WIA Miniarc Owner's manual

CAT.

12/88

CONTENTS

-1-

-

OPERATING

AND

MAINTENANCE

INSTRUCTIONS

Introduction

Specifications/InstaLlation

Preparing

Machine

for

Work

Maintenance and

Accessories

Machine Assembly Drawing No.

and

Spare

Parts

List.

PAGE

NO.

1

2

3

4

5

Safety

Practices

Equipment Guarantee

GEXIERAL-

This

m.anual

has

been

prepared

especially

for

use in

familiar-

ising you with the design, installation,

operation,

mainten-

ance, and troubleshooting of

this

equipment.

All

information

presented

here

should

be

given careful consideration to assure

optim.um

perform.ance

of

this equipment.

-

RECEIVING/HANDLING

Prior

to

installing

this

machine, clean

all

packing

material

from around the unit and carefully inspect

for

any damage

that

may have occurred during

shipment.

Any

claims

for

loss

or damage that may have occurred

in

transit m.ust

be

filed

by

the

purchaser

with

Welding Industries

of

Australia Pty.

Ltd.

or authorised agent immediately

(refer

to

EQUIPMENT

WARRANTY

card

enclosed

with

Operating Instruction Manual).

When requesting information concerning this equipm.ent,

it

is

essential

to

supply correct Model identification and machine

Serial

No.

SAFETY

Before

the equipment

is

put into operation,

the

SAFE2Y

PRACTICES

section

at

the

back

of

this manual

MUST

BE

READ

COMPLETELY.

This

will

help avoid possible injury due to

misuse

or

improper

welding applications.

-

2-

DESCRIPTION

The

W.I.A.

'MINIARC'

Model MC69

is

a

compact

portable

A.C.

arc

welding unit.

It

is

designed

for

use with coated

arc

welding

electrodes

from

2mm

up

to

3.25mm.

diameter.

This unit complies

with

Australian Standards Specification

AS

1966

for

limited

input

class

machines, which,

in

effect,

means

a

machine

is

designed

for

use

from

a

15

amp.

240 volt

50

hertz single

phase

AC

supply and the Duty Cycle and Current Output

are

so

desig-

ned

to

m.atch this

15

amp.

supply.

-

SPECIFICATIONS

The welding current rating

is

1&5

amps 24.5 volts

25%

Duty Cycle,

5

minute averaging

periods,

140

C

temperature

rise,

Class

H

insulation.

Welding

Current Output,

45

-

140

amp

continuously

variable over the range. The Duty Cycle

at

the maximum output

(

140

amps)

is

15%.

"

INSTALLATION

FOR MC69

The

'MINIARC'

is

dedgned

to

be

connected

to

a

240 volt

50

hertz

single phase

A.C.

supply. The welder

is

fitted

with

a

15

amp.

primary

cable

and plug and

it

is

recornended that

this

plug

be

only connected

to

a

suitable

15

amp.

switch plug outlet,

capable

of

delivering

a

continuous

load

of

15

amperes.

The plug and plug

socket

are

both identified by

a

wide earth pin and the

15

arnp.

plug

will

not enter

a

10

amp.

domestic

socket.

However,

a

10

amp,plug such

as

used on

electric

power

tools

etc.

can

be

used

with

a

15

arnp

socket.

Therefore, ensure that your

electric

installation

for

the

'MINIARC

MC69'

welder

is

wired

with

a

15

amp.

socket.

For

you, the user, to correctly understand

the

above

specifica-

tions,

we

have included the following

brief

explanation on the

meanings

of

the

various

terms

used in the specification*

'Duty Cycle': In any

5

minute period, the Duty Cycle

is

the

ratio

of the

total

arcing

time

to

5

minutes, expressed

as

a

percentage,

e.g.

a

3.25mm

electrode

takes 1.25 minutes

to

run

its

full length. The operator

takes

3.75

m,inutes

5-0

set

up

the

job

for

welding and to

clean

the

slag

off

after

welding.

Duty Cycle

of

above example

=

25%.

'Limited

Input Current':

This

is

a

definition

agreed

to

by

Electric

Supply Authorities and welding manufacturers through-

out Australia and

restricts

the output

of

the machine

to

8.5

KVA

at

a

maximum Duty Cycle

of

25%.

'Rated

Input Current':

is

a

current drawn by the machine when

it

is

so

adjusted

to

give

its

100%

Duty Cycle output(approx-

imately 60

amps).

The

rated

input current

of

the 'Miniarc'

is

12.5

amps.

-

3-

It

should be readily appreciated from the above that input

currents

in

excess

of

15

amps. can be drawn from the supply,

and every care should be observed not to exceed specified

Duty

Cycle period.

