WIA Weldarc 300 Owner's manual

CAT.

12/88

1.

~'OI?ERATTlT:'NG

AND

MAINTENANCE

INSQRUCTIONS'

INTRODUCTION

GENERAL

This manual ba,s been prepared es,peciallg.for us'e

in

familiarising

personnel wi.-th"the design, installation, operation, maintenanbe

and troubleshooting

of

this equipment,

All

information presented

herein

should

be ..given

..careful

consideration

to

assure optimum

performance,

of

this equipment.

WCEIVING/HANDLING

Prior

to

installing this equrpment, clean

alb

packing material

from

around

the unit

and

carefully inspect

for

any

damage that

may

have occurred during shipment., Any

claims

for

loss

or

damage

.that

may

,have. occurred in.. transit must .be

fi.led.~by

the

purchaser. with Welding Industries

of

Austraj:ia'Pty.-.

Ltdb

or.

authorised agent immediately (refer

to

EQUIPMENT URRANTY

CARD

enclosed with Operating Instruction

Manual)

SAFETY

Before the equipment is put into operation,

the

SUETY PRACTICES

section.at- :the

bgck,

of this

Lmanual

MUST

BE

READ

COMPLETE1;Y0

This

will.

.help.

ayoid

possible

injury

due

to

plisuse

or

improper

welding applica$iQn,$!.

.C

..O

N

T

E

,I$

T,

.S

,PAGE

Installation,

Operati'on,

'Maintenance

1

Parts Idst

-

Assembly

Drawing

NO':

MC30-01

2

Assembly Drawing

lVo*

MC3O-Ol

3

Pmts List

Transformer

Rssem'bly

Drawing

No.

MC30-lO/l

4

Transformer

Asse'mbly

Drawing.

No,

'MC3O-lO/l

5

SAFETY ,mCPsCES

GUARANTEE

CARD

ATTACBWT

11

2.

WCLDARC

300

A

,C,

ARC

WELDER

MAXNTENRNCE

&

OPERATING INSTRUCTIONS

INSTALLATION: The welder is deslgned to operate on a singlo phase

415

volt,

50

hz

A,C.

supply,

Rated

Input Current

to

Australian Standard C97-1964 is

26

amps. On installation

your

electrical contractor

will

ensur0 that wiring

specifications

will

meet the local power Authority's requirements. However,

hia attention should be drawn

to

the

maximum short circuit

of

65

amps and

H.R.C.

fuses should

be

avoided

if

possible

or

this figure taken into account

when

selection

of

H.R.C.

fuses

is

mads.

Machine should

be

located

in

a

well

ventilated area,

i.e.

not

under bench

or

similar confined Bpaces,

RATING:

Manufactured ta Australian Standard

C97-1964,

the

Weldarc

300

is

rated

as follows:-

LOW

RANGE

-

80

Volts

Qp0n

circuit.

HIGH

RANGE

-

S5

Volts open circuit

130 ampa

25

Volts

10%

Duty

Cycle

190

amps

28

Volts

100%

Outy Cycle

170

amps

26

Volts

6%

Duty Cycle

250

amps

30

Volts

60%

Duty Cycle

230

amps

29

Volts

3%

Outy

Cycle

300

amps

32

Volts

4%

Duty

Cycle

Maxfium

Short Circuit Current

18

65

amps.

i

JECOMNENDED

WELDING

CABLE

SIZES:

For

Electrode and Work leads

to

100

Pt.

in

length.

use

1330/.0076 cable.

If

longer lengths are required

use

.l660/.0076

cable.

+OPERATING

PROCEDURE:

Connect the Work lead to the Work terminal and connect

the

Electrode lead to

the

selected current ranqe.terminal. Ensure that the

terminals

are

tight and secursly fastened.

For

light gauge welding, out

of

position wolding and special. electrode

applications, the low current,

high

open circuit voltage range

will

provide

the most stable welding conditions.

