ) fo l lowed by purging and i n e r t i n g w i t h n i t rogen or c a r k n dioxide, and using protective equipment a s recommended i n AS.1674-1974. Water-f i l l ing just below working l e v e l may s u b s t i t u t e f o r i n e r t i n g .

Hollow cas t ings or con ta ine r s m u s t be vented &fore welding o r c u t t i n g . They. can explode. Never weld or c u t where the a i r may conta in flammable d u s t , gas, o r l iquid vapors such as petrol).

5. Shock Prevention

E x p s e d conductors or other bare metal i n the welding c i r cu i t , o r ungrounded e l e c t r i c a l l y a l ive equipment can f a t a l l y shock a person whose body becomes a con- ductor. Ensure that t h e maohine is correct ly connected and ear thed . If unsure have machine i n s t a l l e d b y a q u a l i f i e d e l e c t r i c i a n . On mobile or portable equipment, r e g u l a r l y i n s p e c t c o n d i t i o n o f t r a i l i n g power l eads and connect ing plugs. mpair o r r e p l a c e damaged leads .

6. Electrode Holders and Connectors

Ful ly insu la ted electrode holders should be used. DO n o t use h o l d e r s w i t h protruding screws. F u l l y i n s u l a t e d lock-type connectors should be used to join welding cable lengths .

7 . Terminals

Terminals and o t h e r exposed p a r t s of e l e c t r i c a l units should have insulated knobs or covers secured before opera t ion .

4 . Fire and Explosion Prevention

Causes of f i k e and explosion are:- Combustibles reached by the arc , f lame, f ly- ing sparks , ho t s lag , or heated material; misuse of compressed gases and cylin- de r s ; and s h o r t c i rcui ts .

Be aware t h a t f l y i n g s p a r k s or f a l l i n g s l a g can pass through cracks, along pipes, through windows or doors , and through wall o r f loor openings , ou t o f s igh t of the goggled operator. Sparks and s l a g can f l y 10 metres.

To prevent f i res and explosions:- Keep equipment clean and operable, free of o i l , g r e a s e , a n d ( i n e l e c t r i c a l parts) of metallic p a r t i c l e s t h a t c a n cause s h o r t c i r c u i t s .

I f combustibles are in area, do NOT weld or cu t . Move t h e work i f p r a c t i c a b l e , t o an area free of combustibles. A v o i d pa in t sp ray rooms, d ip t anks , s to rage a r e a s , v e n t i l a t o r s . I f t h e work can not be mved , move combustibles a t least 10 metres away out of reach of sparks and heat ; or p ro tec t aga ins t i gn i t i on w i th su i t ab le and snug- f i t t i ng f i r e - r e s i s t an t covers or sh ie lds .

Walls touching combustibles on opposite s ides should not be welded on ( o r c u t ) . Walls ,cei l ings, and f l o o r n e a r work should be pro tec t ed by hea t - res i s tan t covers o r sh i e lds . Fire watcher must be s tanding by w i t h s u i t a b l e f i r e e x t i n g u i s h i n g equipment during and for some t ime a f te r weld ing o r c u t t i n g i f :

(1) combustibles ( inc luding bu i ld ing cons t ruc t ion) are wi th in 10 metres. (11) combustibles are fu r the r t han 10 metres b u t can be i g n i t e d by sparks. (111) openings (concealed or v i s i b l e ) i n f l o o r s or wal ls within 10 metres

(1V) combustibles adjacent t o w a l l s , c e i l i n g s , r o o f s , o r metal p a r t i t i o n s may expose combustibles to spa rks . ,

can be i g n i t e d by r ad ian t or conducted heat.

A f t e r work is done, check t h a t area is f r e e of sparks, glowing embers, and flames.

An empty container that held &mbust ibles , or can produce flamable vapors when heated, must never be welded on or cut, u n l e s s c o n t a i n e r h a s f i r s t been cleaned as descr ibed ifi AS.1674-1974;the S.A.A. Cutting and Welding Safety Code. This includes: a thorough steam or caustic c leaning (or a so lvent o r water washing, depending on the combust ible 's solubi l i ty) fol lowed by purging and iner t ing with n i t rogen or carbon dioxide, and using protective equipment as recommended i n AS.1674-1974. W a t e r - f i l l i n g j u s t below working l e v e l may s u b s t i t u t e f o r i n e r t i n g .

Hollow cas t ings or con ta ine r s m u s t be vented before welding or c u t t i n g . They can explode. Never weld or c u t where the a i r may conta in flammable dus t , gas , o r l iquid vapors such as petrol).