EXTENSION

CABLES

.

If

it

is

necessary

to

use extension cables on the supply cable,

ensure that these are at least the size fitted to the welding

machine

(3

core

30/0.25),

also,

the longer the extension cable,

the larger the size the cable should be, to reduce the voltage

drop between the supply point

and

the machine, otherwise the

welding capabilities

will

be reduced

in

proportion to the volt-

age drop on the supply cable.

PORTABLE

MOUNTING,

The compact

'MINIARC

MC69'

is

supplied complete

with

wheels and

handle for ease

of

moving the machine around the workshop area.

To assist

in

packing and transport,the machine

is

usually supplied

with

tkae handle fitted down behind the machine. The handle may

be fitted

in

its

correct position

by

removing the two screws

in

the top cover, changing the handle to the upright position and

refitting the screws.

PREPARING

MACHINE

FOR

WORK.

On

setting up the welder ready for work, connect the Work Lead

to

the terminal marked

'WORK'

and the welding lead to the

terminal marked

'ELECTRODE'

and tighten knobs securely.

NOTE:

for

A.C.

arc welders

of

this

type,

it

doesn't matter

if

the leads are accidentally reversed, as no damage can be done

to the welder

and

welding output

is

unaffected, however the

correct terminals should always be

used.

Select the electrode

you

wish

to

use and adjust the electrode selector

by

unlocking

the knob on the front panel

of

the

machine and sliding

it

across

the quadrant. Switch the mains power

ON

whereby a faint

'hum'

should be heard, indicating the transfromer

is

energised.

After mmking final welding current adjustments, ensure that the

locking knob

is

firmly

secureds

"

ELECTRODE

SELECTION.

For

best

results

from your

'MINTARC

MC69'

use

W.I.A.

'AUSTARC'

arc welding electrodes for fast, dependable high quality

welding, The

full

range

is

obtainable from your nearest

W.I.A.

State Branch or authorised Distributor. For the majority

of

mild steel

welding,

a general purpose all position type welding

electrode should be chosen, such as

W.I.A.

'AUSTARC

12P'.

For

material of

1.6mrn

(1/16")

thickness and less, use

2.5mm

or

2mm.

electrodes. For material thicknesses over

1.6mm

use

3.25mm

diameter electrodes.

-4-

Before

performing any maintenance, ensure machine

is

discon-

nected

from

the power supply.

In

dry, dusty locations,

the

air

ducts

of

the

m.achine can

become

clogged causing

lack

of

ventilation, resulting in

possible

over-

heating

of

the welding transformer.

It

is

good

practice

to

blow

the

transformer out at regular intervals with dry

air

and keep

the vent

grills

at

the

base

of

the

machine

clear.

RECOMMENDED

WELDING

CABLE.

For

both

ELECTRODE

and

WORK

cables,

322/0.20

flexible

welding

cable

is

the

correct

size

to

match the rating

of

the machine.

Best

results

are

obtained with genuine

W.I.A.

leads,

thus

ensuring

all

fittings and connections

are

the

correct

type, For

longer welding

cables,

i.e..

5

metres

and over, use

a

larger

size

cable

to

prevent excessive current

loss,

e.g.

511/0.20

or

792/0

.

20.

ACCESSORIES

The recommended Accessory

Kit

for

the

'MINIARC'

is

W.I.A.

Kit

No.AA32, and comprises the following:-

l

x

3

metre

Welding

Lead

complete

with

Fully Insulated

1

x

3

metre

Work

Lead

with

Clamp

and

Lug

Connector

l

x

Welding

Helmet

complete

with lens (shade

LO)

and

Tong Type electrode holder

and

Lug connector.

clear

glass.

WELDING

HANDBOOK

-

'INTRODUCTION

TO

ARC

WELDING'

This

W.I.A.

publication gives

brief

but

concise welding instru-

ction and techniques

for

various applications and welding

position, Obtain

extra

copies

from

any

W.I.A.

Sales

Office

or

Distributor

a

AFTER

-

§ALES

SERVICE

AND

SPARES

W.I.A.

have

a

Sales

Branch in

all

major

states

of

Australia,

together

with

a network

of

Distributors

for

each

State.

Not

only

are

you, the

user,

assured

of

after

sales

service but you

are

also

assured

of

the

availability

of

expert

assistance

on

all

welding problems

from

the Top

Team.

in Welding Technology.

WARWTY

Have you

filled

out your Warranty

Card

and

posted

it

to

your

State

W.I.A,

Sales

Office?

if

not,

do

so

NOW.

SAFETY

We

strongly recom.end you read thoroughly

the

information

on

'Safe

Practices in Using Welding and Cutting Plant'.

