WIA Weldmatic 120G Owner's manual
- Category
- Welding System
- Type
- Owner's manual
WIA Weldmatic 120G is a welding power source designed for use with self-shielding consumable wires. It can weld with both 0.9mm and 1.2mm diameter wires, making it suitable for a variety of welding applications, from sheet metal to thicker materials. The machine has a maximum welding current of 120 Amps and a duty cycle of 17%. It features voltage control switches for adjusting the welding voltage and a wire speed control for setting the wire feed rate. The Weldmatic 120G comes with a 3-meter, 160 Amp gun cable and a heavy-duty PVC mains power supply cable.
WIA Weldmatic 120G is a welding power source designed for use with self-shielding consumable wires. It can weld with both 0.9mm and 1.2mm diameter wires, making it suitable for a variety of welding applications, from sheet metal to thicker materials. The machine has a maximum welding current of 120 Amps and a duty cycle of 17%. It features voltage control switches for adjusting the welding voltage and a wire speed control for setting the wire feed rate. The Weldmatic 120G comes with a 3-meter, 160 Amp gun cable and a heavy-duty PVC mains power supply cable.
WELDING
INDUSTRE§
OF
AUSTRALIA
A
DIVISION
CIF
WELDING INDUSTRIES
LTD
ACN
OQ4
547
1
l
l
Head
Office
and International
Sales
5
Allan
Street, Melrose
Park
South Australia,
5039
Telephone (08)
8276
6494
Facsimile
(08)
8276
6327
OWNERS MANUAL
WELDMATIC
120G
MQDEL
NO.
CP103-0,
REV.
E
81/95
QUALITY WELDING PRODUCTS,
SYSTEMS AND
SERVICE
8/
y:J!V
Page
2
WELDMATIC
120G
MANUAL
SAFETY
Before this equipment is put into operation. the SAFE PRACTICES section at the
back of the manual must
be
read completely
.
This will help
to
avoid possible injury due
to
misuse
or
improper welding applications
.
PLASTIC HANDLE
the machine by hand only
.
manner
.
Please note that the handle fitted
to
the WELDMATIC 120G is intended for carrying
BO
NOT
use this handle for suspending or mounting the machine in any other
CONTENTS
Sec
.
1
....................
Introduction
....................................................
P.3
Sec.2
....................
Receiving
.......................................................
P.3
Sec.3.
...................
Specifications
.................................................
P.4
Sec4
....................
Power Source Controls
..................................
P.5
Sec.5
....................
Installation
......................................................
P.6
Sec.6
....................
Basic Welding Information
.............................
P.8
Sec.7
....................
General Maintenance
.....................................
P.
11
Sec.8
....................
Trouble Shooting
............................................
P
.
11
Sec.9
....................
Service Information
........................................
P
.
12
Sec
.
10
..................
Parts Lists
......................................................
P
.
14
Sec
.
1
1
..................
Safe
Practices
................................................
P
.
18
FIGURE§
Fig.1
.....................
Power Source Controls
..................................
P.5
Fig.2
.....................
Fitting the Gun Cable
.....................................
P.6
Fig.3
.....................
Fitting Consumable Wire
................................
P.7
Fig.4
.....................
Weld Setting Charts
.......................................
P.8
Fig.5.
....................
‘Good’ Weld
...................................................
P.9
Fig.6.
....................
‘Bad’ Weld
......................................................
P.9
Fig.”.
....................
Gun Position
...................................................
P.9
Fig.8
.....................
Duty Cycle Chart
............................................
P
.
IO
Fig.9
.....................
Wirefeed Control Board
.................................
P
.
12
Fig
.
10
...................
Circuit Diagram
............................................
..P. 13
Fig.1
l
...................
Power Source Assembly
................................
P.15
Fig1
3
...................
Wire Drive Assembly
......................................
P.
17
Fig
.
12
...................
Gun Cable Assembly
......................................
P
.
16
L
WELDMATIC
120G
MANUAL
Page
3
The information contained in this manual
is
set out 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 required at any future time.
