CAT. 12/88

WELDMATIC 180s MANUAL PAGE 2

2, RECEIVING

I n g e n e r a l i t i s a g o a d p r a c t i c e t u moue the e q u i p m e n t t o t h e s i t e o f i n s t a l l a t i o n b e f o r e urrpacking Use c a r e i n o r d e r t o au o i d damage t ct the i t ems. en c 1 osed ,

Check t h e e q u i p m e n t r e c e i v e d a g a . i n s t t he s h i p p i n g i n v o i c e t o make su re the s h i p m e n t i s c c r r l p l e t e a n d u n d a m a g e d .

I f a n y damage has. c t c c u r r e d i n t r a r l s i t i m m e d i a t e l y n c l t i f y W e l d i n g I n d u s t r i e s o f A u s t r a l i a o r t h e i r a u t h o r i s e d a g e n t ,

For a l l r e q u e 5 t e d i n f o r m a t i o n r e l a t e d t o t h i s e q u i p m e n t g i v e the c o r r e c t Model I d e n t i f i c a t i on a n d S e r i a l N u m b e r , T h i s i s l o c a t e d on a name p l a t e a t t a c h e d t o t h e h a c k o f t h e m a c h i n e .

3. INSTALLATION

3.1 MACHINE LOCATION

- Auai l a t l i 1 i t y oi el e c t r i c a l a n d z . h i e 1 d i n g gac-. z .upp1 i e 5 .

- A i r b o r n e d u s t p a . r t i c l E . 5 . w i l l a.1wa.ys a c c u m u l a t e i n v e n t e d e q u i p m e n t ! p a r t i c u l a r l y t h a t wi ttl f o r c e d a i r c o o l i n y a n d e x c e s ~ . i u e b u i 1 dup can of ten he the c a u s e of premature m a c h i n e f a i l u r e . A t a1 1 t i m e s e r l d e a v c ~ u r t o p u s i ticlrt the r r ~ a c h i n e t o m i n i m i s e the i n t a k e o f c o n t a m i n a t e d a i r , p a r t i c u l a r l y t h a t c o n t a i n i n g m e t a l l i c p a r t i c l e s s u c h 6.5. irom q r i n d i n q o p e r a t i c t r l z . . < S e e a1 SCI MkINTENANCE SECTION cl$ t h i 5. Plar1ua.l , page 6:i

T h e WELDMATIC 180s is d e s i g n e d t o r conr lec t ior l t o .a E.irlgle phase, 5E1 h e r t z e l e c t r i c a l m a i n s pawer s u p p l y .

T h e c h a r t b e l o w 1 i s t s the s u i t a b l e e l e c t r i c a l m a i n s uol +.ayes. a n d t h e a p p r o p r i a t e c u r r e n t d e m a n d .

MA1 NS VOLTAGE CURRENT DEMAND

WELDMATIC 180s MANUAL PAGE 3

3.3 CONNECTIOW TO ELECTRICAL MAINS POWER SUPPLY

A l l electrical work s h a l l o n l y be u n d e r t a k e n by a q u a l i f i e d el e c t r i c i a n

The recommended Supply F u s e R a t i n g i c . 20 Amps.

b J h e n m a k i n y c o n n e c t i u n t o t h e M a c h i n e S u p p l y t e r m i r r a l 5 , e n s u r e t h a t l o c a l codes a r e a d h e r e d t o , and t h a t t h e EARTH c o n n e c t i o n i 5. sec u re 1 ;v made.

T h e thins Power S u p p l y Cattle s h o u l d o n l y be r e p l a c e d w i t h an e q u i v a l e n t s i z e cable as t h a . t f i t t e d .

FIGURE 1 . CONNECTION OF F L E X I B L E SUPPLY CABLE

IdELWTIC 1865 MANUAL PAGE 4

-SHIELDING GAS HOSE

The gas h o s e f r o m t h e b a c k o f t h e m a c h i n e c u n n e c t s t o t h e s h i e l d i n g g a s r ~ g u l a t o r - f l ~ w m e t e r , s e c u r e d ~ i t h t h e m e t a l ' 0 . ' c l i p c.upp1 i e d .

