WIA Weld n Charge Owner's manual

MANUFACTURED

BY

WELDING INDUSTRIES:

OF

AUSTRALIA

PT'Y

LTtj

EUUI

PMENT

MANUFACTURING

DIU1

SI

ON

i

12

Dawz.

Road, Edwards

t

own

,

Sou

t

h

SALES

BRANCHES

MelGuurnE

83

429

4766

AA324P3

Sydney

02

647

2655

AA24155

biewc;kstl

e

845'

61

1668

Wol

1

ongong

642

29

3447

Brisbane

07

344

135'1

clic.

3074

pi-I

83

465

Facsimile

U3

4.55

Aust.

5837

ph

88

276

Facsimile

08

276

Mac

kay

079

51

Adel

ai

de

88

352

Per

t

h

89

361

Laurrcestorr

003 44

WELD-t.1-C:HARGE

251i

AA32493

861

2

64P4

AA82856

8303

3532

3022

AA82856

76

88

AA92936

9322

THE

I

NFCIRPlATI

01.1

CONTAINED

IN

THE FOLDER

I

S

SET

OUT

TO

ENABLE

YOU

TO

PROPERLY

MAINTAIN YOUR

NEW

EQUIPMENT

AND

ENSURE THAT YOU OBTAIN

MAXIMUM

OPERATING'

EFFICIENCY,

PLEASE ENSURE THAT THIS

FOLDER

I

S

KEPT

IN

A

SAFE

PLACE

FOR

READY

REFERENCE

WHEN

REQUIRED

RETURN FlACHINE

TO

PLACE

OF

PURCHASE

OR

YOUR

NEAREST

WIA

SALES

AND

SERVICE

BRANCH

FOR

REPAIR

IF

FAULTY.

SAFETY

Before

this

equiprrter1t

is

put

into

operation,

the

SAFETY

PRACTICES

section

at:

the

back

of

the

Manual

MUST

BE

READ COPlPLETELY. This

will

help

avoid possible

injury

due

to

misuse

or

improper

welding

applications.

I

WELD-1.1-CHARGE

PlANUAL

PAGE

1

CONTENTS

General

Description

1

Prepara

t

i

or1

for.

Me1

di

nq

Opera

t

i

or1

1

Preparation

for

Battery

Charging Operation

2

War

rl

i

n

CJS

3

Servicing

3

Safe

Practices in Using Electric

Arc

Processes

and

Equiptment

3

Opera.tor's Personal Protection

3

Operating Precautions

4

Uerl

t

i

l

a.

t

i

on

5

Fire and Explosion Prevention

5

Page

Mu

I

GENERAL

DESCRI

PT1

ON

The

Model

MC81

Hobby

Welder

is

a

smal

1

,

lightweight portable

k.C.

arc

welding machine

of

the fixed tapped transformer

design, suitable

for

marrual

arc

welding Iwith

2.5mm

and

3.25mm

coated electrodes,plus

a

12

volt medium duty battery charger

suitable

for

car,

boat

and other

medium

duty

batteries.

The

rrlachine

has

been

manufactured

to

operate

from

the

normal

household

240

v01

t

10

arrrp

58

Hz

single

phase

power

supply,

and

ful

lr

rsompl

ies

~i

th

Austral

ian

Standards specification

ASlP66

for

limited input class

machine^,

tested

tu

Australian

Test

Specification

AS31P5,Approual

Number

S/221/MC81.

Cooling

is

by

cc~nuection with

entry

located underneath

the

rrtachine,

so

a5

tu

remove

heat

from

the

transformer

in

an

updraught manner,

always

ensure

the

welder

is

located in

a

dry

place

and do not obstruct

the

bottom

of

the

unit.

PREPARATI01.4

FOR

WELDING

OPERATION

1

Careful

ly

read

the

enclosed

Safety

In~ttuctiorns.

3.

Irlsert

the

three-pin

plug into

a

18

amp

power point.

r

&l.

Place

the

proper elec

trctde

in

the

el

ec trode holder

at

the

desired angle.

(For

best

results,

use

the

qual

itr

Austat-c

electrode

nominated

from

the

electrode guide..)

6.

To

strike

the

arc,

move

the

electrode along

the

piece to be

welded,

as

if

c,triking

a

rrlatch.

As

the

puddle

of

molten

metal

forms,

move

the

electrude

in

the

direction to

be

welded.

(It

i

5

rlormal

to

drag

an

el

ec

trode

when

we1

ding.

>

7.

To

stop welding, simply lift

the

electrode and

break

the

arc,

8.

The

rrlachirle is

of

rugged cunstruction

with

a

1

iberal

rating

far-

its c1a.s~.

It

must,

however,

be

remembered it

has

been

desigr~ed

tu

run

2.51~1m

and

3.25mm

electrodes

CIFI

a

10

amp

power

point,

A

sensible a.pproach to

work

capacity

will

avoid

an

over1

clad condi tion on both machine

and

houc,ehcll

d

supply.