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 supplying the correct parts.
1
.INTRODUCTION
The WELDMATIC
120G
is
a
welding power source designed for use with "self
shielding" consumable wires. Wires of this type contain a core of
flux
which, during
welding, generates gases to shield
the
arc and the molten weld
pool.
A
separate
supply of shielding gas is not required. The flux also leaves a light protective slag
over the cooling weld deposit. The consumable wire is fed to the welding gun by
motor driven drive rollers. The arc is struck between the workpiece and the end of
the
wire, which melts to form the weld deposit.
The WELDMATIC 120G can accept both 0.9mm and 1.2mm self shielding
consumable wires. The smaller wire size is recommended for welding at lower
currents such as for sheet-metal applications. Increasing the wire diameter permits
higher welding currents to be selected.
2.
RECEIVfNG
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
CP-103-0
Package contains;
m
WELDMATIC 120G Power source.
m
BE951OWlA BERNARD
160
Amp Gun cable, gasless,
3
metre.
M
(This) Owners Manual.
Page
4
WELDMATIC
120G
MANUAL
3.
SPEClFlCATtOMS
Manufactured to Australian Standard AS1966.1, and tested
to
Australian Standard
AS3195. Supply authority Approvals Number N13243.
PRIMARY VOLTAGE
.....................................
240
Volts A.C., Single Phase,
50
hz.
RATED PRIMARY CURRENT
.......................
10
Amps.
MAX PRIMARY DEMAND
.............................
22 Amps,
5.3
Kva.
FUSE RATING
...............................................
15
Amps.
FllTED SUPPLY CABLE
...............................
32/0.20
Three Core,
Heavy Duty PVC.
WIRE
SIZE
RANGE
.......................................
0.9mm
-
1.2mm diameter.
OPEN CIRCUIT VOLTAGE
...........................
23
-
37
Volts
D.C.
COOLING
......................................................
Fan cooled, air drawn in
OUTPUT RATING
.........................................
100
Amps, 22 Volts,
25%
Duly
MINIMUM WELDING CURRENT
...................
35
Amps
MAX.
WELDING CURRENT
.........................
120 Amps,
17%
Duty Cycle.
DIMENSIONS
................................................
L
-
400mm,
W
-
240mm,
H
-
380mm
through rear fan grille.
Cycle.
including handle.
MASS
............................................................
29
Kg,
without wire-spool.
(Duty cycle is defined in Australian Standard AS1966.1 as the ratio of arcing time
to
5
minutes in any
5
minute period, expressed as a percentage.)
L
WELDMATIC
120G
MANUAL
Page
5
4.
POWER SOURCE CONTROLS
FIGURE
1.
POWER
SOURCE CONTROLS
l.
VOLTAGE CONTROL SWITCHES
The two voltage control switches together provide
4
steps
of
output welding voltage
adjustment. The right-hand switch
(2)
produces
a
small step change
of
voltage, and the
left-hand switch
(3)
a large step change
of
voltage.
Minimum welding voltage is obtained when both switches are set to the
'LO'
position. Maximum welding voltage is obtained when both switches are set to the
'HI'
position.
IMPORTANT:
Do
not operate the Voltage Control switches during welding.
2.
WIRE
SPEED
CONTROL
Rotating the dial clockwise increases the wirespeed,
so
increasing the welding current.
This control is used to adjust the feeding rate of the consumable electrode wire.
Section
6
of this manual, or the weld setting chart located inside the wire-spool
enclosure cover, gives information relating the setting
of
these controls to the
consumable wire diameter and the intended welding current.
L
L
Page
6
WELDMATIC
120G
MANUAL
5.
INSTALLATION
CONNECTION
TO
ELECTRICAL MAINS
POWER
SUPPLY
The WELDMATIC
120G
is supplied with a
3
metre,
3
core Heavy Duty PVC mains
power supply cable and standard
10
Amp plug. Due to peak current requirements,
the
Electrical Mains supply to welding machines is best protected by fuses. Circuit
Breakers may trip frequently if used in this application.