-WELD1 t.1G CURRENT CABLES

G . M . A . w e l d i n g i s c o n d u c t e d w i t h t h e e l e c t r o d e p o l a r i t y p o s i t i u e , a n d t h e w o r k p i e c e n e g a t i v e .

T h e p o s i t i v e o u t p u t o f t h e p o w e r ~ , c l u r c e i s c c l n r ~ e c t e d t o t h e Gun C a b l e o u t l e t . T h e n e g a t iue o u t p u t a9 t h e power z .c~urce i s cor lnec t e d t u t h e work 1 ead ,

4. FRONT PANEL CONTROLS

S

"d \ 10

POWER I OFF VOLTAGE

F1 GURE 2. FRONT PANEL CClNTROLS

WELDMATIC 180s MANUAL PAGE 5

-UOLTAG€ SWITCH:

a u t p u t {JQI ta.ge wi l l ir1creac.e w i th i n c r e a s i r ~ g p u 5 . i t i u n n u m b e r s .

T h i c . i s i l l u m i n a t e d when t h e p o w e r - ~ . o u r c e is e n e r g i s e d , i n d i c a t i n g t h a t t h e power a n d c o n t r o l c i r c u i t s are a c t i v a t e d .

-!A I R € SPEED CClNTROL : l ~ C u n t r c ~ l s t h e w i r e t e e d s p e e d - r u t a . t i n g t h e c o n t r o l c l o c k w i s e

wi 1 1 i n c r e a s e t h e w i r e speed.

-SPOT T I t l E CONTROL :

I f t h e C y c l e A r c mode is n o t r e q u i v e d t h i s c o n t r o l c . h o u l d be r o t a t e d a n t i - c 1 o c k w i s . e and . ‘ c l i c k e d ‘ i n t o t h e B p o s i t i o n .

5 . WELDING SET-UP

- S e l e c t the a p p r o p r i a t e s i d e cl+ the d r i v e rcl1 1 fu r t h e wire d i a m e t e r . T h e d r i v e r o l 1 is r e v e r s i b l e - t h e l a r g e r g roove c.u i ts 1,ui r e s . 8 . Yrrtrr~ t cl I , 2mm a n d t h e m a 1 1 e r I 0 . drrm t cl 0 . 8mm

WELDMATIC 1885 MANUAL PAGE 6

WELDING CONSUMABLE TYPICAL SHIELDING GAS

MILD STEEL

STAINLESS STEEL

ARGON car ARGON ./ HEL I Ut1 M I XTUHES;

- S e t t h e gas f l o w r a t e t o s u i t t h e w e l d i n g p r o c e d u r e , u s u a l l y i n t h e r a n y e o f 1 8 t o 15 1 i t r e s / ' m i n ,

NOTE:- E x c e s s i v e gas f l o w i s c o c . t l r a n d may a d u e r s e l r a f f e c t t h e we1 d i n g r e c . 1 ~ 1 t ,

l 6. GENERAL MAINTENANCE

Care must be t a k e n t c ~ p r e v e n t e x c e s 5 i v e b u i l d - u p ci f d u s t a n d d i r t wi t h i n t h e we1 d i n g Power -Source . I t is recommended that a t r e g u l a r i n t e r v a l s , a c c o r d i n g t o t h e p r e v a i l i n g c o n d i t i o n c . , the mach ine cc11der.s be r e m o v e d a n d a n y d u s t a c c u m u l a t i o n be rerrloued t l y t h e u:.e of d ry , 1 CII.J.J F I ~ ~ E . S I . J ~ ~ cclrrlpre=.sed a i r ! l u r d. vacu urn c 1 ear ler ,

