WIA Vortex PAPR System Owner's manual

WELDING INDUSTRIES

OF

AUSTRALIA

A

DIVISION

OF

WELDING INDUSTRIES

LIMITED

ACN

004

547

Ill

.-

Head

Office and International Sales

5

Allan

Street, Melrose Park

South Australia, 5039

Telephone (08) 8276 6494 Facsimile

(08)

8276 6327

OWNERS

MANUAL

VORTEX

AD15

MODELS VRADl5-0

&

VRADIS-1

08/96

QUALITY

WELDlNG

PRODUCTS, SYSTEMS AND

SERVICE

Page

2

VORTEX

AD15

OWNERS

MANUAL

The information contained

in

this manual has been prepared to enable you

to

properly maintain your new equipment and ensure that you obtain maximum

operating efficiency

.

Please ensure that this information

is

kept

in

a

safe place for ready reference

When requesting spare parts, please quote the model and serial number of the

.

machine and part number

of

the item required

.

All

relevant numbers are shown

in

lists

contained

in

this manual

.

Failure

to

supply this information may result

in

unnecessary delays

in

suppling the correct parts

.

when required at any future

.-

time

.

SAFETY

Before this equipment is put into operation. the Safe Practices section at the

back of

this

manual must be read completely

.

This will help to avoid possible injury

due to misuse

or

improper welding applications

.

CONTENTS

Sec

.

1

...............................

Introduction

................................

3

Sec

.

2

................................

Receiving

..................................

4

Sec

.

3

.............................

Speclflcatlons

...............................

4

Sec

.

4

......................

power Source Controls

.......................

5

Sec

.

5

..................

Connection

to

Mains Power

....................

7

Sec

.

6

..........................

MMAW Operation

............................

7

Sec

.

7

..........................

GTAW Operation

............................

9

Sec

.

8

.......................

General Maintenance

.........................

10

Sec

.

9

..............................

Fault Finding

...............................

10

Sec

.

1

o

.......................

Service Information

..........................

11

Sec

.

I

..............................

Parts Lists

.................................

14

Sec

.

12

......................

Remote Foot

Control

.........................

15

Sec

.

13

...................

Remote Pulsing Control

.......................

16

Sec

.

14

.................

Safe Practices Information

.....................

17

...

FIGURES

Fig

.

l

.......................

Power Source Controls

.......................

5

Fig

.

2

......................

Connections

for

MMAW

.......................

7

Fig

.

3

.............................

Striking the Arc

..............................

8

Fig

.

4

.......................

Connections for GTAW

.......................

9

Fig

.

5

..........................

Circuit Diagram 1

Q

..........................

11

Fig

.

6

..........................

Circuit Diagram

3Q>

..........................

12

Fig

.

7

..............................

Parts Diagram

..............................

13

Fig

.

8

.........................

Remote

Foot

Control

.........................

15

Fig

.

9

.....................

Pulsing Control Functions

..................... 16

Fig

.

9

......................

Remote Pulsing Control

.......................

17

VORTEX

AD15

OWNERS

MANUAL

Page

3

1

:

INTRODUCTION

MANUAL

METAL

ARC

WELDING (MMAW)

MMAW

is

a

welding process where

an

arc is struck between a flux-coated

consumable electrode and the workpiece. The arc and the weld pool are both

shielded by gases generated

by

the

flux coating of the electrode.

The VORTEX AD15 has been designed to be used with 2.0mm to 4.0mm

diameter electrodes. The smaller sizes are used when welding at lower currents,

such as sheet-metal applications. Increasing the electrode diameter permits higher

welding currents to be selected.

”

WIA

markets a wide range of mild steel and special purpose electrodes which

cater for home workshop, rural, and industrial requirements. Some popular

AUSTARC electrodes are listed below. The correctly selected AUSTARC electrode

used

in

conjunction with your new VORTEX AD15 will influence the quality of the

weld, and the stability of the arc.

Austarc

12P,

Classification E41

12

A

popular general purpose electrode used with ease in all positions, vertical up

or

down. The smooth forceful arc makes it an ideal electrode for

all

general mild

steel applications.

Austarc

13S,

Classification

E41

13

A smooth running electrode with a soft arc, particularly suited to light sheetmetal

and smooth mitre fillet welds.

Austarc 16TC, Classification E481

6

A

low

hydrogen electrode with good arc stability and out-of-position welding

characteristics. This electrode is ideal for medium carbon steels.

