WIA Arc Stabilizer Owner's manual

1.

INSTALLATION

MU

OPERATING

INS'FRUCTIONS

le

Check the supply volkage

to

which

the

IW2

unit

will

be connected

(230/240V

or 400/415V)

.

2.

Ensure

that

the power connecting lead

is

connected

to

%he

correct

supply voltage

terminal

on

the terminal block

situated

adjacent

to

the

HT

transformer,

_I_

NOTE2

The

unit

is

connected for

400/415

volt

single

phase

supply

before

leaving

tho

factory,

3*'

For

optimum

results

the

IF2

unit

must

be connected

ta

the

same

2

phases

as

supplied

to

the welder. When

used

in the

240

volt

mode

one

of

the

single

phases

used

to

supply

the

welder mufat be selected,

4.*

Connect the welder

to

the

IW2

unit

as

shown

schematically

on

the front

of

the

IW2

panel

with

the

flexible jumper cab1

CS

supplied,

5.

Connecf electrode and work

leads

-to

their respective terminals

on

the

HF2

unit.

6'*

Swikh

on

Welder

and

IF2

unit;.

7,

The

spark

gape

are

preset

at

the factory

to

0.015"

Aftor

8ome

time

in

service

the spark

gaps

will

need

re-adjusting

to

the

above

setting

to

achieve

maximm

continuous brilliance of the

indicator

lampo

Tesi; tho

1l.Z'.

outpnt whilst

welding and,

if

imufficient, reverm

the

400

volt

connectian, The

IW2

unit

should

then

be

correctly

'!in

phase"

with

welder

output.

0.010"

NOTE:

When

IF2

units

are permnmtly

connected

to

the

400

volt

mu

of welder,

a

fused connection pancl

is

recomndod

-&o

be fithd

-h

We

welder

with

2

x

5

,amp

fmes,

For

further information, contact

your

W.1.A.

Sales Ilranch

for

do-bails

of

connection

panels

available

for

lY.IeAc

machines.

2.

3

I

P

h

ITEM

NO

1

2

3

4

5

6

7

8

9

10

10.1

11

11.1

12.1

12.2

12.3

12.4

13

14

15

16

3.

DRAWING NO HF200-1 PARTS LIST ISSUE

1.

~~ ~

PART NO

HF213

HF214

HF215

CP4-16/2

HF202

MC14-1/14

HF203

MC35-0/12

FTW4

13

CP2-0/25

HF200-12/1

W1-23

HF200-13/1

HF209-1

BF209-2

MC20-41/3

MC20-41/2

HF201

HF200-1/15

H2097

DESCRIPTION

CASE

COVER

HANDLE

BYPASS CAPACITORS

2

mfd

400V

HIGH FREQUENCY CAPACITOR 0.002

mfd

6000V

SUPPLY TERMINAL ASSEMBLY

HIGH VOLTAGE TRANSFORMER

OFF/ON SWITCH

SPARK GAP ASSEMBLY

INDICATOR LAMP HOLDER

LAMP 24 VOLT 2 WATT

FUSE HOLDER

FUSE

-

3

AG

1

AMP

TERMINAL INSULATOR

TERP-IINAL INSULATOR

TERMINAL STUDS

TERMINAL KNOB

HIGH FREQUENCY COIL ASSEMBLY

SUPPLY FLEX

PLASTIC BUFFERS

CABLE CLAMP

CIRCUIT

DIAGRAM

FOR

HF

2

UNIT

DRAWING

NoHF210-C2

50

Hx.

5

UPPXY:

I

l

I

l

I

l

I

l

I

i

1

1.

SWITCH

2.

FUSE

-

1

AMP

3.

H.T.

TRANSFORMER

4

H.F.

COIL

5

SPARK

GAP

ASSEMBLY

6

HI

CAPACITOR

04OOZmfd.

6000v.

7

HE

BYPASS

CAPACITORS

2mld.LOOv

8

INDICATOR

LAMP

9

TERMINAL

ASSEMBLY

-""

SAFE PRACTICES

IN

USING WELDING

EQUIPMJWl’

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

more

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 PROTECTION.

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,

vapors, heat,

or

oxygen enrichment

or

depletion

that

welding

(or

cutting) may produce. Prevent them with adequate ventilation.

NEVER

ventilate with oxygen.

Lead, cadium,

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.

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

02:

cutting atmosphere

or

where the radiant energy

can

penetrate

to

atmspheres containing

evep

minute

amounts

of trichlorethylene or percholorethylene.

4.

Fire and Explosion 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.

Ts

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

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.

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

10

metres

but can

be

ignited

by

sparks.

(111)

openings (concealed

or

visible)

in floors

or

walls within

LO

metres

(1V)

combustibles adjacent

to

walls,

ceilings, roofs,

or

metal paxtitions

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 conductors

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

Terminals. and other exposed

parts

of

electrical

units

should have insulated knobs or

covers secured before operation.

.

-

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

b

i

"I'@LDAnC

HF2"

INSTALLATION

AND

OPERATING

INSTRUCTIONS

Check the supply voltage

to

which.

the

IIF2

unit

will

be connected

(230/240V

or

400/415V)

e

Ensure

that the power connecting lead

is

connected

-to

the correct

supply voltage

hrminal

on

the

terminal block situated adjacent

to

the

HT

-bansf

ormero

-

NOTEI

The

unit

is

connected

for

400/4l5

volt single

phase

supply before

Leaving

the

factory,

For

optimum results

the

€W2

unit

must

be connected

.t;O

the

same

2

phases

as

supplied

to

the

welder., When used in the

240

volf mode

one

of

the

single

phases used

to

supply

the welder

mst

be selected.

Connecf the welder

to

the

I@2

unit

as

shown schematically

on

*he

front

of

the

IW2

panel

with.

the flexible

jumper

cab1

es

supplied.

Connect electrode

and

work

leads

to

their respective terminals

on

the

m2

unit.

Switch

on

Welder

and

IIF2

unit,

The

spark

gaps

are

proset

at

the factory

fo

0.01511

After some

time

in semict

the

spark

gaps

will

need re-adjusting

-t;O

the

above setting

to

achieve

maximum

contimom

brilliance

of

the

indicator

lamp,

Test

the

ILJ?,,

output

whilst

welding and, if

imuffieienl,

rever~e

the

400

volt connection, The

IF2

unit

should

then

be

correctly

in

phase"

with

welder

output.

..

.

..

.o.

010"

I.

NOTE:

When

IP2

units

are

permanently

conneekd

to

the

4-00

vo1.t

sf

welder,

a

fused

connection. panel

is

recommended

to

be fithd

to

the

welder with

2

x

5

amp

ftlses,

For

further

information,

contact

your

'IY.

LA..

Sales

Ilranch

for

dekails

of

connection

panels

available

for

WY.I,A,

machineso

WIA Arc Stabilizer Owner's manual

WIA Arc Stabilizer Owner's manual

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