For

,higher duty

cycles

and

as

the current requirements

far

the particular

welding condition increases

(e.g.

8G

and

6G

Iron Powder and

6G

Standard

electrodes) arc stability

is

achieved by these higher currents and

the

high

current

low

voltage range

is

used.

Current

adjustment can

be

made

at

any.-time,.i.e. before

or

during

the

welding

cycle

and

is

achieved

by

turning the adjusting handle

on

top

of

the machine

which

raises

or

lowers the current indicator arm

in

the'calibration plate

slot.

The welding currant

is

indicated

by

the

position of the indicator

arm

to

the

current calibration plate, which

in

turn

has two ecalss on either

side

of

the

slot labelled

Low

Renge, High Range, which corresponds with the Electrode

terminals marked

in

a

similar manner.

The

rsading

is

taken

from

the scale

which represents

the

current range being used.

MAINTENANCE:

The

welder is

designed

to

draw

in

air

by convection means

from

the

bottom

of

the

case. In adverse conditions, dust and dirt can

be

drawn

in

with

this

air

and

it

ia

advisable every

6

months

to

blow

machine out

with

clean dry

air.

The

lead

screw bearings

are

of

the

self-lubricating

type

end

should

not

require any attention.

Ensure

et

all

timos

that

welding

leads

are securely fastened to machine

terminal8 and to work and Electrod6 Holders,

Ir

b

Q

I

P

h

1

I

ITEPI

NO.,

1

2

3

4

5

6

7

8

9

10

l1

12

13

14

4,

DMVING

MC.30-01

PARTS

LIST

ISSUE

1

~c30-10/1

MC30-54

MC30-53

AM1

6

MC30-49/2

080293'

09050

04050

37

MC;SO-59

~~11-32

080410

MC30-52

MC30-54/1

MC30-29

DESCRIPTION

TRAlVSFORMEEI

ASSEMBLY

CASE

BASE

ASSEMBLY

OUTPUT

TERMINAL

ASSEMBLY

SPACER

TUBE

EYE

NUTS

FIBRE

'GJASHEII

SET

SCmWS

CURRENT

INDICATOR

ARM

ADJUSTING WDLE

DOME

NUT

FRONT

PmL

BOTTPOM

BACK

€'AXEL

SUPPLY

TERMINAL

ASSEJ9BLY

5.

C

DRAWlN

G

MC

30

-10/1

/-""

0

U

I

c:

I;

1

I

XTlPl

NO,

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

l6

17

18

19

6.

PART

NO,

MC35-1/1

T/icg5"/2

~~30-1.1

~~30-12

"230-l

3

~~30-15

~c30-21/2

MC33-16

~C30-28

MC30-26/1

MC30-26/2

~~20-

30

~~20-31

MC4O-14

0615050

0655050

06010F

08010

081-4s

DESCRIPTION

22/2"

x

1%"

x

.02Qtt

LAMEI!TATIONS

3-1/7"

X

.l.,/,''

X

.020"

LAMINATIONS

BOTTOM

COXE

CLAMP

TOP

CORE

CMP

(FRONT)

TOP

corn

CLAMP

(REAR)

SIDE

CLRMPS

SECONDARY

COIL

PRIMRIiY

COIL

BEARING

BLOCKS

ADJUSTING

SCREW

TEHXION

NUT

COMPRESSION

SPRING

COMPFtESSION

SPRING

LIPTIKG

STRAP

-j/8"W

x

1St1

EoH0

Bolt

3/8"l.J

X

51/2"

H,

Bolt

3/8"IJ

HEX

NUT

~lt

FLAT

STEEL

WASHER

,/,tfbJ

HEX

HALF

NUTS

U

-

..“I8I

SAFE

PRACTICES

IN

USING

WELDING

EQUIPMENT

Produced by Welding Industries of Australia Pty. Ltd.

in

the interests of

improving operator safety. These notes 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 Depart-

ment and other Local Health or Safety Inspection Authorities may have

additional requirements.

