WELDMATIC 200

MODEL NO. CP15

CAT. 7522

8/81

FROM SERIAL NO.

1 5 2 7 - 1

THE INFORMATION CONTAINED IN THE FOLDER IS SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER IS KEPT IN A SAFE PLACE FOR READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NO. OF THE MACHINE AND THE PART NO. OF THE ITEM

IN UNNECESSARY DELAYS IN SUPPLYING THE CORRECT PARTS. REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

SALES AND SERVICE DIVISIONS Melbourne 429 4766 Sydney 534 2144 Newcastle 61 1 6 6 8 Adelaide 352 3022 Perth 3 6 1 7088 Brisbane 44 1391

STATE AGENTS Launceston 31 7004 Darwin 8 1 6 4 2 7 & 84 3076

OPERATING AND MAINTENANCE INSTRUCTIONS

WELDMATIC 200 (CP15)

INTRODUCTION

GENERAL.

This manual has been prepared especially for use in familiar- izing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All inform- ation presented herein should be given careful consideration to assure optimum performance of this equipment.

RECEIVING/HANDLING Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for losses or damage that may have occurred in transit must be filed by the purchaser with Welding Industries of Australia Pty. Ltd., or authorised agent immediately (refer to EQUIPMENT WARRANTY card enclosed w i t h Operating Instruction Manual).

When requesting information concerning this equipment, it is essential to supply correct Model identification and machine Serial Number.

SAFETY Before the equipment is put into operation, the SAFETY PRACTICES section at the back of this manual MUST BE READ COMPLETELY. This will help avoid possible injury due to misuse or improper welding applications.

CONTENTS PAGE NO.

General Description 1

Setting Up for Operation 2 & 3

Welding Operation Instructions 4

Maintenance Instructions 5 & 6

Welding Data Table 6

Parts List CP15-Q1 7

Assembly Drawing CPP5-01 8

Circuit Diagram CP15-C2 , 9

Accessory Leads

AM118 Mobile Kit Assembly

Safety .Practices

Guarantee Card

10

11

- 1 -

STANDARD U N I T

The c o n s t r u c t i o 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 des- i g n e d f o r i n s t a l l a t i o n a n d o p e r a t i n g i n a wide v a r i e t y of a p p l i c a t i o n s , s u c h a s h i g h p r o d u c t i o n f a c t o r i e s a n d g e n e r a l f a b r i c a t i o n s h o p s .

"WELDMATIC" P l a n t s c o n s i s t o f t h r e e basic u n i t s : -

1. C o n s t a n t P o t e n t i a l Rect i f ier Power Source .

2 . Semi-Automatic Wire Feeder

3 . Welding Gun and Cable Asse.mbly.

S e p a r a t e o p e r a t i n g a n d m a i n t e n a n c e i n s t r u c t i o n s are p rov ided f o r t h e wire feeder and gun cab les .

1. POWER SOURCE - FEATUIiES - The s t a n d a r d C . P . r e c t i f i e r power source i s h o u s e d i n a d r i p - p r o o f e n c l o s u r e . L i f t i n g l u g s a re 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 . Wheel mount ing wi th four so l id . rubber ty red wheels i s p r o v i d e d , t h e two f r o n t w h e e l s are s t e e r a b l e p e r m i t t i n g e a s y movement in rest r ic ted f l o o r s p a c e . A push ba r i s pro- v i d e d o n t h e f r o n t o f the machine and a g a s c y l i n d e r ca r r i e r w i t h a s u p p o r t bracket a n d c h a i n a t t h e rear. A swivel mount- i n g f o r t h e wire feeder i s f i t t e d t o t h e t o p o f t h e power source.

A l10 v o l t p l u g s o c k e t i s l o c a t e d o n t h e rear p a n e l fo r connec- t i o n of gas p r e h e a t e r when w e l d i n g w i t h C 0 2 g a s s h i e l d . Located on t h e f r o n t p a n e l are 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 power O N / O F F ) , f i n e v o l t a g e s e l e c t i o n s w i t c h , c o n t r o l fu ses , wire feeder p l u g s o c k e t a n d r ec t i f i e r power o u t p u t s o c k e t s .