If
it becomes necessary to replace the mains power supply cable, use only a cable
with an equivalent or higher current rating.
Access to the machine supply terminals is gained by removing the power-source
side panel opposite to the wire-spool enclosure.
FITTING
THE
GUN CABLE
Loosen the gun cable retaining screws
(3).
First pass the gunswitch wires through
the front panel gun cable entry, then the gun cable end
(2)
through the front panel
and into the wirefeeder housing. Rotate
the
gun cable
so
that the gunswitch wires are
directed downwards as pictured. Tighten both screws
(3)
to retain
the
gun and to
establish welding current transfer to the gun. Attach each of the two gunswitch wires
to the terminal block
(4).
U
FIGURE
2.
FITTING THE GUN CABLE
WELDMATIC
120G
MANUAL
Page
7
FITTING
THE
CONSUMABLE WIRE
Note! In order to obtain the most satisfactory welding results from the
WELDMATIC
120G,
the wirefeed must be smooth and constant. Dirty, rusty or kinked
wire will not feed smoothly through the gun cable and will cause erratic welding.
Deposits from the wire will clog the gun cable liner requiring
it
to be replaced
prematurely. For best results use
T70
or
T80
type self shielding consumable wires
available from
WIA
or
their distributors.
Place the spool of welding wire onto the spool holder as illustrated. Fit the spool
retaining
'R'
clip
(5)
supplied.
FEEDING
THE
CONSUMABLE
WIRE
Open the two roll drive mechanism by lifting the pressure spring
(6)
outwards,
allowing the upper roller assembly
(7)
to be rotated away from the driven roller
(8).
The end of the welding wire can now be passed through the inlet guide, over the
bottom driven roller, and into the gun cable assembly.
Check that the drive roller groove is correct for the wire in use. The appropriate
size is stamped on the visible side of the installed roller
(8).
Check also that the
correct size contact tip is fitted at the gun end. Refer to section
10
for gun part
numbers.
Return the top roller to the closed position and, with the machine turned on, close
the gun switch to feed wire through the gun cable. Adjust the compression screw
(9)
to provide just sufficient clamping
of
the drive rolls drive to achieve constant
wirefeed.
Bo
not overtighten the compression screw, or the consumable wire can be
crushed leading to erratic wirefeed.
FIGURE
3.
FITTING
THE
CONSUMABLE
WIRE
Page
8
WELDMATIC
120G
MANUAL
6.
BASIC
WELDING
INFORMATION
ESTABHSHING
A
WELD
SElTING
The WELDMATIC
120G
has been designed for use with 0.9mm and
1.2rnrn
self
shielding electrode wires. For best results use WIA
HANDICORE
mild steel electrode
wires availabte from WtA or their accredited distributors. The charts below indicate
how to adjust the power source to obtain the desired welding output.
For each
of
the four combinations
of
Vottage Control switch settings, there is a
range
of
Wire Speed settings which may be selected to obtain the approximate
welding current indicated.
IMPORTANT:
Do
not operate the Vottage Control switches during welding.
The welding current should be chosen to suit the thickness
of
the metal to be
welded.
It
is important to check that the deposited weld provides sufficient strength
to suit the application.
Q.9mm
HANDICORE
IJ
Wirespeed
settings
246
a
10
HI
HI
HI
LO
h0
HI
2
4
6810
LO
LO
U
U
2
4
68
10
U
2
46810
W
I I
I I
40
60
80
100
120 140
Welding
Amps
1.2mm
HANDICORE
Sf
Wirespeed settings
HI
HI
HI
l0
L8
HI
LO
LO
2
4
6
810
IIIII
0248
U
024
U
I
Q0
60
80
100
120
140
Welding
Amgs
FIGURE
4.
WELD
SETTING
CHARTS
WELDMATIC
f20G
MANUAL
Page
9
A
llgood" weld will have the characteristics illustrated in figure
5.