5. Shock Prevention

Exposed conductors o r o t h e r bare metal i n t h e w e l d i n g c i r c u i t , or ungrounded e l e c t r i c a l l y alive equipment can f a t a l l y shock a person whose body becomes a con- duc tor . Ensure tha t - the machine is correctly connected and earthed. If unsure have machine i n s t a l l e d by a q u a l i f i e d e l e c t r i c i a n . On mobile or portable equipment, regular ly inspec t condi t ion of t r a i l i n g power leads and connecting plugs. Repair o r rep lace damaged leads .

6 . Electrode Holders and Connectors

Fu l ly i n su la t ed electrode holders should be used. D o no t use ho lders wi th p ro t ruding screws. Ful ly insulated lock-type connectors should be used t o j o i n welding cable lengths .

7 . Terminals

Termina ls and other exposed par ts of e l e c t r i c a l u n i t s s h o u l d have in su la t ed knobs or covers secured before operation.

d

SAFE PRACTICES I N USING WELDING EQUIPMENT

Produced by Welding Indus t r i e s of Australia P t y . L t d . i n t h e i n t e r e s t s of improving operator safety. These notes should be considered only as a b a s i c guide to Safe Working Habits. A f u l l list of Standards pertaining to indus t ry i s avai lab le from h e Standards .Association of Aus t r a l i a , a l so va r ious S t a t e Electricity Au thor i t i e s , Departments of Labour and Industry or Mines Depart- ment and o the r Local Health or Safety In8pection Authorit ies may have additional requirements.

1. A neat unc lu t te red work area makes for safe working hab i t s .

2. Burn Prevention

The welding arc is intense and visibly bright . Its rad ia t ion can damage eyes; penetrate l igh tweight clothing, r e f l e c t f r o m l ight-coloured surfaces, and burn the sk in and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are mre severe and painful.

Wear protective c l o t h i n g - leather {or asbestos) gaunt le t g loves, hat , and safety-- baota. Button shirt collar and pocket flaps, and wear c u f f l e s s trousers to avoid entry of sparks and s lag .

NEVER Ixx)K AT AN ARC WITHOUT P ~ C T I O N .

Wear helmet w i t h sa fe ty goggles or g lasses w i t h side shields underneath, appropriate f i l t e r l e n s e s or plates (protected by clear cover g l a s s ) . Thia is a MUST for welding or c u t t i n g , (and chipping) to p ro tec t t he eyes f r o m radiant energy and f lying metal. Replace cover g l a s s when broken, pit ted,or spattered.

Avoid oi ly or greasy c lo th ing . A spark may ignite them. Hot metal such as electrode stubs and workpieces should never he handled without gloves.

Ear plugs should be worn when welding in overhead posit ions or i n a confined space. A hard hat should be wurn when o t h e r s work overhead.

Flanmvlhle h a i r p r e p a r a t i o n s should not be used by persons i n t e n d h g to weld or cu t .

3. Toxic Fume Prevent ion

Adequate v e n t i l a t i o n is essent ia l . Severe discomfort , i l lnesa o r death can result from fumes, vapors, hea t , or oxygen enrichment or dep le t ion that, welding (or cu t t ing ) may produce. Prevent them w i t h adequate ventilation. NEVER ven t i l a t e w i th oxygen.

Lead, cadium, zinc, mercury, and beryllium bearing and similar materials when welded ( o r c u t ) may produce harmful concentrations of t o x i c fumes. Adequate local exhaus t ven t i l a t ion m u s t be used, or each person in the area a s well as t h e operator m u s t wear an a i r -suppl ied respirator . For beryl l ium, both m u s t be used. Heta ls coated w i t h or containing materials that emit fumes should no t be heated un less coa t ing is remved f r o m the wrk su r face , t he area is well ven t i l a t ed , or the ope ra to r weare an a i r - suppl ied resp i ra tor .

Work i n a confined space only whila it is being vent i la ted and, i f necessary, while wearing a i r -suppl ied respirator .

Vapors from chlor ina ted so lvents can be decomposed by the hea t of the arc (Or flame) to form PHOSGENE, a highly toxic gas , and lung and eye i r r i t a t i n g products. The u l t r a - v i o l e t ( r a d i a n t ) energy of the arc can a lso decompose t r ichlorethylene and perchlorethylene vapors to form phosgene. Do n o t WELD or c u t where solvent vapors can be drawn into the welding or cutt ing atmosphere o r where t h e radiant energy can pene t r a t e t o atmepheres containing even minute a m u n t s of t r i c h l o r e t h y l e n e or percholorethylene.