2 . CONSTRUCTION

The power s o u r c e i s 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 Rectifier D . C . Welder, w i t h a t h r e e p h a s e t r a n s f o r m e r a n d a t h r e e p h a s e rec t i f ie r br idge . Connec ted i n t h e o u t p u t c i r c u i t i s an induc- t a n c e 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 " o r d e g r e e of s l o p e n e c e s - s a r y for 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 of t h e s i l i c o n d i o d e s , t r a n s f o r m e r w i n d i n g s a n d i n d u c t a n c e u n i t is by a s i n g l e p h a s e a x i a l f a n . The power source i s p r o t e c t e d a g a i n s t f a n f a i l u r e a n d o v e r h e a t i n g b y t h e r m o s t a t s m o u n t e d o n d i o d e h e a t s i n k s .

3 . WELDING PROCESS

Gas metal a rc w e l d i n g w i t h i n t h e c a p a c i t y of t h e power source can be carried o u t w i t h t h e f o l l o w i n g e q u i p m e n t : -

a ) Semi-automatic wire feeder model W17. b) W17 Semi-automatic wire f e e d e r w i t h s p o t timer AM128. c ) "Hobart" spool gun weld ing un i t model SP9 w i t h CV2 c o n t r o l l e r . - d ) "Mini-mig" push and p u l l g u n a n d c o n t r o l .

4 . WELDING CAPACITY ~I._"

Power Source Capac i ty i s as f o l l o w s : - 200 Amps, 25 volts, 1 0 0 % d u t y c y c l e .

- 2 -

5. " SUPPLY AND WEEDING CABLES. ",".- -.

Power Sources are suitable for connection to a 415 v o l t 50 Hertz 3 phase supply.

The reconmended fuse size, primary cable size and welding cable size are as follows:-

a) Fuse - 15 amp b) Primary Cable - 4 core 3 2 / 0 . 2 0 T.R.S. c) Welding Cable - 792/0.20 T.R.S.

6 . SHIELDING GASES.

a) Welding Grade C02 for all mild and alloy steel weldiny in thicknesses ranging from 1 nun upwards.

b) Argon/C02 or Argon/Oxygen mixtures for all applications on low currents requiring minimum of spatter on sheet steel and for stainless steel welding,

c) Argon/Oxygen and Argon/C02 mixtures for prime welding of stainless steel .

cl) Argon (pure) for all aluminium welding.

" "

7. SETTING UP TJNIT FOR OPERATION. a) General Assembly " of Packaged Plant The power source is shipped on its skid base. Wheels, handle, bottle carrier and bottle cradle should be assembled as shown on drawing AM118. W17 Wire Feeder is fitted to the top.of power source in the special swivel mount on the machine. Fit the W14-16 pivot pin assembly to the wire feeder and ensure fibre thrust washer is on the pin before locating in the swivel mounting. Check that wire feeder is free to swivel in all directions, if necessary apply a small amount of graphite

"___.I

grease to s h a f t .

b) Connection To Mains Supply " Note: This work should only be done by a qualified electrician. The power source is designed for connection to 415 v o l t , 50 hertz, 3 phase supply and the supply voltage should be ascer- tained before connecting the machine. Access to supply csnnec- tion terminals in machine may be gained by removing left hand side panel. Use a flexible 4 core primary cable for portable machines and cla.mp cable to ensure that there is no strain on cable connections. The earth (or ground) connection (green/ yellow) must be securely fastened to the 'earth' terminal on the machine adjacent to the supply connection terminals. CAUTION Before inserting primary cable plug in mains supply socket, ensure that switch on both plug socket and welding machine is in'OFF' position.

c) Connection of Cables/Hoses, etc.

