WELDING KIT Model No: CGW1 OPERA TING & MAINTENANCE

WELDING KIT Model No: CGW1 OPERA TING & MAINTENANCE
WELDING KIT
Model No: CGW1
Part No : 6000670
OPERATING & MAINTENANCE
INSTRUCTIONS
0305
Please note that the details and specifications contained herein are correct at the time of going to print.
However CLARKE International reserve the right to change specifications at any time without prior notice.
NOTES
-13-
-12-
NOTES
Thank you for purchasing this CLARKE Welding Kit.
Before attempting to use the welding kit, please read this manual thoroughly and follow
the instructions carefully. In doing so you will ensure the safety of yourself and that of
others around you, and you can look forward to the equipment giving you long and
satisfactory service.
Please note, these instructions are designed to aid you in the basic principles of welding,
flame cutting, brazing, silver soldering, heating and the safe use of gases, regulators and
torches, they are NOT a definitive instruction manual. With practice, a beginner can
become proficient in the art of gas welding and flame cutting. Once acquired, this skill
will prove to be very useful and possibly profitable.
CLARKE GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period
of 12 months from the date of purchase. Please keep your receipt as proof
of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
Specifications
Model No: .............................................................................. GWC1
1
1
1
1
1
1
3
3
2
2
1
1
Qty
Part No: .................................................................................. 6000670
Check List
Item
Moulded Carry Case: ...............................................................
Oxygen Regulator: ....................................................................
Acetylene Regulator: ................................................................
Welding Torch/Handle: .............................................................
Welding Nozzle Adapter: .........................................................
Cutting Torch: .............................................................................
Welding Nozzles: .........................................................................
Cutting Nozzles: ..........................................................................
Hoses: ...........................................................................................
Non Return Valve/Flashback Arrestor: ...................................
Spark Igniter: ...............................................................................
Tip Cleaners: ...............................................................................
-1-
General Safety Precautions
WARNING:
12.
11.
10.
9.
8.
7.
6.
5.
4.
3.
2.
1.
ALWAYS concentrate on the job in hand, no matter
how trivial it may seem. Be aware that accidents are
caused by carelessness due to familiarity.
ALWAYS ensure the switch is off before plugging in to mains. Avoid
accidental starting.
ALWAYS handle with extreme care do not carry the tool/machine
by its’ electric cable, or yank the cable to disconnect it from the
power supply.
ALWAYS maintain machine in top condition. Keep tools/machines
clean for the best and safest performance. Follow maintenance
instructions.
ALWAYS keep children away. All visitors should be kept a
safe distance from the work area, especially whilst operating the machine.
ALWAYS ensure that adequate lighting is available. A
minimum intensity of 300 lux should be provided. Ensure
that lighting is placed so that you will not be working in
your own shadow.
ALWAYS keep work area clean. Cluttered areas and
benches invite accidents.
ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.
Everyday eyeglasses do not have impact resistant lenses, they are not safety glasses.
ALWAYS disconnect the tool/machine from the power supply before servicing and
when changing accessories.
ALWAYS check for damage. Before using the machine, any
damaged part, should be checked to ensure that it will operate
properly, and perform its intended function. Check for alignment
of moving parts, breakage of parts, mountings, and any other
condition that may affect the machines operation. Any damage should be properly
repaired or the part replaced. If in doubt, DO NOT use the machine. Consult your
local dealer.
ALWAYS use a face or dust mask if operation is particularly dusty.
ALWAYS Learn the machines applications, limitations and the
specific potential hazards peculiar to it. Read and become familiar
with the entire operating manual.
As with all machinery, there are certain hazards involved with their operation
and use. Exercising respect and caution will considerably lessen the risk of
personal injury. However, if normal safety precautions are overlooked or
ignored, personal injury to the operator or damage to property, may result.
13.
ALWAYS keep your proper footing and balance at all
times - don’t overreach. For best footing, wear rubber
soled footwear. Keep floor clear of oil, scrap wood,
etc.
-2-
Trouble Shooting
• Tip too close to work.
• Nozzle too large.
•
•
•
•
•
•
Replace nozzle.
Tighten nozzle nut.
Return unit for
replacement.
Clean with tip cleaner or
replace nozzle.
Move tip further from the
work area.
Use next smallest size
nozzle.
Increase pressures,
consult tip table (page
6).
Remedy
Defective seat.
•
Nozzle loose.
•
Consult pressure table.
(page 9).
Probable Cause
Flames not clearly defined,
smooth or even.
•
Seat nicked.