M i t h a n y G . M . A . u s e l d i n g p r o c e s ~ . , i n o r d e r t o o b t a i n t h e mct l~ . t 5 a . t i s f a c t o r . y w e l d i n g r e s u l t " . , t h e w i r e f e e d s h o u l d tle s m o o t h a n d c o n ~ . t a n t . I t ir. t h e r e f o r e impctlrta.nt t o obC.erve t h e f o l l o w i n g p o i n t s : -

- Keep t h e g u n cat11 e 1 i n e r c l ear of d u s t a n d c . w a r f t l u i 1 d-up . lJhen rep lacerr~ent : becomes necessary, f i t o n 1 ~ t h e c o r r e c t 1 i n e r t o wi t t h e gun cat11 ~i model , a n d el ec t r o d e t y p e a n d s i z e . The b u i l d - u p of d u s t i n a c a b l e 1 i n e r c a n tle m i n i m i z e d b y r e g u l a r p u r g i n g o f t h e 1 i n e r IAJ~ t h d r y cc~rr~prec.c.ed a i r , T h i E. may be c o n v e n i e n t l y d o n e e a c h t i m e t h e w i r e s p o o l i s r e p l a c e d .

- Rep1 a c e t h e w e 1 d i n g t i p ac. i t becclmes I U J C I ~ ~ o r damaged.

- Keep t h e w i r e d r i v e m e c h a n i s m c l e a n . P e r i o d i c a l l y c h e c k t h e d r i v e r o l l e r s f o r wear and for f r e e r o t a t i o n .

WELDMATIC 1130s MANUAL PAGE 7

7, TROUBLE SHOOTING

7 . 1 POOR WELDING RESULT

- Check for g o o d w i r e f e e d c o n d i t i o n s , i ,e. d r i v e rol 1 e r s n o t c l o g g e d w i t h d u s t b u i l d - u p , d r i v e r o l l e r s a r e t h e c o r r e c t s i z e a n d t y p e t o s u i t t h e we1 d i n g ire, and t h e d r i v e r o l 1 pres.z.ure i c . a d e q u a t e f c t r c o n s i s t e n t f e e d i n g . C h e c k a.1so t h a t t h e g u n c a b 1 e 1 i n e r ic, of c c t r r e c t size a n d n o t tal o c k e d a n d t h a t t h e w e l d i n g t i p i s i n good c o n d i t i o n a n d n o t e x c e s s i u e l r w o r n , A1 1 of t h e above can cau5.e e r r a t i c we1 d i n g c s n d i t i o n c , a n d I T I S T H I S AREA WHICH HAS THE HIGHEST PROBABILITY OF F A I L U R E I N ALL GAS METAL ARC WELDING a n d , t h e r e f c ~ r e , s h c t u l d be t h e f i r s t p o i n t checked when p r o h l ern5 c lccur .

- C:hecC: t h a t t h e s h i e l d i n g gas is c o r r e c t f o r t h e e l e c t r o d e w i r e i n u s e a n d f o r c o r r e c t ga.s flow r a t e a t t h e w e l d i n g t o r c h n o z z l e . E n s u r e t h e r e a r e no gas 1 e a k s , as. t h i 5. wi 1 1 r e s u l t i n weld p o r o s i t y . T h e gas n o z z l e m u s t be f r e e f rom s p a t t e r a n d f i rml y a t t a c h e d t o t h e we1 d i n g n c t z z l e t o e n s u r e t h a t a t m o s p h e r i c g a s i s n o t drawn i n t o t h e s h i e l d i n g gas.

- E n s u r e t h a t t h e w c ~ r k c lamp i s c .ecu re1 ;~ t i g h t e n e d a n t c l t h e w u r k - p i e c e so t h a t gclod e l e c t r i c a l c o n t a c t i s a ,ch ieved .