With unit switched 'OFF' connect control cable (4 pin plug) from power source to wire feeder. Connect gas hose from wire feeder to gas regulator/flowmeter, ensuring all connections 'are tightened firmly. If C02 Gas Shield is being used, plug heater into 110 volt socket at rear of u n i t . Next inser.t

-3-

gun c a b l e i n t o s o c k e t o f wire f e e d e r ou tpu t gu ide . Connec t "Gas Hose" and "Gun S w i t c h " l e a d s 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 d o n e w i t h e l e c t r o d e wire c o n n e c t e d t o " p o s i t i v e " p o l e commonly known a s D . C . reverse 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 l e a d from 'l+''

socke t ommach ine t o t e rmina l l ug on gun cable. The work l e a d ( " n e g a t i v e " ) s h o u l d b e p l u g g e d i n t o t h e ''-'l s o c k e t o n the mach ine . The p l u g s of t h e w e l d i n g cables m u s t b e f u l l y i n s e r t e d i n t h e s o c k e t s , 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 . To a v o i d e r r o r , w e l d i n g s h o u l d n o t b e a t t e m p t e d u n t i l a l l c o n n e c t i o n s h a v e , . b e e n s e c u r e d . The wire feeder may b e i n s t a l l e d remote from t h e power sou rce , i n wh ich case e x t e n s i o n lead sets compr i s ing power cab le , gas hose a n d c o n t r o l c a b l e ( f o u r c o r e ) are 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 d e s i r e d l e n g t h , s t a n d a r d l e n g t h ava i lab le from s t o c k is 9 metres.

e ) Wire Feeder and Gun Cable

F i t a spool o f wire t o t h e wire feeder (see n o t e s i n "Wire Feeder 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 f ec 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 r e v e n t " o v e r - r u n " when wire f e e d s t o p s . The wire d r ive r o l l s and i n l e t wi re gu ide shou ld be s e l ec t ed i n a c c o r d a n c e w i t h t h e . d i a m e t e r a n d t y p e o f wire be ing u sed . Refer t o c u r r e n t wire feeder m a n u a l f o r c o r r e c t s e l e c t i o n of wire feed rolls and input guides.

0 .8 mm = 0 . 0 3 0 " 0 .9 mm = 0 . 0 3 5 " 1 . 2 mm = 0.045"

The gun c a b l e a n d gun are n o r m a l l y 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 a n d l i n e r s p r i n g f o r wire 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 are corxect s i z e f o r wire b e i n g u s e d .

- 4 -

WELDING OPERATION INSTRUCTIONS I

8. SINGLE FUNCTION CHECK

U n i t is now r e a d y f o r o p e r a t i o n , b u t p r i o r t o commencing weld- i n g , t h e f o l l o w i n g " f u n c t i o n s c h e c k " i s recommended s w i t c h on power sou rce and check a i r f low. See t h a t a l l we ld ing lead p l u g s are i n s e r t e d i n the c o r r e c t p o l a r i t y s o c k e t s - e l e c t r o d e " p o s i t i v e " , work "negat ive" . Check a11 we ld ing connec t ions and 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 "worlc" clamp.

Next ensure t h a t a l l ! c o n t r o l cables and gas h o s e s are s e c u r e l y connected and 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 . S w i t c h on wire feeder, i n d i c - a t o r 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 fu l l -y and check con ten t s gauge fo r adequa te gas supp ly .

Press "Gas Purge" s w i t c h and set gas 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 f low i s adequate f rom gun nozz le . S e t "wire s p e e d " c o n t r o l t o desired wire speed . Press "wire i n c h " s w i t c h and check wire f e e d f o r c o r r e c t p r e s s u r e on d r i v e r o l l s . 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 feeding th rough gun and c a b l e .