The weld has
penetrated into the parent metal, fusing the root of the joint where the two plates
meet, and the weld blends smoothly into the side walls.
A
"bad" weld is shown
in
figure
6.
The weld has not penetrated the joint root, and
there
is
poor side wall fusion. This lack of fusion
is
normally corrected by increased
welding current.
FIGURE
5.
"GOOD" WELD FIGURE
6.
"BAD" WELD
GUN
POSITION
For
"down hand" fillet welding with self-shielded consumable wires, the gun
is
normally positioned as in the figures below with the nozzle end pointing away from
the direction
of
travel, referred
Po
as 'dragging' the weld. Self shielding consumabe
wires should be operated with approximately
15mm
of
wire 'stick-out' from the
welding contact tip.
FIGURE
7.
GUN
POSITION
Page
10
WELDMATIC
120G
MANUAL
DUTY
CYCLE
The WELDMATIC 120G has a rated duty cycle
of
25%
at
100
amps welding
output current. Duty cycle is defined in Australian Standard AS1966.1 as the ratio of
arcing time to
5
minutes in any
5
minute period, expressed as a percentage. The
diagram below illustrates the duty cycle rating for the range
of
welding currents
available from the
120G,
and allows
the
maximum welding time per
5
minute period to
be estimated.
The WELDMATIC 120G welding power source is protected by an inbuilt overload
protection device. This will trip if the machine
is
operated in excess of its current and
duty cycle rating, or
if
there
is
a sustained short circuit between welding gun and
workpiece.
If
this occurs, the fan and contactor will continue to operate, but the
machine will not deliver welding current until
the
overload device is manually reset.
The reset button
is
located on the machine rear panel, adjacent
to
the mains supply
cable inlet. Allow approximately
5
minutes cooling time before attempting to reset.
5
-7
Welding time
per
5
mins.
48
6Q
80
100
120
l#
Welding
Amps
FIGURE
8.
DUTY
CYCLE
RATlNG
CHART
WELDMATIC
I20G
MANUAL
Page
1
1
7.
GENERAL
MAINTENANCE
DUST
Care should be taken to mevent 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, or a vacuum cleaner.
WIREFEED
In order to obtain the most satisfactory welding results from the WELDMATIC
120G,
the wirefeed must be smooth and constant.
It
is therefore important to observe
the following points;
H
Keep the gun cable liner clear of dust and swarf build-up. When liner
replacement becomes necessary, fit only the genuine replacement part. The
build-up of dust in a cable liner can be minimized by regular purging of the
liner with dry compressed air. This may be conveniently done each time
the
wire spool is replaced.
m
Replace the welding tip as
it
becomes worn or damaged. Ensure
the
tip size
is correct for the welding consumable wire in use. See Section
10
for gun part
numbers.
LI
Keep the wire drive mechanism clean. Periodically check the drive roller for
wear or clogging, and that the compression roller rotates freely.
8.
TROUBLE
SHOOTING
UNSATISFACTORY
RESULTS
WIREFEED
E
Erratic wirefeed is
the
MOST
LIKELY cause of failure in all continuous
electrode wire welding processes.
It
should therefore be the first point
checked when problems occur. Refer to the section above.
WELDING
CIRCUIT
E
Ensure that the work clamp is securely tightened onto the work-piece
so
that
good
electrical contact is achieved.
Surface contamination
of
the work-piece by water, oil, grease, galvanizing,
paint, or oxide layers can severely disturb the welding arc resulting in a poor
weld. In this situation, surface cleaning of the work piece will be beneficial.
Page
12
WELDMATIC
120G
MANUAL-
WIREFEED
/
ARC VOLTAGE RELATIONSHIP
If
the consumable wire is stubbing into the wsrkpiece and a steady arc cannot be
obtained, it is likely that the wirespeed is set too high to suit the welding voltage.
To
correct this situation, decrease the Wire Speed setting.
If
the arc length is too long,
increase Wire Speed setting.
NO WELDING CURRENT
Check the electrical continuity of the welding current circuit, i.e., work lead, work
clamp and gun cable connections.