•
Fully open oxygen valve.
Problem
Regulator not holding
constant pressure.
•
Too much pressure.
•
Replace cylinder with full
one.
Welding tip popping.
Cutting tip popping.
•
Oxygen needle valve on
torch handle partly
closed.
•
• Tip is operated at too low
heat.
Difficult to light.
•
Oxygen cylinder almost
empty.
Dirty tip.
Flame changes during
cutting.
•
Accessories
A wide range of tools and accessories is available from your nearest CLARKE dealer, for
further information, contact your nearest dealer, or telephone CLARKE International Sales
department on 01992 565300.I
IMPORTANT:
The use of parts other than CLARKE replacement parts may result in safety hazards,
decreased tool performance and may invalidate your warranty.
-11-
Flame Cutting Contd
Once the correct nozzle is tightly secured
in the cutting torch, correct pressure set
on the regulators, and flame is adjusted
to a neutral one, follow these simple
procedures to cut steel using
oxyacetylene.
1. Before lighting, open the oxygen
valve on torch handle, one full turn.
Make all oxygen adjustments with
valve on the cutting attachment.
2. Move the flame to the edge of the
steel and position the preheat cones
just above the metal.
3. When the steel becomes red, slowly
depress the cutting lever to release
the oxygen stream to cut through the
steel.
4. Slowly move the torch in the direction
of the cut. The correct speed is
accompanied by a sputtering
sound, and a steady stream of sparks.
This results in a clean, slag free cut
with square top and bottom edges.
5. Too fast a movement does not allow
time for the oxygen stream to cut all
the way through the metal. Slag fills
the kerf and the two pieces are not
severed.
6. Too slow a movement leaves a
rounded top edge with slag sticking
to the bottom of the metal.
7. The size of the preheat flame
determines how quickly the cut can
be started. Often, a small preheat
flame is desirable to conserve gases,
and prevent melting of the top edges.
-10-
Perfect Cut
Shows regular surface with slightly sloping
drag lines. Surface can be used for many
purposes without the need to machine.
Extremely Fast
Not enough time is allowed for the slag
to blow out of the kerf. Cut face is often
slightly concave.
Extremely Slow
Produces pressure marks which indicate
too much oxygen for cutting conditions.
Too Hot Preheat
Rounded top edge caused by too much
preheat. Excess preheat does not
increase cutting speed. It only wastes
gases.
8.
7.
6.
5.
4.
3.
2.
1.
ALWAYS use recommended pressure settings. Improper settings are wasteful. Extreme
pressure build up in regulators is a warning to have them checked and repaired.
ALWAYS ensure non return valves/flash back arrestors are fitted to both lines.
ALWAYS ensure all hoses and connections are tight and leak free, test for leaking
joints etc using soapy water, NEVER use an open flame. DO NOT overtighten
connections.
ALWAYS prepare the work area before welding/cutting, work in a well ventilated
area.
ALWAYS Store gas cylinders and related equipment etc, according to local
regulations.
ALWAYS use acetylene cylinders in an upright position, NEVER lying down.
ALWAYS Handle cylinders with care, chain or otherwise secure cylinders to a
permanent fixture. Take care when moving.
ALWAYS Wear the correct safety wear specified for welding, i.e. welding goggles,
welding gloves, apron and safety shoes etc.
Additional Safety Precautions
9.
ALWAYS “Crack” the oxygen cylinder valve before installing the regulator, this is
carried out by briefly opening the valve and allowing the escaping oxygen to clear
away any dust which could damage the regulator.
10. ALWAYS prime oxygen and acetylene lines separately before lighting up, this will
help prevent incorrect mixing of gases.
11. NEVER use oxygen to blow off work or clothing. Pure oxygen supports combustion
and a spark can ignite oxygen-saturated clothing.
12. NEVER use oil or grease on the equipment, oil and grease is easily ignited and burns
violently in the presence of oxygen.
13. NEVER work with damaged/leaking hoses and equipment, check for leaks using
soapy water, any defects must be rectified before continuing.
!! WARNING !!
Ensure there are no naked flames or sparks which could
ignite when priming or purging the lines etc.
Ensure a fire extinguisher is always to hand in case of
accidents.
-3-
Setting Up Instructions
Attaching The Regulators (Fig. 1)
Open the oxygen cylinder valve (arrowed) briefly to
blow out any dust etc, ensure the valve is fully closed
before continuing. Attach the oxygen regulator (Blue)
and tighten the connector using 25mm open ended
spanner, DO NOT overtighten.