Next , c lose gun swi tch momentar i ly for wire f e e d , g a s f l o w and welding power check. S e t t h e v o l t a g e s e l e c t o r s w i t c h e s i n a c c o r d a n c e w i t h r e q u i r e d v o l t a g e (see weld ing tab le) u n i t i s now r e a d y fo r we ld ing ,

9, SETTING O F W E L D I N G CURRENT AND VOLTAGE

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 by t h e 'wire s p e e d ' . The 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 s p e e d b y d r i v e r o l l s t h r o u y h the gun c a b l e t o t h e a rc a t a c o n s t a n t s p e e d , unchanged except when r e s e t by t h e 'wire s p e e d ' c o n t r o l . The h i y 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 .

".

The o u t p u t v o l t a g e of t h e power source when t h e gun s w i t c h i s c l o s e d , i s d i v i d e d i n t o a number of s t e p s by c o a r s e s e l e c t o r a n d f i n e s e l e c t o r switches. The ' c o a r s e ' s e l e c t o r s w i t c h i s a combined high/low range ON/OFF s w i t c h w o r k i n g i n c o n j u n c t i o n w i t h a " f i n e " s e l e c t o r swi t ch g i v i n g 2 0 v o l t a g e s t e p s .

The f o l l o w i n g s e q u e n c e o f w e l d . s e t t i n g i s recommended:-

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

b ) Se lec t w e l d i n g c u r r e n 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 l o w i n g t h e s e t t i n g s of wire s p e e d a n d v o l t a g e shown on the s e t - t i n g cha r t . To " t u n e " each weld s e t t i n g , a d j u s t wire speed o n l y .

c ) If v o l t a g e is t o o low f o r t h e a p p l i c a t i o n , wire " s t u b b i n g " w i l l o c c u r , p a r t i c u l a r l y a t s t a r t of weld and weld c o n t o u r w i . 1 1 be ve ry convex . If t h e v o l t a g e i s t o o h i g h , met.al t r a n s - f e r w i l l be e r r a t i c w i t h e x c e s s s p a t t e 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 w i l l be an opt imum t u n e d w e l d i n g c o n d i t i o n w i t h a s m o o t h s p a t t e r - free arc .

- 5 -

1 0 . SAFETY DEVICES

I n t h e e v e n t o f t h e power source becoming overheated t h e ther - m o s t a t s o n t h e d i o d e h e a t s i n k s w i l l o p e r a t e p r e v e n t i n g f u r t h e r welding. The . thermostats will a u t o m a t i c a l l y reset an.d w i t h t h e c o o l i n g f a n o p e r a t i n g t h i s w i l l t ake approx ima te ly 10 minutes . A check should be made t o a s c e r t a i n t h e r e a s o n f o r t h e o v e r h e a t i n g s u c h as f a n n o t o p e r a t i n g o r a i r f low rest r ic- t e d . F u s e s p r o v i d e d f o r a l l c i r c u i t s are as fo l lows and are i n d i c a t e d o n t h e f r o n t p a n e l : -

Fuse E l - 3 amps ( Delayed ac t ion ) Fuse E2 - 3 amps ( Fuse E 3 - 5 amps ( Fuse E4 - 5 amps (

11. MAINTENANCE

a ) Power Source

Apart f rom t h e f a n t h e r e c t i f e r h a s n o r o t a r y c o m p o n e n t s , To ach ieve comple t e d i s s ipa t ion o f hea t f rom t h e ac t ive componen t s , t h e r e c t i f i e r s h o u l d b e t h o r o u g h l y blown off w i t h dry compressed a i r a f t e r 6 mon ths ' ope ra t ion . C lean ing sh -ou ld be c a r r i e d out. a t s h o r t e r i n t e r v a l s i f d u s t a c c u m u l a t i o n i s c o n s i d e r a b l e .