Check that mains supply voltage
is
available to the WELDMATIC
120G,
i.e. that
the fan
is
running and the contactor can be heard operating as the gunswitch is
closed.
Check to find if the thermal overload device has been tripped, and
if
so,
reset
after a
5
minute cooling period. The reset button is located on the machine rear
panel, adjacent to the mains supply cable inlet.
If
the forgoing checks have been made and have not revealed the fault condition,
a QUALIFIED SERVICE person should be consulted.
9.
SERVICE
INFORMATION.
WIREFEED CONTROL BOARD
CP103-10
MOTOR SPEED
POTENTIOMETER
WIREFEED
MOTOR
DYNAMIC
BRAKE CONTACT
FIGURE
9.
WIREFEED CONTROL BOARD
L
Page
14
WELDMATIC
120G
MANUAL
IO.
PARTS
LISTS
WELDMATIC 120G POWER SOURCE
CP103-0
PACKAGE
ITEM
#
PART# DESCRIPTION
l
.................
CP103-10
.................
Wirespeed PCB Assembly
2
.................
CPIO 3-15
.................
Transformer
/
Inductance Assembly
3
.................
CPIO 3-20
..................
Base Assembly
4
.................
CP103-21
.................
Side and Top Cover, Fixed
5
.................
CP103-22
.................
Side cover, Opening
6
.................
SA14 0-0/1
................
Handle
7
..................
CPIO 3-28
.................
Spool Holder Axle
8.................CP103-29
.................
Spool Adaptor
9
...............
..AM1 33-3
...................
Spring
'R'
Clip
10
...............
AM1 33-2
...................
Thrust Washer
l1
...............
CP27-0/15
................
Cooling Fan
12
...............
CP103-l8
.................
Rear Louvre Panel
13
...............
CP103-0/1
................
Diode Bridge Assembly
14..
.............
CP103-0/2
................
Control transformer
15
...............
CP103-0/3
................
Contactor
16
...............
MK6/3
.......................
Terminal block
17.
..............
MC79-0/13
................
Primary Flex and Plug
18
...............
W6-9/10
....................
Plastic Bush, Male
19.
..............
W6-9/11
....................
Plastic
Bush,
Female
20
...............
HF200-1 /l
5
..............
Mounting Foot
21
...............
H906
.........................
Cable Clamp
22
...............
H285
.........................
Earth Tab
23
...............
H774
.........................
Cup washer
26
...............
CP103-0/4
................
Switch, Change-over
27
...............
CPlO3-0/5
................
Terminal Block
28
...............
CP103-0/6
.................
Thermal Overload Device
29
...............
W5-10/19
..................
Potentiometer Knob
30
...............
W26-l
.......................
Wirefeed Motor and Two-roll Drive
31
................
CABWIO
...................
Welding Flex 1 Omm2
32
...............
H1407
.......................
Crimp Lug
33
...............
H1408
.......................
Crimp Lug
34
...............
C150
.........................
Work Clamp
35
...............
BE951 OWlA
..............
Gun Cable Assembly (Gasless)
36
...............
CP103-26
.................
Loom Assembly
Page
16
WELDMATIC
120G
MANUAL
BE9510WIA
GUN
ASSEMBLY
1
...
BE8675A
......
Nozzle,Fibreglass Inner
2
...
BE8611
........
Head
2A. BE8678
........
Head Insulator
3
...
BE8607
.......
Body Insulator
4
...
BE8691WIA..Cable Assembly
7
...
BE25200207.Strain relief
8
...
BE9176
........
Wire
Tie
9
...
BE8630
........
Strain Relief Adaptor
IQ.
BE2280010
...
Plastic Screw
11
.
BE8707
........
Control bead
12
.
BE4932
........
Butt Connector
13
.
BE4714
........
Grub Screw
14.
BE1346
........
Quick Connect Tab
15
.
BE1920264
...
Liner .9mm-1.2mmx3M
16. BE2830004
...
Washer
5
...
BE8680
........