Repeat the above procedure for attaching the
acetylene regulator (Red).
NOTE: The acetylene connections are all left handed
whilst the oxygen connections are all right handed.
Connect the hoses to the regulators, blue hose to the
oxygen outlet reg marked ‘OUT’ and red hose to the
acetylene outlet reg marked ‘OUT’, again observing
left and right handed threads. Tighten both
connectors using a 19mm open ended spanner. DO
NOT overtighten.
Attaching The Torch (Fig. 2)
Attach the acetylene hose (Red) to the torch inlet
valve marked ‘GAS’ and the oxygen hose (Blue) to
the torch inlet valve marked ‘OX’. Tighten both
connectors using a 19mm open ended spanner, DO
NOT overtighten. Ensure both valves are closed fully
before continuing.
Opening The Valves (Fig. 3)
Ensure both regulator knobs are opened fully (turned
anticlockwise), carefully using cylinder key, slowly open
both cylinder valves in turn, starting with the oxygen
one.
Adjusting Operating Pressure (Fig. 4)
When adjusting the operating pressures, refer to the
relevant table on page 6, depending whether welding
or cutting etc.
Adjust the operating pressure on both cylinders by
turning the regulator valve knobs in a clockwise
direction, observe the low pressure gauge (Right Hand
Gauge) until gauge reading is at the correct pressure
setting.
NOTE: the left hand gauge shows the pressure in the
cylinder, and is not adjustable, this is an indication
how much oxygen/acetylene remains inside the
cylinder.
Installing Cutting/Welding Nozzle (Fig .5)
Welding: Remove the cutting torch if fitted, attach
the welding nozzle adapter to the welding torch/
handle, tighten hand tight only.
Select the required welding nozzle and screw into the
adapter, to prevent the adaptor from turning, hold in
-4-
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Flame Cutting
Flame cutting is a simple process that can be quickly mastered. Only steel can be cut
with the oxyacetylene method, since cast iron, stainless steel, aluminium, brass and other
ferrous metals do not burn the way that steel does.
The way to cut steel is to heat it to its kindling temperature (a reddish colour), then burn
it with pure oxygen. A cutting torch provides both the preheat flames and pure oxygen
cutting stream. Acetylene and oxygen are combined in the torch head, and burn at the
torch tip with a 6000ºF flame, these are the preheat flames. The centre hole in the cutting
tip is the cutting oxygen hole, through which pure oxygen, which is not mixed with acetylene,
flows to cut the steel after the metal is sufficiently preheated.
Cutting Nozzles
76.2 - 101.6mm
50.8mm
12.7 - 25.4mm
9.6mm
3.2 - 6.4mm
Metal
Thickness
(mm)
4
3
2
1
0
00
Tip Size
55 - 65
45 - 55
45 - 50
35 - 45
25 - 35
25 - 35
Oxygen
Pressure
(P.S.I.)
6
6
6
6
6
6
Acetylene
Pressure
(P.S.I.)
Cutting nozzles are available in a wide range of sizes, the correct size being determined
by the steel thickness. Refer to the table below for correct pressures and tip sizes.
127 - 152mm
Tip size and pressure may vary according to operator
choice. This table is a guide only.
-9-
Brazing
Brazing differs from welding because the two pieces of metal to be joined are not fused
together. The brazing rod melts at a lower temperature than the parent metal, and the
braze strength comes from the surface overlay of the brazing rod.
The advantage of brazing over welding is that it is the best way to join dissimilar metals, or
repair cast iron. Almost any two metals can be joined by brazing, excluding aluminium
and magnesium.
Brazing is separated into two types, depending on the type of rod used, bronze or silver.
Bronze is less expensive than silver, and should be used when the fit between the two
metals to be joined is not close. The metals must be cleaned thoroughly before attempting
to braze, gently play the flame onto both parts until they become a dull reddish colour.
Both pieces must be of equal temperature otherwise the braze will flow to the hottest
piece. Heat the rod by placing it in the flame, then dip it into the flux (note the heat
causes the flux to melt and stick to the rod). If a prefluxed rod is used, this heating and
dipping step may be eliminated. Once the rod is fluxed, and the metals are heated to
the correct temperature, touch the rod to the joint, the rod melts and flows over the
heated area, depending on the size of the joint, it may be necessary to dip the rod into
the flux again. Abundant flux must be used, otherwise the molten rod will not stick to the
metals being joined.
Silver brazing is a little faster than bronze brazing. This is because silver melts at a much
lower temperature, and less heat is required, however, the joint must fit tightly together.