P r i o r t o c l e a n i n g , remove t h e u n i t c o v e r by de tachment o f lugs a n d t h e f i x i n g screws. Thus a l l the components of the power s o u r c e w i l l be accessible.

b ) The wire feed motor /gearbox i s p re -packed w i th grease and needs no o the r l ub r i ca t ion . Change t he g rease a f t e r approx ima te ly

II II

II 'I

ll I '

)

1 4 , 9 0 0 service h o u r s . . (see Wire -Feede r In s t ruc t ions Manua l )

The d r i v e r o l l e r s and t h e i n n e r wire g u i d e s s h o u l d b e k e p t c l e a n . If necessa ry , b low off t h e i n s i d e o f t h e wire f e e d e r w i t h com- p r e s s e d a i r .

c ) Gun and Cable

Remove any spa t t e r wh ich mic& a d h e r e t o t h e n o z z l e b o r e so t h a t t h e s h i e l d i n g gas o u t f l o w i s not impeded. The condi t ion o f t h e c o n t a c t t u b e s s h o u l d b e r e g u l a r l y c h e c k e d . Damaged and/or b u r n t t u b e s are a n i m p e d i m e n t 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 and should be rep laced immedia t e ly .

T r o u b l e - f r e e o p e r a t i o n d e p e n d s t o a l a r g e e x t e n t on 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 o b s e r v e t h e a r c 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 tance t h a t t h e w e l d e r 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 .

- 6 -

13. STOPPAGES AND THEIR ELIMINATION

The machine should be checked only by a f u l l y s k i l l e d e lec t r ic - i a n .

I f t h e u n i t s t o p s w o r k i n g , f i r s t d e t e r m i n e w h e t h e r s t o p p a g e s are i n i t i a t e d b y t h e m a i n s ( f o r i n s t a n c e , b u r n t f u s e ) o r by t h e s u p p l y c a b l e ( loose c o n n e c t i o n , c a b l e b r e a k ) o r by t h e u n i t p r o p e r .

I f t h e t h r e e t e r m i n a l s Ill, L2 and L 3 on t h e p r i m a r y t e r m i n a l boa rd are c o r r e c t l y c o n n e c t e d t o t h e m a i n s ( v o l t m e t e r r e a d i n g ) 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 b e 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 on 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 o f t h e d e . f e c t .

018mm COARSE V0 LT S

:*O30”)

WIRE SPEED DIAL SETTING

-

WIRE SPEED DIAL SETTING

-

1.2mrn COARSE

FINE (1 0 4 5”) VOLTS

SETTINGS GIVEN FOR C02 SHIELDIWG GAS.- FLOW RATE 8- lOLlTRES/MIHU1IE. USE THIS CHART AS A PRELlWlladARY SETTING GUIDE. TO ‘TUNE’ EACH WELD SEPTIHG, ADJUST WIRE SPEED ONLY. FOR FURTHER DETAILS, lHCLUDlNG USE OF ARGON MIXED GAS REFER MANIHA1.

I f mixed gases 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 still pro- 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 o r optimum 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 b e n e c e s s a r y - i n g e n e r a l t h e v o l t a g e s e t t i n g w i l l need t o b e r e d u c e d . Recommended gas f l ow ra te for mixed gas,es i s 10 - 1 5 l i t r e s / m i n u t e .

ITEI NO.

1 2

3

4 5 G

7

8 . 9

10 11 1 2

13

P4

15 1 6

1 7 1 8

L9 20

2 1 22

23 24

l1

25

? G !7

PART NO.

CP15-34

CP15-12

CP15-14

CP15-01/4

CP24-0/5

CP15-35

CP15-0/7

CP15-0/9

w1-22

W1-23

CP25-0/18

CP25-0/3.9

CP15-0/14

2P15-32

ZP15-33 .