- E c . t a b l i s I - 1 t h a t t h e a r c vo1 tage i s . c c ~ r r e c t l : ~ s e t . An a r c v o l t a q e w h i c h i s t o o l o w wil 1 ca.uc-.e e x c e e . ~ ; i v e crackle, s h o r t i n g a n d s p a t t e r , w h i l e a n a r c vol t a g e t o o h i g h may rec.u1 t i n w e l d u n d e r c u t a n d / o r 1055 o f a r c ' d i r e c t i o n ' A r c 1 e n q t h i s . p r o p o r t i o n a l t o a r c vcl1 t a g e .

- (Jork-piece surface c u n t a m i n a t i o r ~ b;g water I cti 1 , g r e a ~ e , gal l , j d n i s i n q , p a i n t or o x i d e l a . y e r s c a n s e v e r e l y d i s t u r b t h e w e l d i n g a r c r e s u l t i n g i n a p o o r w e l d d e p o s i t , Shou 1 d t h i c, c o n d i t i o n o c c u r , ~ . u r f a c e c l e a n i n g of t h e wcark p i e c e ~ i 1 1 b e n e c e s s a r y .

- P i a g n e t i c a r c b l o w may be e n c o u n t e r e d p a r t i c u l a r l y h~then w e l d i n g f e r r o u s m e t a l s . M a g n e t i c f i e l d s I / J h i c h r e s u l t f r o m t h e we1 d ing c u r r e n t b e i n q cctnduc t e d t h r c t u q h t h e ~ ~ ~ ~ ~ r k - p i e c e c a n s e v e r e l y d i s t u r t t t h e ~ e 1 d i n y a r c T h i s protjl em rrlay b e ~ o e r c o r r ~ e by r e - p o 5 . i t i o r l i n g t h e .;wcark" c l a m p ti welding c u r r e n t r e t u r n > so WC, t o w e l d tao,l.ardE. it:, w e l d i n g tul,u,lardz. a he icuy t a c k w e l d , o r i n 5.evef-e case^. u t i l i z i r l q t h e ' t e c k ~ . t e p p i n q ' ~ ~ ~ e l d i n q t e c h n i q u e . - Lack c14 cine Plainz. uppl ply phase c a n e i t h e r c c ~ m p l e t t l y d i s a b l e

w e l d i r l q c o n d i t i o n s . Have a q u a l i f i e d e l e c t r i c i a n c o n f i r r r l t h a t ma.i nc. supp 1 Y i 5 ava, i 1 ab1 e a,t t h e WELDP.1ATI C: 1865 P o w e r - S o u r c e .

t h e !JELDPlATIC I 8 B S POI OF^ S o u r c e , or 1~1ere1 2' a , d ~ ~ . ' r ~ . ~ . l y a . f f ~ c t

7 . 2 NO WELD I N G C:UF:HEt\IT

- Check t h a t MainE. Supply is a v a i l a b l e a t t h e WELDMATIC 1 8 U S Power S o u r c e , i . e . , t h a t t h e f a n i s r u n n i n g a n d - t h e i n d i c a t o r 1 i y h t i s . on.

- Check c o n t i n u i t y o f t h e w e l d i n g c u r r e n t c i r c u i t , i .e. , 1 ~ 0 r k 1 ead, work c l amp and gun cab1 e c o n n e c t i o n s .

WELDMATIC 180s MANUAL PAGE 8

- I n s p e c t , and r e p l a c e i f necessary f u s e s on t h e WELDMATIC 1805 P w e r S o u r c e p r i n t e d c i r c u i t p a n e l , R e p l a c e f u s e s only w i t h t h e c o r r e c t t y p e ( D A 2 8 5 F 1 > a n d c o r r e c t c u r r e n t r a t i n g .