DRAWING

NOMC69-0

0

PARTS LIST

ITEM

N9

PART

N3

DESCRIPTION

1

MC69-11

TRANSFORMER ASSEMBLY

11

MC69-19/1 LOCKING SCREW

2

3

4

5

6

7

8

9

10

MC69-25

BASE

ASSEMBLY

12

MC66-39 CLAMPING PLATES

MC69-l4

FRONT

PANEL

I3

WIN

84

SERIAL Nb

PLATE

MC6.9-15

BACK

PANEL

14 MC69-0/14 WHEELS

MC69-16

COVER

15

MC74

-13

HANDLE

MC66-22

OUTPUT

TERMINAL AS§EM.

MC66-24

LOCKING KNOB

MC20-0b5 TERMINAL

BLOCK

1.1

MC66-23

PRIMARY COIL

MC6$-0/f3

FLEX

&

PLUG

1.2

MC66-21

SECONDARY

COIL

CABLE

BUSH

-0

SAFE

PRACTICES

IN

USING

WELDING EQUIPMENT

Produced by Welding Industries

of

Australia

Pty.

Ltd.

in

the

interests

of

improving operator safety. These notes 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

Depart-

ment and other Local Health

or

Safety Inspection Authorities may have

additional requirements.

1.

A

neat uncluttered work

area

makes for safe working habits.

2.

Burn

Prevention

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. Skin burns

resemble

acute sunburn, those from gas-shielded

arcs

are

mre

severe and painful.

Wear protective

clothing

-

leather (or asbestos) gauntlet gloves, hat, and

safety-toe

boots.

Button

shirt

collar

and pocket flaps, and

wear

cuffless

trousers

to

avoid entry of sparks and slag.

NEVER

LOOK

AT

AN

ARC

WITHOUT

PI)ISTECTION.

Wear

helmet with safety goggles or

glasses

with side shields underneath,

appropriate filter lenses

or

plates

(protected by clear cover glass). This

is

a

MUST

for welding

or

cutting, (and chipping)

to

protect the eyes

from

radiant energy and flying

metal.

Replace

cover glass when broken,

pitted,or

spattered.

Avoid oily

or

greasy clothing.

A

spark

may ignite them. Hot

metal

such

as

electrode

stubs

and workpieces should never he 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 work overhead.

Flammable

hair preparations should not

be

used

by persons intending to

weld

or

cut.

3.

Toxic

Fume

Prevention

Adequate ventilation

is

essential. Severe discomfort, illness

or

death can

result from

fumes,

vaprs,

heat,

or

oxygen enrichment or depletion

that

welding

(or

cutting) may produce. Prevent them-with adequate ventilation.

NEVER

ventilate with oxygen.

Lead,

cadium, zinc, nkrcury, 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

remved 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.

Vapors

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

ox

cutting atmosphere

or

where the radiant energy can penetrate

to

atmospheres containing even minute

amounts

of

trichlorethylene or pexcholorethylene.

4.

Fire

and Emlosion Prevention

Causes

of fire and explosion are:- Combustibles reached by the arc, flame,

fly-

ing sparks, hot slag,

or

heated material; misuse

of

compressed gases and cylin-

ders: and short circuits.

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 goggled operator. sparks and slag can fly 10 metres.

'Po

prevent fires and explosions:- Keep equipment clean and operable, free

of

oil,

grease, and

(in

electrical parts)

of

metallic particles that

can

cause short

circuits.

If

combustibles

are

in

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

mved, 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.

Fire watcher must

be

standing by with

suitable

fire extinguishing equipment

during and

for

some

time

after welding

or

cutting if:

(1)

combustibles (including building construction) are within 10

metres.

(11)

combustibles

are

further than

l0

metres

but can be ignited by sparks.

(111)

openings (concealed

or

visible) in floors

or

walls

within 10

metres

(1V)

combustibles adjacent to walls, ceilings, roofs,

or

metal

partitions

may

expose

combustibles

to

sparks.

can

be

ignited by radiant

or

conducted heat.

After work

is

done, check that area

is

free of sparks, glowing embers, and flames.

An

empty container that held combustibles,

or

can produce flamable

vapors

when

heated,

must

never be welded on

or

cut,

unless container 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 vapors such as

petrol).

5.

Shock Prevention

Exposed conductor6

or

other bare metal

in

the welding

circuit,

or

ungrounded

electrically

alive

equipment can fatally shock

a

person whose

body

becomes

a

con-

ductor. 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.

6.

Electrode Holders and Connectors

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.

7.

Terminals

WIA Miniarc Owner's manual

WIA Miniarc Owner's manual

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