.-

~

LJELD-N-CHARGE

IIHNUAL

PAGE

2

9.

When

welding

on

motor

vehicles1

ensure

battery leads

are

removed

f

rum

the

terrrri

nal

S.

WIA

manufacture

a

wide range

of

mild

steel

and special

purpose

electrodes

which

cater

for

industry needs. The

table

5et

out

below lists

those

kustasrc electpudes

that

are

cornmun1y

used

for

the

welding

you

are

1

ikely

to

per+urrr~.

The

correct

selected electrode

will

influence

Goth

the

quality

of

we1

d

and

stabi

1

i

ty

of

arc

Therefore,

shoul

d

you

want

the

best

resul

t,

ask

for

f4uc.tar.c

now

available in

the

ccrtvenient

E41

13

*EHUSTHHC

135

2.5mm

3

,

25mm

F1

ux:

B1

ue

and

Wh

i

t

e

Stripe

Tip: Plain

E481

6

%LISTARC

16TC

2,

~KIKI

3.25mm

F1

ux:

Grey

Tip:

Bronze

HPPII

CATION

Popular general

purpose

(G.P.)

electrode used

with

ease

in

a1

1

posi t ions, vertical

up

or

down.

The

smc~oth

Qurceful

arc

makes

it

an

ideal

rad

fur

all

general

mild

steel

appl

ications.

Smooth

running

wi

th

a

ssf

t

arc

I

qen

era

1

purpose

electrode

particularly

suited tu

1

igh

t

stlee

tme

tal

and

smcm

t

h

mi

tre

f

i

11

et

we1

ds.

A

low hydrogen

el

ectrade

with

good

arc

5.ta.tril

i

tr

and out-af-

position welding characteristics.

This electrode is ideal

for

medium

carburl

steel

or

steel

with

doubtful

anal

rsi

5.

1.

Discunnect battery

from

car,

boat,

etc.

2.

Connect

the

work

clamp

to

the negative

(->

battery

terminal,

4.

Insert

the

3

plug

into

a

10

amp

power.

point,

5.

Turn

the

current switch to

"L~w

Current"

for

norma

or

to

"High

Current"

for

faster

charging.

6.

Leave

battery in

well

ventilated

area

for

charging

1

charging

I/JELD-1.\l-CHAf?OE

PlAblUAL

PAGE

3

WARNINGS

1

,

Corlnec

t

and disconrtec t battery

charger

1

eads

m1

y

when

supply

cable is disconnected

from

supply

rr1air15,

as

any

resu

l

tan

t

spark

may

cause

an

expl

osiclrl,

2.

Whilst

the

charger is disconnected

from

the

supply

mains,

csnnect

only

the

positive

lead

of

the

charger

to

the

positive

lead

of.

the

battery and

only

the

negative

(work>

lead of

the

charger

to the negative

terminal

of

the battery.

3.

Do

not

over

charge

the

battery.

An

over

charged battery

KI~Y

develop excessive

heat

which

may

cause

an

explosion,

4.

Do

not

STTIUkF?

strike

a

rrlatch, cause

spark,

weld

or

alluw

conductive

materials

in

the

vicinity

of

the

battery during

cha.rging.

5,

Use

in

a

we1

1

ventilated

area

and

do

not

operate

in

a

conf

i

ned

space.

SERU

I

C1

NC3

The

battery charger

is.

protected

from

short

circuit uuerlclad

by

a

6

amp

3AG

standard action

type

+use,

The fuse will blow if

the

uutpu

t

1

eads

are

shorted

togettier

or

if

the

charger is

cannected

to

a

battery with

a

short

circuit fault,

Replace tilobJr1 fuse

only

with

a

6

amp

3AG

standard acticlrl

type

fuse.

SAFE

PRACTICES

IN

USING

ELECTRIC

ARC

PROCESSES

AND

EQUIPrlEbJT

Welding

equipment

and

prcrces5e5

are

nett

particularly

hazardous:

however,

ther

are

certain safe practises

the

user

should

fol

low

tu protect himC.el

f

and

others

from

injury.

The

following

notes

prepared

by

Welding Industries

of

Australia

Pty,

1

td.

tu

assist with

operator

safety

are

only

a

basic guide

to

E.afe

working habits.

k

detailed list

of

standards

for

use

thruughuut industry is available

from

the

Standards Association

of

Austral

ia.

Individual State Authorities

such

as

Electricity,

Department

of

Labour, Industry

or

Mines

Department

and

other

local

health

OP

safety Inspection Authorities

may

also

have

additional

requirements.

I

NSTALLAT

I

Ut4

OF

EQU

I

PblENT

Instal

1

and rrlaintain equipment in accordance with

the

local

electrical a.1~thor.i

ty

codes.