- C h e c k o p e r a t i o n of the w e l d i n g g u n swi tci-1, i . e . ~ ~ i r e - f e e d m o t o r r u n s , a n d gas IJdl IJe o p e r a t e s When g u n S W ~ t c h ~ l c l s e d . I f n o t r e p l a c e the gun c a b l e a s s e m b l y , a n d r e - t e s t ,

- The WELDFIATIC 138s w e 1 d i n g power s o u r c e i n c o r p o r a t e s an i n b u i l t o v e r temperature t h e r m o s t a t clrr the r e c t i f i e r which hli 1 1 t r i p i f t h e w e l d i n g l o a d e x c e e d s the o p e r a t i n g d u t y c y c l e .

I n t h i s euent t h e Power -Source w i l 1 not d e l iuer w e l d i n g c u r r e n t u n t i l t h e r e c t i + i e r has cooled s u f f i c i e n t l y . T h e thermostat r e se t s a u t o m a t i c a l l y - do n o t s w i t c h t h e power- s o u r c e o f f as the c o o l i n g far1 uJi1 1 assist the r e s e t i n g of the t t-I rrmclc. ta t .

- I f t h e f o r g o i n g c h e c k s have been made a n d n o t r e v e a l e d the f a u l t c o n d i t i on i t i s p c ~ s s i t r l e t h a t a. f a i 1 ure has c lccu r red i n the e l e c t r o n i c c o n t r o l c i r c u i t s clf the WELDMATIC 188s.

CP27- l1

L J

@RV1 M N - B A C K

9.1 PWER SOURCE ASSEMBLY

ITEM fi 2 3 4 5 6 7 8 9

10 l 1 11.1 l 1 . z 11.3 12 1 3 14 1 5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 32 35 36 37 38 39

PART #

CP27- l3 CP27- l 4 CP27-1 S CP27- 1 4 CP27- 1 7 CP27- l8 CP29-22 CP20-28 CP29-1 i CP20-l l C834-14/19 CP34-14/28 CP3-9/8 CP2B-12 CP19-17 CP27-6/15 w22-0 CP20-0/14 ld i -33 /1 W 1 1-1 l/l CF'2Q-Wi 9 CP20-0/20 t=P i7-0 / iB CP17-0/f B MCi4-1/14 Wll-W16 w3-10/19 W1-41 W17-2/12 CP28- l 4/ l 0 L0308 AM177 CP20-0/35 WIN44 CP2Q-37

DESCRIPTION

FRONT PANEL BACK PANEL CENTRE PANEL SIDE PANEL SIDE COVER M F F L E HINOED TOP AND SIDE PANEL BASE ASSEMBLY PRINTED CIRCUIT BOARD RECTIFIER DIODE SKR 130/04 DIODE SKN 13%/04 THERMOSTAT MELDING TRANSFORMER WELDINQ INDUCTANCE COOLING FAN MOTOR & 2 ROLL DRIVE ASSEMBLY CONTROL TRANSFORMER GAS VALUE HOSE BARE VOLTAOE SW ITCH ON/OFF SWITCH WELDING CONTACTOR RES1 STOR TERMINAL STRIP KNOB KNOB MAGNETIC CATCH LENS PCB MQUNTS WORK CLAMP §POOL HOLDER ASSEMBLY LOW ASSEMBLY NAMEPLATE CAPACITOR BANK ASSEMBLY OAS HOSE PRIMARY CABLE

t f

Q' i 8

a

9

9

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l

-3 'r +

j', i

h X

h X

l I

FIGURE 4. POWER SOURCE ASSEMBLY

ITEM #

l 2 3 4 5 8 7 8 P

10 11 l 2 13 1 4 i5 1 6 1 7 18 l? 28 2 1 22 23 24

25 28 27 28 29 3El 36 32 33

PART #

W22-8/1 W22-#/2 W22-8/3

W22-b/5 bJ22-0/6 W22-8/7 W22-Q18 W22-019 W22-8/ l B W22-8/1 l W22-8/12 W22-8/13 w22-11 w22-l2 W22-8/14 W22-8/17 w22-13 W2-31