Unicord

31

2

Classification E31

2-1

6

A high tensile

(770

MPa), high chromium nickel electrode specially formulated

for

joining all alloy steels and irons, for tool and die maintenance and steels of

unknown analysis.

GAS

TUNGSTEN

ARC

WELDING

(GTAW)

GTAW

is

a welding process where the arc is struck between a non-consumable

tungsten electrode and the workpiece. A ceramic nozzle surrounds the tungsten

electrode and directs a flow of inert gas, usually Argon, over the electrode and the

weld zone. If filler metal

is

required, it is hand fed into the weld pool.

When set for

DC

(direct current), the

VORTEX

AD1

5

is suitable

for

welding

most

ferrous and non-ferrous metals. When set for

AC

(alternating current) the square

wave output with adjustable frequency and polarity balance enables ideal welding

conditions

to

be obtained for even highly oxidised aluminium materials.

Page

4

VORTEX

AD1

5

OWNERS

MANUAL

2.

RECEIVING

Check the equipment received against the shipping invoice to make sure the

shipment

is

complete and undamaged.

If

any damage has occurred

in

transit,

please immediately notify your supplier.

The VORTEX AD1

5

package contains:

Vortex AD1

5

Inverter Power Source

Gas Hose

w

(This) Owners Manual

Optional additional items

for

VORTEX AD15

TC693 Bernard

200

Amp TIG Torch c/w Torch Switch

w

VRADl5-20 Remote Foot Control

VRAD15-21 Remote Pulsing Control

AA53-115 Work

Lead Assembly,

5

metre

m

HAl01-185 Argon Regulator and Flow Gauge

AA53-015 MMAW Welding Lead Kit,

5

metre

3.

SPECIFICATIONS

240

Volt Single Phase Package (VRAD15-0):

Primary Voltage

.....................................

240

Volts Ac,

+/-

IO%,

50160

Hz

Maximum Primary Demand

....................................................

33.6

Amps

Rated Output

20

Amp Primary Supply

................

150

Amps,

26

Volts,

35%

Duty Cycle

15 Amp Primary Supply

................

150 Amps,

26

Volts, 20% Duty Cycle

41

5

Volts Three Phase Package (VRADI

5-1

):

Primary Voltage

.....................

41

5

Volts AC,

+/-

1

O%,

3

phase,

50/60

Hz

Maximum Primary Demand

........................................

9

Amps per Phase

Rated Input Current

....................................................

6

Amps per Phase

Rated Output

.............................

150 Amps

@

26 Volts,

40%

Duty Cycle

Both Models:

Welding Current Range

........................................................

5-1

50

Amps

Open Circuit Voltage

..................................................................

.70

Volts

Electrical Efficiency

..........................................................................

80%

Dimensions

.........................................

H:

310mm W: 180mm D:

500mm

Mass

................................................................................................

.23kg

L

VORTEX

AD15

OWNERS

MANUAL

Page

5

4.

POWER SOURCE CONTROLS

FIGURE

1.

POWER

SOURCE

CONTROLS

POWER

ONlOFF

SWITCH

A

rotary switch is located on the back panel. In the

OFF

position, the power

source is isolated from the mains power supply. Rotate the switch clockwise

to

energise the power source.

l.

POWER

ON

INDICATOR.

Yellow

LED

(1)

is illuminated when the machine

is

energised, that is when

electrical mains power is connected

to

the welder, and the

ONlOFF

switch

to

ON.

is set

2.

FAULT

INDICATOR.

Red

LED

(2)

is illuminated if any

of

the following faults have occurred:

Over-

temperature, Over-supply voltage, Under-supply voltage.

3.

MODE INDICATOR.

Red

LED

(3)

is

illuminated when the welding

output

is energised.

4.

CURRENT CONTROL.

This control is used

to

set the output current of the power source within its

output range

of

2

-

150

Amps.

tt

is active only when the LOCALlREMOTE switch

(1

3)

is set for local control.

Page

6

VORTEX AD15

OWNERS

MANUAL

5.

UOWNSLOPE

CONTROL

(b).

When

GTA

welding, this control can be set to ramp down the output current at

the end of

a

weld over

a

period of

0.1

-

10

seconds. Downslope is typically used

to

avoid the formation of end

of

weld

craters. Rotate the knob clockwise to

increase the downslope time. Downslope commences when the torch switch is

opened.

6.

POSTGAS CONTROL

(c).