Always

use

cc1rrec1;

rated

pri~~2r.y

cable and

~.uppl~

outlets,

and

have

only

qualified electrical

personnel

carry nut

instal

lat

ion

and main tenat-lce

work,

Make

sure

you

always

USE

the

provided

work

cab1

E

fur. grclurld

returt-1

from

wsrk

to

we1

der,

Never

use

p

ipes

carrying

gas

or

flammabl

e

l

iquidc. for ground return circui tc.,

OPERATOR'

E;

PERSONAL

PROTECT

101.4

The

radiation

from

the

arc

welding

process

is

intense

and

visibly bright and

can

damage

eyes.,

penetrate

1

ightweight

clothing and burn

the

skin.

Therefore, adequate protection

for.

both operator and

persur~c,

working within

the

we\ding

area

must

be

VJOT'~

at

a1

1

times.

Caution:

Do

not

use

ordinary

ga.s

WEI

ding

goggles

as,

these

yoygl

e5

do nut

provide suff icier1

t

face and

eye

protect i una

In

the

case

o-f

eye-burn, otltain professional medical attention

irrmediate1;v.

For

temporary

treatment,

apply

a

drop

of

2%

Butrn

sclluticln to

eyes

at

twe-hour.

intervals

or

CMurirle'

at

hourly

intervals,

fur

as

lung

as

acute burning sensation persists.

Avoid contact with electrode and ground circuits.

Use

a.

rubber

mat

or

uJouden

platform

to

stand

on

when

welding

in

damp

lucatisrls

or

on

metal

floors,

Do

not

loup

an

energised cable

around your body

or

tuck

an

electrode holder under your

arm.

E>:pased

corlductorc,

ur

ather

bare

metal

in

the

welding circuit,

or

an

electrical

lr

alive piece of equiptment which

is,

not

correctly eapthed, can

cause

a

fatal

s.hock

tu

a

person

whose

body

becorr~es

a

cclnductor.

USE

only

fully insulated, appr~ued electrode hulders

and

luck

type

cable connectors. Plaintain holder,

work

clamp,

welding

cable=.,

and

other

exposed

parts

uf

the

rnachine

in

good

cundi

t

iun

.

LJELD-1.4-CHHRGE

PlAt4UCiL PAGE

S

VENT

I

LAT

I

ON

Adequate ventilation rr~ust

be

provided for operator safety

.as

severe

dis.corrlfort, il

lrIec,s

or

even

death

can

result

f.r.om

toxic

fumes,

Good

veri

ti

lation

is

particular1

y

needed

when

we1

ding

or

gas-cutting alloys which

a.re

likely to contain lead,

zinc,

cadmium, beryl ium,

and

other rmterialf;

that

may

produce toxic

vapours and gases.

Do

not

Mork

in

a

conf ined space

url1

ess

i

t

is correc

t

1

y

ventila.ted by air, and if

neceSsa.ry,

wear

air supplied

respirators.

Never

ventilate

with

oxygen,

and

always

make

sure

any

person within

the

suspect

area

has

adequate protection.

Do

not

we1

d

or

gas-cut containers or

ve5,sel

E.

which have

he1

d

toxic materials b~ithout exercising

all

proper precautions.

The

heat

of

the

arc

or

flame

wi

11

decCllTlpoc,e vapours

fr~m

cl

urinated

solvent5

and

form

phosgene,

a.

highly toxic

gas

which irritates

both

eye

and

1

ung,

Trichlorethyl

ene

and perchlorethylene

VapuUrfj

can

be

decomposed by

the

ultra-violet iradient>

pr1er.y

of

an

arc to

a1

SCI

furm

ptlc~c,gena,

F

I

RE

AND

EXPLUS

I

UN

PREVENT

I

ON

Safety conscious clperatclrs

always

take

the

proper precautions

in preparing

a

location to prevent

fires

be-fore

setting

up

their

equip

tmen

t

,

Combuc,tabl

@E.,

suet-I

az.

wood,

paper,

c~i

1

,

grease,

paint

,

containers which

have

held gasoline

or

volatile liquid, can

cause fires or

rxy

I

usion and

shw1

d

be

removed

at

1

east

18

metres

(preferably

more)

frcrm

the

work location. Sparks

c+'.rt

travel

18

metres

or

mure

and lodge in

floor

cracks

to

stay

hot

er1wgi-l and srr~oulder

1

any after the

job

is

finished.

Empty

containers,

or

v,es;selc,

that

have

held cc~mbustable

or

can

produce f lamrrlable vapours

when

heated,

rr~clst

never

be

welded

or

-Flame-cut

without completing

the

precautions

set

aut

and

described

in

A51674-1388

"Fire

Precautions in Cutting, Heating

and

LJeldirrq Operatiens". Extracts

frorrl

this code, c.uch

as

thorough steam

or

cauc,tic cleaning, solvent

or

water

washing

dcpendir1g

clrl

the combustable's ~.olubil i

ty,

fcl1

lowed by purging

and inerting with ni trogen

or

carbon diuxide, should

be

stictly

adhered to.

Water-f

i

11

ing

just

below

working

level

may

substitute

fur

inerting.

WIA Weld n Charge Owner's manual

WIA Weld n Charge Owner's manual

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