W22-24

TC382-811 W24-8/& CP27-12

DESCRI PT1 O N

DRIUE MOTOR SUPPORT ROLL HOLDER

WASHER TENS I ON NUT PRESSURE SPRING LOCKING LEUER AXLE AXLE BALL GRIP BOLT PRESSURE SPRING BUSH TOP ROLLER SHAFT TOP ROLLER DRIVING PLATE DRIVE ROLLER WIRE GUIDE SOCKET CAP SCREW M6 x 1 2 SOCKET CAP SCREW M5 x 1 2 SOCKET CAP SCREW M4 x l 5 C/SUNK SOCKET SCREW P118 x 1 6 GUN CABLE ADAPTOR & NUT GUIDE TUBE BERNARD QUICK CONNECT MOUNTING BRACKET SOCKET CAP SCREW X 8 GRUB SCREW r14 x 5 SOCKET CAP SCREW r m X I E J STAR WASHER 8MM FLAT WASHER 8MM STAW WASHER 12"

L

. .

ITEM # PART #

1 4335 1A 71 Zd 2 4323 3 4327 4 4'385 5 438 6 d 4426 7 4391

4392 4393 4395

8 431 7 9 4332 10 4328 l 1 4434 I2 4422 13 457 14 3448 15 4841 16 4925 17 4P0 3 18 4PP l 19 4943

T I P S (SHORT SERIES>

DIAMETER

13 . &mm Q.Efmm 8 . P m 1 .#mm 1 .2mm 1 .3mm 1 .&mm

b I NERS

DESCRIPTION

5m ( 1 2 f t ) 7rri ( 1 5 f t >

DESCRI PVION

HEAD ASEiEIIBL?' "0" R I N G CAP BODY TUBE CONE NUT HANDLE KIP HANDLE FASTENER KIT NOZZLE, STANDARD NOZZLE TAPERED BRASS NOZZLE, HEAVY DUTY COPPER NOZZLE , P I PEL I NE STEP WASHER

BODY INSULATION HGNOE UP HOOK KIT TRIGGER SWITCH ASSEMBLY SW ITCH TERMINAL RC BODY ASSEMBLY CABLE END P I N & WIRE ASS'Y CABLE END (2 EACH) LOCKING SLEEVE STRAIN RELIEF

C LAP1 P

BODY ARrmuR

C t A w

PART #

7497 9486 748P 7496 7498 74P8 748 1

PART #

4421 2 4421 5

WELDHATIC 1885 MANUAL PAGE 13

WELDMATIC 1 8 @ S MANUAL PAGE 14

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m n

l J " - -

a ON/OFF Switch b Rectifier Thermostat c Contactor d Voltage Switch c Welding Transformer f Rectifier g Capacitor Bank h Llmitlng Inductance I Discharge Resistor

J Welding Inductance k Cooling Fan I CMrd Transformer

m Gas W v c n Gun Switch o Wire Feed Motor p Printed Clrcuit B o a r d

LOLTAGE SWITCH

FIGURE 7 . WELDHATIC 188s CIRCUIT DIAGRAM

r l

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9

9

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WELDMATI C l b 8 S MANUAL PAGE 16

ER

l".

ITEM # I 2

4 5 8

1 0

c A

n

I c

FIGURE 9 . W21-7 PORTABLE WIRE FEEDER

PART # W2 1 - 1 6 AM1 77 W2 1 "l 1 /'P AM1 38-2 W 2 2 - B TC262 W I N 4 4 CP27-12

D E S C R I P T I O N BASE ASSEMBLY SPOOL HOLDER ASSEPlBLY PLASTI C DUST FLAP t.10UNTING ROD PLASTIC DUST FLAP MOTOR 44 2 R O L L D R I V E ASSEMBLY GAS N I P P L E NAMEPLATE 2 R O L L Dl? I (SE PlUUP4T P P4G E(RC?ICI<ET

b

W Z I . 7 WIU FEWER l cp27"

POWER SDVRLE

FIGURE 1 8 . CONNECTION DETAIL FOR PORTABLE WIRE FEEDER

10 .4 AM169 EXTENSION LEAD K I T ( 1 B M )