1.

A

neat uncluttered work area makes for safe working habits.

2.

Burn Prevention

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.

Skin

burns resemble acute sunburn, those from gas-shielded

arcs are mre severe and painful.

Wear protective clothing

-

leather (or asbestos) gauntlet gloves, hat, and

safety-toe boots. Button shirt collar and pocket flaps, and wear cuffless

trousers to avoid entry of sparks and slag.

NEVER

LOOK

AT

AN

ARC

WITHOUT

PROTECTION.

Wear helmet with safety goggles or glasses with side shields underneath,

appropriate filter lenses or plates (protected by clear cover glass). This

is

a

MUST

for welding or cutting, (and chipping) to protect the eyes from

radiant energy and flying metal. Replace cover glass when broken, pitted,or

spattered.

Avoid oily or greasy clothing.

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 positions or

in

a confined

space.

A

hard hat should be worn when others work overhead.

Flammable hair preparations should not be used by persons intending to weld

or cut.

3.

Toxic Fume Prevention

Adequate ventilation

is

essential. Severe discomfort, illness or death can

result from fumes, vapors, heat, or oxygen enrichment or depletion that welding

(or cutting) may produce. Prevent them with adequate ventilation.

NEVER

ventilate with oxygen.

Lead, cadium, 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

it

is

being ventilated and, if necessary,

while wearing air-supplied respirator.

Vapors 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 wel.ding or cutting atmosphere

or where the radiant energy can penetrate

to

atmospheres containing even minute

amounts

of

trichlorethylene or percholorethylene.

4.

Fire and Explosion Prevention

Causes of fire and explosion are:- Combustibles reached by the arc, flame, fly-

ing sparks, hot slag, or heated material; misuse

of

compressed gases and cylin-

ders; and short circuits.

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 goggled operator. Sparks and slag can

fly

10

metres.

To prevent fires and explosions:- Keep equipment clean and operable, free of

oil, grease, and (in electrical parts) of metallic particles that can cause short

circui.

ts

.

If combustibles are

in

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.

Fire watcher

must

be standing by

with

suitable fire extinguishing equipment

during and for some time after welding or cutting if:

(l)

combustibles (including building construction) are within

10

metres.

(11)

combustibles are further than

10

metres but'can be ignited by sparks.

(111)

openings (concealed or visible)

in

floors or walls within

10

metres

(1V)

combustibles adjacent to walls, ceilings, roofs, or metal partitions

-

may expose combustibles to sparks.

can be ignited by radiant or conducted heat.

After work

is

done, check that area

is

free of sparks, glowing embers, and flames.

An

empty container that held combustibles, or can produce flamable vapors when

heated, must never be welded on or cut,

unless

container has first been cleaned

as described in AS.1674-1974, 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 vapors such as petrol).

5.

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 con-

ductor. 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.

6. Electrode Holders and Connectors

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.

7.

Terminals

Terminals and other exposed parts of electrical

units

should have insulated knobs or

covers secured before operation.

C

0

m

2

b

ITEM

NO,

1

2

3

4

S

6

7

8

9

10

11

12

13

L4

15

16

17

18

19

20

21.

22

23

24

28

PART

NUMBER

hfc30-l0

M30-36/1

hdc30-37/1

N30-38

m3040

wrm

kK3049/2

0802

9F

09050

@406037

MC2043

NlO-32

08

041

0

m30-37/2

W30-36/2

E30-36/3

W30-29

MC30-0/20

Mc30-0/21

W30-0/22

0416032

10010

_""""".

..

...

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

PART

NO,

,

n

0

,.

,

..

.

..