This control can be set to provide

5

-

30

seconds of shielding gas flow at the end

of a weld. Postgas is used

to

protect the cooling weld pool from atmospheric

contamination. Rotate the knob clockwise to increase the postgas time.

7.

FREQUENCY CONTROL.

This control sets the frequency

of

the AC squarewave welding output in the

range of

50

-

200

Hz.

Higher frequencies may assist when GTA welding highly

oxidised materials. Frequency control

is

only operative when the AC welding

mode is selected.

8.

BALANCE CONTROL.

This control can be used

to

adjust balance between cleaning action and

penetration when welding aluminium in the AC welding mode. The control can

be set from

30%

(maximum penetration)

to

70%

(maximum cleaning).

9.

AC/DC MODE SELECTION SWITCH.

AC output mode is selected when set to the lower position,

DC

mode when set

to

the upper position.

IO.

TORCH SWITCH MODE SELECTOR.

When set

to

the upper position, two step torch switch mode is selected. The

torch switch is closed

to

commence welding and released to end welding.

When set to the lower position, four step switch mode

is

selected. The torch

switch is closed to initiate manual pre-gas, released to initiate welding, closed

to

commence downslope time

(5),

and released

to

commence post-gas time

(6).

l

l.

MMAWIGTAW MODE SWITCH.

Set to the upper position

for

GTA welding, and to the lower position for MMA

Welding.

12.

ARC START MODE SWITCH.

When set to the upper position, this switch selects

HF

arc starting mode. When

set to the lower position, lift arc mode is selected.

HF

and

lift

arc starting modes

apply only

to

GTA welding.

13.

LOCAL REMOTE SWITCH.

When set

to

the upper position, the output welding current

is

adjusted by the

front panel current control. The switch must be set to the lower position when a

foot control

or

remote pulsing control is

to

be used.

14.

REMOTE CONTROL CONNECTOR.

.

Optional devices such as the foot current control and remote pulsing control are

'.

..

attached to the machine via this connector.

VORTEX

AD15

OWNERS

MANUAL

Page

7

5.

CONNECTION

TO

ELECTRICAL MAINS

POWER

SUF'PLY

The VORTEX AD15 is supplied fitted with a

3

metre mains power supply cable.

If

it

is necessary

to

replace the mains power supply cable, use cable with the correct

current rating.

An appropriate mains plug should be fitted by a qualified electrician. In

the

case

of

the single phase.-model VRDXI

5-0,

a

15

or

20

Amp single phase plug is required.

If

used on a

15

Amp supply, the output duty cycle of the machine must be derated

as detailed

in

Section

3

of this manual.

The capacity

of

the mains wiring and power outlet supplying a welder is selected

according

to

the rated input current

of

the machine. The circuit breaker or fuse

however must tolerate the periods

of

maximum demand which occur during arcing.

For this reason, Australian standards allow the fuse

or

circuit breaker supplying a

welder to be rated at up to twice the rated input current of the welder, (AS3000,

clause

2.4.3.4).

If the equipment is used with an extension primary supply cable, ensure that it is

correctly rated. Voltage drop which will occur over long lengths of cable will reduce

the capacity of the welder.

6.

MMAW

WELDING

A)

FRONT

PANEL

SETTINGS.

Set switch

11

(Ref. Figure

1

)

to

the lower position for

MMAW.

DC welding

current will provide excellent arc stability, however any tendency

to

arc blow can be

minimised by the use

of

AC.

The

HF

selection switch

12

should be set to the lower

(HF

Off)

position.

B)

OUTPUT

POLARITY.

For DC operation, most

MMAW

electrodes are operated electrode positive

(+),

however in all cases refer to the manufactures' recommendations

for

the electrode

in use. Electrode positive connection

is

illustrated in the figure below.

FIGURE

2:

CONNECTIONS

FOR

"MAW

-

ELECTRODE

POSITIVE

Page

8

VORTEX

AD15

OWNERS

MANUAL

C)

ARC

INITIATION.

setting the Current control

(4)

on the machine front panel.

Select an appropriate welding current

to

suit the electrode diameter

in

use by

To

strike the arc, drag the end

of

the electrode along the workpiece as if striking

a

match.

As

the arc initiates, lift the electrode slightly away, aiming

to

establish an

arc length of approximately

3mm.

As

the electrode is consumed, feed the electrode

into the arc

to

maintain

-a

constant arc length. As a general rule, the arc should be

held as short as possible, consistent with stable burn

off

and good weld appearance.