c1P15-27

2P15-28

W3 5 JP15-0/20

K 1 4 - 1 / 1 4

VIN4 4

U N 8 1

:P-l5-0/2 8

:P15-01/26

:P15-30

DESCRIPTION

BASE ASSEMBLY

TRANSFORIWR ASSEMBLY

INDUCTANCE ASSEMBLY

FAN BLADE

FAN MOTOR

W C T I F I E R ASSEMBLY

3EATER PLUG SOCKET

mLDING CONTACTOR

INDICATOR LIGHT

?USE HOLDER

?INE VOLTAGE SELECTOR SWITCH

30ARSE VOLTAGE SELECTOR SWITCH

:ONTROL PLUG

?RONT PANEL

3ACK PANEL

cop COVER

jIDE PANELS

IUTPUT TERMINAL ASSEMBLY

:ONTROL TERMINALS

IUPPLY TERMINALS

'YPE NO./SERIAL NO. PLATE

:YE NUTS

'ERMINAL CONNECTION NAMEPLATE

:ABLE ENTRY BUSH

!ABLE ENTRY BUSH

'RIMARY CABLE

IOOM ASSEMBLY *

IVOT MOUNTING FOR WIRE FEEDER

L

8

9

c-

' -T "

I

1 n

j

p L.

MIG ACCESSORY KIT LEADS FOR CP15 POWER SQURCE'Wl4P(17. WIRE FEEDER.

i,

N U T 1 TAIL.

F

Ln II

0

0

1

0 0 c

.G

0 .os , . " 0

r

,*-.

4 . F i r e and ExplosTon Prevention

Causes of €$re and explosTon aye:- Combustibles reached by the a rc , f lame, f ly - ing sparks , hot s lag, or heated mater ia l ; misuse of compressed gases and cy l in- ders ; and s h o r t c i r c u i t s .

Be aware . that f lying sparks o r f a l l i n g s l a g can pass through cracks, along pipes, through windows or doors , and through wal l or f loor openings, out . of s ight of the goggled operator. Sparks and s l a g can f l y L O metres.

To p r e v e n t f i r e s and explosions:- Keep equipment clean and operable, Eree of o i l , g r e a s e , and ( i n e l e c t r i c a l p a r t s ) o f m e t a l l i c p a r t i c l e s t h a t can cause short c i r c u i t s .

I f combust ibles are i n a r ea , do NOT weld o r c u t . Move the work i f p r a c t i c a b l e , t o an area f ree of combust ibles . Avoid pa in t spray 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 moved, move combustibles a t l e a s t 10 metres away out of reach of sparks and hea t ; o r p ro t ec t aga ins t i gn i t i on w i th s u i t a b l e and snug- f i t t i ng f i r e - r e s i s t an t cove r s o r sh i e lds .

Walls touching combustibles on opposi te s ides should not be. welded on (or c u t ) . Wal l s ,ce i l ings , and f loo r nea r work should be pro tec ted by hea t - res i s tan t covers o r s h i e l d s . Fire watcher must be standing by wi th su i t ab le f i r e ex t ingu i sh ing equi.pment during and f o r some time a f t e r welding OK c u t t i n g i f :

(1) combust ibles ( including bui lding construct ion) are within L O metres. (11) combus.t ibles are further than 10 metres but can be i g n i t e d by sparks . (11.1) openings (concealed o r v i s i b l e ) i n f loors o r wal l s w i t h i n 10 metres

(1V) combus t ib l e s ad j acen t t o wa l l s , c e i l i ngs , roo f s , o r me ta l pa r t i t i ons

"""-_ll-

may expose combust ibles to sparks .

can be igni ted by r ad ian t ox conducted heat.

Af te r work is done, check t h a t are'a is free of sparks, glowing embers, and flames.

An empty container that held combustibles, or can produce f lamable vapors when heated, must never be welded on o r c u t , 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 described i n AS.1674-1.974, the S.A.A. Cutting and Welding Safe ty Code. This includes : a thoxough steam o r causk ic .. cleaning...-(or a solvent 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 ni t rogen or carbon dioxide, and using protective equipment as recommended i n AS.1674-1974. Water - f i l l ing j u s t below working l e v e l may subs t i t u t e €o r i ne r t ing .

Ilollow cas t ings o r conta iners must be vented before welding or cutt ing. They can explode. Never weld o r c u t where t h e a i r may contain flammable dus t , gas , o r l i qu id vapor s such a s pe t ro l ) .