TC 3 b W

4

0" Cwm* CA4L.r

4

DRAWING N! AM 16f

FI(3lJRE 11. W169 EXTENSIW LBW KIT ( lam)

1

SAFE PRACTICES I N USING WELDING EQUIPMENT

Produced by Welding Indus t r i e s of Aus t ra l ia P t y . Ltd. i n t h e i n t e r e s t s of improving operator safety. These notes should be considered only as a b a s i c guide to Safe Working Habits. A f u l l l i s t of Standards per ta ining to industry is ava i l ab le from t h e Standards Associat ion of Austral ia , a lso var ious State E lec t r i c i ty Au thor i t i e s , Departments of Labour and Industry or Mines Depart- ment and o the r Local Health or Safe ty Inspec t ion Author i t ies may have additional requirements.

1. A neat: unclut tered work area makes f o r s a f e working habi t s .

2 . Burn Prevention

The welding arc is intense and v i s i b l y b r i g h t . Its radiation can damage e y e s , pene t ra te l igh tweight c lo th ing , re f lec t from light-coloured surfaces, and burn the s k i n and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs a r e mre severe and pa infu l .

Wear p ro tec t ive c lo th ing - l e a t h e r (or asbestos) gauntlet gloves, hat , and safe ty- toe boots . But ton sh i r t collar and pocket flaps, and wear c u f f l e s s trousers t o avoid entry of sparks and slag.

NEVER LOOK AT AN ARC WITHOUT PRO'IXCTPON.

Wear helmet with safety goggles or glasses with s ide shields underneath, a p p r o p r i a t e f i l t e r l e n s e s o r p l a t e s ( p r o t e c t e d by c lear cover g lass ) . This i s a MUST for welding or cutt ing, (and chipping) to protect the eyes from rad ian t energy and flying metal . Replace cover glass when broken , p i t ted ,or spa t te red .

Avoid o i ly o r g reasy c lo th ing . A spark may i g n i t e them. Hot metal such as e l ec t rode stubs and workpieces should never he handled without gloves.

Ear plugs should be worn when welding in overhead posit ions or i n a confined space. A hard hat should be worn when o t h e r s work overhead.

Flammable hair preparations should not be used by persons intending to weld or cu t .

3 . Toxic Fume Prevention

Adequate v e n t i l a t i o n is essent ia l . Severe d i scomfor t , i l lness o r death can result from fumes, vapors, h e a t , o r oxygen enrichment or depletion that welding (or c u t t i n g ) may produce. Prevent them with adequate ventilation. NEVER v e n t i l a t e w i t h oxygen.

Lead, cadium, z inc , mercury, and beryll ium bearing and similar materials when welded (or c u t ) may produce harmful concentrations of toxic fumes. Adequate loca l exhaus t ven t i l a t ion must be used, or each person i n t h e a r e a as well as t h e operator must wear an a i r - supp l i ed r e sp i r a to r . For beryll ium, both must be used. Metals coated with or c o n t a i n i n g mater ia l s tha t emi t fumes should n o t be heate! un less coa t ing is remved from t h e work sur face , the a rea is well ven t i l a t ed , or the operator wears an a i r -suppl ied respirator .

Work i n a confined space only while it i s being ventilated and, i f necessary, while wearing air-supplied respirator.

Vapors from chlor inated solvents can be decomposed by the heat of the arc (or flame) t o form PHOSGENE, a highly toxic gas , and lung and eye i r r i t a t i n g products. The u l t ra -v io le t ( rad ian t ) energy of the a rc can a l s o decompose t r i ch lo re thy lene and perchlorethylene vapors to form phosgene. Do not WELD o r c u t where solvent vapors can be drawn into the welding or c u t t i n g a t m s p h e r e o r where the radiant energy can penetrate to atrimspheres containing even minute m1OUnt8 of t r i ch lo re thy lene o r pexcholorethylene. !