An arc which is too long causes an unwieldy flow of metal with

a

rough weld

appearance and reduced penetration. An arc

too

short leads to

a

narrow weld

deposit and "stuttery" arc characteristic, and the electrode is liable

to

freeze onto the

workpiece.

As the solidified weld deposit forms, move the end of the electrode slowly along

the weld path, aiming

to

maintain a stable pool of molten weld metal behind the arc.

Decreasing this rate of travel will result

in

a wider weld deposit, and similarly

increasing it will narrow the weld deposit.

Always fill the crater which tends

to

form at the end of a weld deposit

by

pausing momentarily before withdrawing the electrode. Unfilled craters are a point of

weakness and may lead to fatigue weld cracking.

FIGURE

3:

STRIKING

THE

ARC

VORTEX

AD15

OWNERS

MANUAL

Page

9

7.

GTAW

WELDING

A)

FRONT

PANEL

SETTINGS.

Set switch

11

(Ref. Figure

1)

to

the upper position for GTAW. Switch

9

is set for

either AC or

DC

output mode dependant on the material

to

be welded. AC is used

for

alumimium, DC for

all

other ferrous and non-ferrous metals.

The use

of

high frequency

(HF)

arc initiation is optional when

DC

output mode is

selected, however

HF

is necessary when AC mode is in use. Set switch

12

as

required. When

HF

is not

in

use, the arc is initiated by

a

touch-start technique as

described below.

B)

OUTPUT POLARITY.

For both

DC

and AC output modes, the torch and work leads

must

be

connected as illustrated in Figure

4,

that is with the

Work

lead connected to the

positive

(+)

output terminal. Before initial use, allow shielding gas

to

purge the torch

and hoses for

5

minutes prior

to

welding.

,

The gas flow rate for welding should be

set

in

the range

2-5

litredmin.

For

DC

GTAW, the tungsten electrode should be

a

1-2%

Thoriated type. This

will provide the best arc initiation, arc stability and tip shape retention characteristics.

Thoriated electrodes can be recognised by

a

red tip.

The electrode should be ground

to

a point, with the grinding marks pointing

towards the tip.

For

welding currents less than

20

amps, the included angle of the

point should be

30

degrees, for currents greater than 20 amps, the recommended

angle

is

60

degrees. When fixed in the torch, the electrode should protrude

6mm

from

the

ceramic gas nozzle.

For

AC

GTAW, the tungsten electrodes should be either Pure

or

Zirconiated.

Pure tungsten electrodes can be recognised by a green tip, Zirconiated by

a

brown

tip. The tungsten electrode should be ground

to

a flat end, and will develop a balled

end during welding.

GAS

HOSE

FRO11

BOTTLE

TO

IN

REAR

OF

MACHINE

FIGURE

4:

CABLE AND HOSE-CONNECTIONS

FOR GTAW

Page

IO

VORTEX

AD15

OWNERS

MANUAL

C)

GTAW

ARC

INITIATION, TOUCH START TECHNIQUE.

Lightly touch the tungsten electrode onto the workpiece, then

in

a smooth

movement, lift the torch

to

initiate an arc slightly longer than the diameter of the

electrode. Once the arc

is

stable,

a

normal working arc length can be established.

A

copper striking plate is recommended

to

minimise electrode contamination.

A

contaminated electrode will produce an unstable arc, and must be reground before

further use.

D)

GTAW ARC INITIATION,

HF

TECHNIQUE.

Rest an edge

of

the open end of the ceramic gas nozzle on the workpiece, with

the tip

of

the electrode approximately 6mm from the work.

To

initiate the arc, close

the torch switch. If the main arc does not transfer, the torch may be rotated

to

decrease the electrode

to

work distance.

To

avoid contamination, care must be

taken not

to

touch the electrode onto the work.

.-

Following arc initiation, the torch should be rotated

to

a normal operating

position.

8.

GENERAL

MAINTENANCE

Before removing the-:machine cover,

ENSURE

fhat the unif is disconnected from

the mains power supply, When-fhe--unit

is

energised

LETHAL

VOLTAGES

are

present

on

the electrical components enclosed.

Care should be taken to prevent excessive build-up

of

dust and dirt within the

welding power source.

It

is recommended that at regular intervals, according

to

the

prevailing conditions, the machine covers be removed and any accumulated dust be

removed by the use

of

dry, low pressure compressed air.