5 . Shock Prevention

Exposed conductors o r o the r ba re me ta l i n t he we ld ing c i r cu i t , o r ungrounded e l e c t r i c a l l y a l i v e equipment can f a t a l l y shock a person whose body becomes a con- ductor . Ensure that 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 o f t ra i l ing power . leads ... and..connectincj plugs. Repair o r r ep lace damaged leads.

6 . Electrode Holders and Connectors

Ful ly insu la ted e lec t rode ho lders should ,bc -used...:. D o ,no t use holders with protruding screws. Fully insulated lock-type connectors should be.used to join welding cable lengths .

7. Terminals

Terminals and other exposed par ts of e lectr ical uni ts should.have insulated knobs or covers secured before operation.

SAFE PRACTICES I N U S I N G WELDING EQUIPMENT

Produced by Welding Industr ies of Austral ia Pty. Ltd. i.n t h e i n t e r e s t s o f improving operator safety. These notes should be considered only as a bas i c guide to Safe Working Habits. A f u l l list of S tandards per ta in ing to indus t ry i s ava i l ab le from the S tandards Assoc ia t ion of Aus t ra l ia , a l so var ious S ta te E l e c t r i c i t y A u t h o r i t i e s , Departments of Labour and Indus t ry o r Mines Depart- ment and other Local Heal th or Safety Inspect ion Authori t ies may have additional requirements.

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

2 . Burn Prevention

The welding arc i s in t ense and v i s ib ly b r igh t . Its radiat 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 l ight-coloured surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded a r c s a r e more severe and painful .

Wear p ro tec t ive c lo th ing - Leather (or asbes tos) gaunt le t g loves , ha t , and sa fe ty - toe boo t s . Bu t ton sh i r t co l l a r and pocket flaps, and wear cuffless t rousers to avoid en t ry o f sparks and s l ag .

NEVER LOOK AT AN ARC WITHOUT PROTECTION.

Wear helmet with safety goggles or glasses with s ide shields underneath, a p p r o p r i a t e f i l t e r l e n s e s o r p l a t e s ( p r o t e c t e d by c l ea r cove r g l a s s ) . Th i s i s a MUST for weld ing or cu t t ing , (and ch ipping) to p ro tec t the eyes from radiant energy and flying metal. Replace cover glass when broken , p i t ted ,or spa t t e red .

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

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

Flammable hair preparations should not be used by persons in tending to weld o r c u t .

3 . Toxic Fume Prevention

Adequate v e n t i l a t i o n is essent ia l . Severe d i scomfor t , i l lness o r death can r e s u l t from fumes, vapors, heat, or oxygen enrichment or deple t ion tha t weld ing ( o r 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 ( o r c u t ) may produce harmful concentrations of tox ic fumes. Adequate loca l exhaus t ven t i l a t ion m u s t be used, o r each person i n t h e a r e a a s well a s the opera tor must wear an air-suppl ied respirator . For beryl l ium, both must be used. Metals coated with or containing mater ia ls that emit fumes should not be heated unless coat ing is removed from the work su r face , t he a r ea i s well ven t i l a t ed , o r t he ope ra to r wea r s an a i r - supp l i ed r e sp i r a to r .

Work i n a confined space only while it is be ing ven t i l a t ed and , i f necessa ry , while wearing a i r -suppl ied respirator .

Vapors from ckdorinated solvents can be decomposed by the hea t of t h e a r c ( o r flame) t o 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 io l e t ( r ad ian t ) ene rgy of the a r c can a l so decompose t r i ch lo re thy lene and perchlorethylene vapors to form phosgene. Do no t WELD o r c u t where solvent vapors can be drawn into the welding o r c u t t i n g atmosphere o r where t h e r a d i a n t energy can penetrate to atmospheres containing even minute amounts of t r ich lore thylene or percholorethylene.