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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
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
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
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
/