Inspect the visible components for any signs of overheating

or

other damage.

Report any observed problems to qualified service personnel.

9.

FAULT

FINDING

NO

WELDING

CURRENT

Check that mains supply is available at the Power Source, ie. that the fan

is

running and the

POWER

ON

Led is

lit.

Check for continuity of the welding current

circuit, ie. work lead, work clamp and electrode holder.

Check that the electrode and work leads are correctly connected for the welding

process in use,.

The welding power source incorporates inbuilt protection devices which will trip if

the unit is overloaded.

In

this event, the machine will not deliver welding current, and

the red fault indicator LED

2

(Ref. Figure

l)

will be illuminated. In this instance, leave

the machine energised with the fan running

to

achieve the maximum cooling rate.

If

equipment failure is suspected, forward the unit

to

your nearest

WIA

Sales

and Service Branch or qualified service agent.

VORTEX AD15 OWNERS

MANUAL

Page

I1

IO:

SERVICE

INFORMATION

CIRCUIT

DIAGRAM

VRADl5-0

YY

II

NV

0,

..

r

---

FIGURE

5:

CIRCUIT

DIAGRAM,

SINGLE

PHASE

Page

12

VORTEX

AD15

OWNERS

MANUAL

CIRCUIT

DIAGRAM

VRADIS-l

l-

L.

L-

f7

*

FIGURE

6:

CIRCUIT

DIAGRAM,

THREE

PHASE

VORTEX

AD1

5

OWNERS

MANUAL

Page

13

PARI

S

DIAGRAM

FIGURE

7:

PARTS

DIAGRAM

Page

14

VORTEX

AD15 OWNERS MANUAL

11.

PARTS LISTS

VRAD15-0

(SINGLE PHASE)

Item

Part

Number

Description

001

................

VR18.74.100

...................

Screw

......................

VR21.06.001

...................

Belt

002

................

VR03.07.017

...................

Upper cover

003

................

VROl,04.212

...................

Plastic front

005

................

VR09.11.205 ................... Knob

006

................

VR15.22.030

...................

Control plate

007

................

VR01.04.213

...................

Front panel

008

................

VR19.06.001

...................

Tig Mechafin adaptor

009

................

VR01.02.024

...................

Lower cover

010

................

VR20.04.002

...................

Handle cover

012

................

VR09.11.201

...................

Knob

014

................

VR03.05.208

...................

Connection panel

015

................

VR10.13.001

...................

Fixed socket

016

................

VR21.03.004

...................

Rubber foot

017

................

VR01.05.204

...................

Plastic back

018

................

VR08.22.002

...................

Cable clamp

019

................

VR08.02.010

...................

Supply cable

020

................

VR24.01.190

...................

Gas nipple

023

................

VR09.01.005

...................

Switch

024

................

VR09.11.010

...................

Knob

025

................

VR10.03.060

...................

Connector

026

................

VR10.03.027

...................

Connector

027

................

VR15.14.097

...................

Filter

028 ................

VR05.03.007

...................

H.F.

Transformer

029

................

VR05.04.202

...................

Inductance

030

................

VR15.14.119

...................

Snubber card

031

................

VR01.15.010

...................

Handle

034

................

VR12.06.101

...................

Condenser

035

,

...............

VR08.25.053

...................

Fuse

......................

VR08.25.301

...................

Fuse holder

036

................

VR09.05.001

...................

Solenoid valve

037

..............

..VR14.10.155

...................

Diode bridge

038

................

VR09.07.002

...................

Thermal cut-out

041

................

VR07.10.014

...................

Cooling fan

042

................

VR05.1

1.021

...................

Auxiliary transformer

043

...............

.VR11

.l

3.1

10

...................

Resistor

045

................

VR09.09.012

...................

Relay

046

................

VR15.14.091

...................

H.F.

card

048

................

VR11.20.006

...................

Shunt

049

................

VR12.03.016

...................

Capacitor

050

................

VR1 1.14.006

...................

Resistor

051

................

VR14.05.073

...................

Diode

052

................

VR15.14.085

...................

Logic card

053

................

VR10.03.021

...................

Connector

054

................

VR15.14.036

...................

Torch button insulation card

055

................

VR05.02.005

...................

Transformer

056

................

VR14.60.028

...................

Primary inverter unit

057

................

VR14.60.038

...................

AC secondary inverter unit

058

................

VR14.14.113

...................