Handle, Switch Ass’y
6
...
BE8603
........
Snap Ring
Contact tips
0.9m
...............
BE8623
1.2
..................
BE8626
Spotting Nozzles
Stud
................
BE8650
Inside
..............
BE8659
Outside
...........
BE8660
Flat
.................
BE8661
To
replace liner: Remove gun cable assembly from the wirefeed mechanism,
remove nozzle (1) and head (2). Loosen grub-screw (13). Withdraw
old
liner and feed
in new liner. Adjust liner position such that the end protrudes
10
mm from the cable
assembly at the wirefeeder
end,
then retighten grub-screw to retain liner. At the gun
end, compress the liner within the gun cable, then cut it one contact tip length past
the end of the
body
tube
(4).
Refit head, tip and nozzle, refit gun to the wirefeeder.
FIGURE
12.
BE951OWlA
GASLESS
GUN CABLE ASSEMBLY
L
L
WELDMATIC
120G
MANUAL
Page
17
W26-1
MOTOR
&
TWO
ROLL DRIVE
ASSEMBLY
ITEM
#......
PART#
......................
DESCRIPTION
1
................
W26-0/1
....................
Motor and Gearbox
2
................
W26-0/3
....................
Screw M6
x
12
5
................
W26-0/6
....................
Feed Plate
6
................
W26-0/7
....................
Screw
M5
x
10
8
................
W26-0/9
....................
Screw
9
................
W26-0/10
..................
Axle Shoulder Screw
10
..............
W26-0/11
..................
Pressure Spring
1
1
..............
W26-0/12
..................
Washer
12
..............
W26-0/13.
.................
Inlet Guide
13
..............
W26-0/14
..................
Pressure Screw
14
..............
W26-0/15
..................
Nut
M5
15
..............
W26-0/16
..................
Retaining Ring
16
..............
CP103-24
..................
Connecting link
17
................................................
Csk
Hd
Screw
M5
x
20
18
................................................
Screw M5
x
12
19
..............
H1972
........................
Quick Connect Lug
20
..............
HI
135
........................
Insulating Boot
21
..............
SLE3MMPL
,..............PVC Sleeving
3
................
W26-0/4
....................
Key
4
................
W26-0/5
....................
Nut M5
7
................
W26-5/8
....................
Feed
Roll
0.9
&
1.2mm
FIGURE
13.
TWO
ROLL
DRIVE
ASSEMBLY
Page
l8
WELDMATIC
120G
MANUAL
?l.
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 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 Department and other Local Health or Safety Inspection Authorities may have additional
requirements. WTlA Technical Note TN7-98 also provides a comprehensive guide to safe practices in
welding.
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.
Recommended
shade
filter lens.
Amps
TIG
MMAW
MlG
Pulsed
MIG
0-100
............
10
.................
9
...................
10
.................
1
100-150
.........
11
.................
10
.................
10
.................
1
150-200
.........
12
.................
10-11
............
11-12
............
1
200-300
.........
13
.................
11
.................
12-13
............
1
300-400
.........
14
.................
12
.................
13
.................
1'
2-1
3
2-1
3
2-1
3
2-1 3
4
400-500
............................
"
13
.................
14
.................
14
500
+
..................................................
"
"
14
.................
14
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 work
pieces 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,
vapours, 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.
WELDMATIC
120G
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.
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;
m
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 combustibles
to sparks.
B
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.
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WIA Weldmatic 120G Owner's manual
- Category
- Welding System
- Type
- Owner's manual
WIA Weldmatic 120G is a welding power source designed for use with self-shielding consumable wires. It can weld with both 0.9mm and 1.2mm diameter wires, making it suitable for a variety of welding applications, from sheet metal to thicker materials. The machine has a maximum welding current of 120 Amps and a duty cycle of 17%. It features voltage control switches for adjusting the welding voltage and a wire speed control for setting the wire feed rate. The Weldmatic 120G comes with a 3-meter, 160 Amp gun cable and a heavy-duty PVC mains power supply cable.
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