WIA Weldmatic 120G Owner's manual

WELDING

INDUSTRE§

OF

AUSTRALIA

A

DIVISION

CIF

WELDING INDUSTRIES

LTD

ACN

OQ4

547

1

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

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

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

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

LO

h0

HI

2

4

6810

LO

U

2

4

68

10

U

2

46810

W

I I

40

60

80

100

120 140

Welding

Amps

1.2mm

HANDICORE

Sf

Wirespeed settings

HI

l0

L8

HI

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

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

WELDMATIC

120G

MANUAL

Page

13

CIRCUIT

DlAGRAM

ac

0

L

"I

1

V

a

-1-10

wow

3>m

"

L

J

L

""""""

-J

"_

J

U

N

FIGURE

IO.

WELDMATIC

120G

CIRCUIT DIAGRAM

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

WELDMATIC

120G

MANUAL

Page

15

FIGURE

11.

WELDMATIC

120G

POWER SOURCE ASSEMBLY

L

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

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

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

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.

i

WIA Weldmatic 120G Owner's manual

WIA Weldmatic 120G Owner's manual

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