Logic card

021

................

VR01.05.206

...................

Back panel

SUBSTITUTE PARTS FOR

MODEL

VRADIS-4

(THREE PHASE)

023

................

VR09.01.005

...................

Switch

055

................

VR05.02.005

...................

Transformer

056

................

VR14.60.028

...................

Primary inverter unit

037

................

VR14.10.155

...................

Diode bridge

057

................

VRl4.60.03801

...............

AC secondary inverter unit

VOETEX

AD15

OWNERS

MANUAL

Page

15

12..REMOTE

FOOT

CONTROL

VRADl5-20

The optional

foot

control

VRAD15-20

provides both torch switch function and

welding current control. The control is attached to the power source via connector

14

of

Fig.

I.

As

the pedal is depressed from the

'foot

off

position,

first

the torch switch

closes, then the welding current setting increases, beginning at the level set by

potentiometer

1,

reaching the level set by control

2

at the fully depressed position.

Foot

current control is particularly advantageous

for

precision

GTA

welding. The

control may also be used

for

MMA

welding, however in

this

instance the torch switch

function is redundant as the welding output

is

permanently energised whenever

MMA

mode

is

selected.

7

3

8

2

9

1

I

0

10

0

10

II

Foot

Off

Fully

Depressed

FIGURE

8:

REMOTE

FOOT

CONTROL

L

Page

16

VORTEX

AD15

OWNERS

MANUAL

13.

REMOTE

PULSING

CONTROL VRAD15-21

The optional remote pulsing control VRAD15-21 provides upslope, downslope

and pulsing controls

for

GTA welding. Upslope and downslope can be applied to

both normal and latched torch switch modes. The control is attached

to

the power

source via connector 14

of

Fig.

7.

UPSLOPE

l

DOWNSLOPE

ONLY

This mode is selected when switch

2

is

in the anticlockwise position. Welding

current is adjusted by the vernier control

3.

Led 1

is

lit

when the welding output is

energised.

On closure

of

the torch switch, the welding current increases from minimum to

the set welding current over

a

timed period (0-10 secs) as adjusted by control

4.

On

release of the torch switch, welding current decreases

to

zero over a second timed

period (0-1

0

secs) as adjusted by control

5.

UPSLOPE

I

DOWNSLOPE

WITH

CURRENT

PULSING

This mode combines Upslope and Downslope with weld current pulsing, where

the welding current is modulated between two current levels referred

to

as the Pulse

and Background currents. Pulsing can provide a high degree

of

weld pool control

for

critical applications.

The pulse current level is set by vernier control

3,

and the background by vernier

control

6.

When

6

is set at

000,

background current equals pulse current.

As

the

setting

of

6

is increased, the backgound current becomes a smaller proportion

of

the

pulse current level.

The duration

of

the pulse is set by control

7

(0-1

sec), the duration of the

background period by control

8

(0-1

sec).

These details are illustrated in the diagram

below.

On

I

Gun

Switch

I

UPSLOPE

/

DOWNSLOPE

Pulse

PULSED CURRENT WAVEFORM

FIGURE

9:

PULSING

CONTROL

FUNCTIONS

VORTEX

AD15

OWNERS

MANUAL

Page

17

0-

o/

n

S

n

05

"L

-

0-

5

n

d@@7

""

FIGURE

10:

REMOTE

PULSING

CONTROL

Page

l8

VORTEX

AD15

OWNERS MANUAL

14.

SAFE

PRACTICES

IN

USING

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 tist 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 Authoriiies 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 lens. This

is a MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal.

Replace the cover lens 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

.................................

.l4

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 slag.

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

FUMES.

Adequate ventilation with air is essential. Severe discomfort, illness

or

death can result from

fumes, vapors, heat, or 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 it is being ventilated and, if necessary, while wearing air-

supplied respirator.

VORTEX ADA5 OWNERS

MANUAL

Page

19

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.

8'

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-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.

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;

Combustibles (including building construction) are within

10

metres.

m

Combustibles are further than

10

metres but can be ignited by sparks.

Openings (concealed

or

visible) in floors

or

walls within

10

metres may expose

i,

combustibles

to

sparks.

m

Combustibles adjacent

to

walls, ceilings, roofs, or metal partitions can be ignited by radiant

or

conducted heat.

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

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.1674-1974, 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 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.

b

WIA Vortex PAPR System Owner's manual

WIA Vortex PAPR System Owner's manual

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