I.

rrml

?I(

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

wvr

NU,

hC35-1/1

W35-1/2

Aic30-ll

hE3O-12

hK30-13

x30-18

!X30-21/2

liC30-16

m30-28

XIC30-2B/l

hIc30-26/2

MC20-30

hic20-31

bE40-14

061

5050

0655050

06010k'

08

01

0

081411

"

ir

7

L

b

Q

I

@B

YELDARC

300

A

IC,

ARC

WELDER

MAIN7'ENRNCE

&

OPERATING INSTRUCTIONS

INSTALLATION:

Ths

welder:

is

designed

to

operate

on

a

single

phase

415

volt,

50

hz

A.C.

supply.

RakarS

Input

Current

to Australian Standard

C97-l964

is

28

amps.

On

installation your

electrical

contractor

will

ensure that wiring

specifications

will

meet

tho

local

power

AuthoriCyls

requirements,

However,

his

attention

should

be

drawn

to

the maximum

short

circuit

of

65

amps

and

H.R.C.

fuses

should

be

avoided

if

possible

or

this figure taken into account when

selection

of

H.R.C.

fuses

is

made.

Machine

should

be

located

in

a

well

ventilated

area,

i.e.

nat

under

bench

or

similar confinad spacesr

RATING:

Manufactured to Australian Standard

C97-1964,

the Weldarc

300

is

rated

as

follows:-

LOW

RANGE

-

ao

VOL~S

opan

circuit'

HIGH

RANGE

-

55

Volts

open

circuit

130

amps

25

Volts

100%

Duty

Cycle

19Q

amps

28

Volts

100%

Outy

Cycle

170

amps

26

Volts

6%

Duty Cycle

250

amps

30

Volts

6@

Outy Cycle

238

amps

29

Volts

30%

Duty

Cycle

300

amps

32

Volts

40%

Duty

Cycle

Maximum

Short

Circuit

Current

is

65

amps.

i

RECOMMENDED

WELDING

CABLE

'SIZES:

For

Electrode and

Work

leads

to

100

Pt.

in

length.

use

1330/.01176

,cabl.e.

If

longer lsngths

are

required use

,l680/.00?6

cabls.

OPERATING

PROCEDURE:

Connect the Work

lead

to the

Work

terminal and connect

the

Electrode lead to the selected current range.tarmina1. Ensure that the

-

terminals

are

tight

and

securely fastened.

For

light

gauge

welding,

out

of

position welding and special electrode

applications,

the

low

current,

high open

circuit

voltage

range

will

provide

the

most;

stable

welding

conditions.

For

,higher duty cycles and

as

the current requirements for

the

particular

welding condition ihcreases (e.g.

8G

and

6G

Iron Powder and

6G

Standard

electrodas)

arc

stability

is

achieved

by

these higher currents and the high

current

low

voltage

range

is

used.

Current

adjustment can be

made

at

any-fime,

i.er

before

or

during the welding

cycle

and

is

achieved by turning the adjusting handle

on

top

of'

the

machine

which

raises

or

lowers the current indicator

arm

in the calibration plate slot.

The welding

current

is

indicated

by

the

positian

of

the

indicator

arm

to

the

current calibration plate, which

in

turn has two

scales

on either side

of

the

slot

labelled

Low

Rangs, High Ranga, which corresponds with the Electrode

terminals

marked in

a

similar

manner. The reading

is

taken

from the

scala

which represents the current range being ussd.

MAINTENANCE:

The

welder

is

designed to

draw

in

air

by

convection means

from

the

bottom

of

the

cam.

In

aduerae

conditions, dust and

dirt

can

be

drawn

in

with this

air

and

it

ia

advisable every

6

months

to

blow machine out. with

clean

dry

air.

The lead

screw

bearings

are

of

the self-lubricating type and

should

not

require any attention.

Ensure

at

a11

timos that welding

leads

are

securely fastened

to

machine

terminals

end

to

work

and

Eiactrode

Holders.

P

E

c

l

5.

U

"--PP

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WIA Weldarc 300 Owner's manual

WIA Weldarc 300 Owner's manual

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