4. Fire and Explosion Prevention

Causes of f i r e and explosion are:- Combustibles reached by the arc, flame, fly- ing sparks , ho t s lag , o r hea ted mater ia l ; misuse of compressed gases and cyl in- ders; and short c i rcui ts .

Be aware tha t f l y ing spa rks or f a l l i n g s l a g can pass through cracks, along pipes, through windows or doors, and through wall o r floor openings, o u t o f s igh t o f the goggled operator. Sparks and slag can f ly 10 metres.

To p reven t f i r e s and explosions:- Keep equipment c lean and operable , f ree o f o i l , g r e a s e , and ( i n e lec t r ica l par t s ) o f meta l l ic par t ic les tha t can cause shor t c i r c u i t s .

I f combust ibles are in area, do NOT weld or c u t . Move the work i f p r a c t i c a b l e , to an area f ree of combust ibles . A v o i d pa in t spray rooms, d ip t anks , s to rage a reas , ventilators. I f t h e work can not be moved, move combustibles a t least l 0 metres away o u t of reach of sparks and heat; or p ro tec t aga ins t i gn i t i on w i th su i t ab le and snug- f i t t i ng f i r e - r e s i s t an t cove r s or sh ie lds .

Walls touching combustibles on opposite sides should not be welded on (or c u t ) . Wal l s ,ce i l ings , and f l o o r n e a r work should be pro tec ted by hea t - res i s tan t covers o r sh ie lds . Fire watcher must be s tanding by with s u i t a b l e f i r e ex t ingu i sh ing equipment during and for some time a f t e r welding o r c u t t i n g i f :

(1) combust ibles ( including bui lding construct ion) are within 10 metres. (11) combust ibles are fur ther than 10 metres but can be ign i t ed by sparks. (111) openings (concealed or v i s i b l e ) i n f l o o r s or walls within 10 metres

(1V) combustibles adjacent t o w a l l s , c e i l i n g s , roofs, o r me ta l pa r t i t i ons may expose combustibles to sparks .

can be i gn i t ed by r ad ian t o r conducted heat.

Af te r work is done, check t h a t a r e a is f r e e of sparks , glowing embers, and flames.

An empty container that held combust ibles , or can produce flamble vapors when heated, must never be welded on or c u t , u n l e s s c o n t a i n e r h a s f i r s t been cleaned as descr ibed in AS.1674-1974, t h e S.A.A. Cut t ing and Welding Safe ty Code. This includes: a thorough steam or caus t i c c l ean ing (or a solvent o r water washing, depending on the combust ible 's so lubi l i ty ) followed by purging and i n e r t i n g w i t h ni t rogen or carbon dioxide, and us ing pro tec t ive equipment as recommended i n AS.1674-1974. Water - f i l l ing j u s t below working l e v e l may substitute f o r i n e r t i n g .

Hollow cas t ings o r con ta ine r s must be vented before welding or cu t t i ng . They can explode. Never weld or c u t where t h e a i r may conta in flammable dust , gas , o r l iquid vapors such as petrol) . 5. Shock Prevention

E m s e d conductors o r other bare metal i n the welding c i rcui t , or ungrounded electrically a l i v e equipment can f a t a l ly shock a person whose body becomes a con- ductor . Ensure t h a t t h e maohine is correct ly connected and ear thed. If unsure have machine i n s t a l l e d by a q u a l i f i e d e l e c t r i c i a n . On mobile o r portable equipment, regular ly inspec t condi t ion of t r a i l i n g power l eads and connecting plugs. Repair o r replace damaged leads.

6- Electrode Holders and Connectors

Fully insulated electrode holders should be used. Do not use holders w i t h pro t ruding screws. Fully insulated lock-type connectors should be used to join welding cable lengths .

7. Terminals

Terminals, and o t h e r exposed pa r t e o f electrical units should have insulated knobs o r covers aecured before operation.