Bronze bridges a gap much better than silver. Instead of putting flux on the silver rod, the
joint should be painted with flux. The way to determine when the metals are at the
correct temperature is to watch the flux as it starts to bubble, as it does so it is time to
apply the silver. The silver melts as it touches the hot metal and the molten silver flows over
the fluxed area.
-8-
position with a 11mm open ended spanner. Adjust
the nozzle position by turning to the desired position
using an 11mm open ended spanner on the nozzle
connector.
Cutting: Remove the welding nozzle and nozzle
adapter if fitted. Attach the cutting torch to the
welding torch/handle, tighten the securing collar
by hand, ensuring the operating lever does not
foul on the valve knobs etc. Remove the cutting
nozzle securing nut, select the required nozzle and
place into the securing nut, screw into the cutting
torch and lock in place using a 23mm open
ended spanner (FIG.7), DO NOT overtighten.
Lighting the torch (Fig .8)
Open the torch acetylene valve approximately
one half turn and ignite using the supplied spark
igniter. Open the torch valve until the flame stops
excessive smoking and leaves the end of the nozzle
tip about 3mm, then reduce slightly to bring the
flame back to the tip. Open the torch oxygen
valve until a bright inner cone appears in the
flame.
The point at which the feathery edges of the flame
disappear and a sharp inner cone is visible is
called the “Neutral Flame”.
Basic Welding Procedures
Fig. 6
Fig. 7
Fig. 8
Gas welding is a method of joining similar metals by heating the adjacent surfaces to
melting point with an oxyacetylene flame, and allowing the two parts to fuse together,
with a filler metal being required on materials 5mm thick or more. The resulting weld is as
strong as the parent metal.
All metal to be joined, should be thoroughly cleaned before welding. Oil, grease, rust,
scale or other impurities affect the weld quality, and the tensile strength. Metal 5mm and
over should be bevelled before attempting to weld, and when bevelled edges are to be
joined, a filler rod of the same material must be used.
The table below is a guide only showing recommended, oxygen and acetylene pressures
relating to the size of the material to be welded etc.
If a too larger tip is used and the flame is softened, the tip heats up unnecessarily and is
often accompanied by a popping noise which splatters the weld puddle. Too hot a
flame burns the steel, and too small a flame is not big enough to get the job done.
Welding Rod
Welding rods are available in various sizes with the most common being 1.6mm, 2.4mm
and 3.2mm, they are also available for welding mild steel, cast iron and aluminium.
The size of rod will be determined by the type of weld, the metal thickness, and the
amount of filler metal required.
-5-
Welding Flame
A neutral flame is used for
almost all gas welding. The
oxyacetylene flame consumes
all oxygen in the welding area,
which
leaves
an
uncontaminated weld area
and a weld of maximum
strength.
An oxidizing flame is rarely used.
Neutral
Bluish to Orange
Nearly colourless
White
Carburizing
Oxygen
Pressure
(P.S.I.)
3
Acetylene
Pressure
(P.S.I.)
1
1
Number
Of
Passes
Fig. 7
Light Orange
White
Intense White
with feathery edge
Oxidising
Rod Size
3
5
1
A carburizing flame is used
mainly for flame hardening and
brazing.
Tip Size
1.6mm
5
5
2
steel. This action has to be done slowly as it
is necessary to have good penetration,
which comes from a deep puddle. When
moving the puddle, it is helpful to lean the
nozzle at an angle of approx 45º away from
the direction you want the puddle to move
Fig. 8.
Exercise 2
Place two pieces of 3.2mm steel together as
shown in fig. 9. Make the puddle again with
a back and forth torch motion, move the
puddle along the seam. Move the torch
slowly for a good penetration. This can be
checked by turning the parts over. The
penetration should be visible from the
bottom side. Test the weld strength by
attempting to pull the pieces apart.
Exercise 3
Nearly colourless
Metal
Thickness
(mm)
2
2.4mm
5
9
Bluish to Orange
1.6mm
5
3.2mm
9
White
2.4mm
5
3.2mm
Material 5mm or thicker should be bevelled
before welding. A 30º bevel on each piece
is the recommended angle. This is necessary
to obtain the best penetration possible
through the entire thickness. A rod is
necessary on all welds with bevelled edges.
Once the torch movement and puddle
control are mastered, you will be able to
make vertical, horizontal and flat welds with
confidence.
Repeat exercise 2, but add welding rod this
time. while the flame is directed at the steel
to form the puddle, put the rod into the
flame. when it becomes red, maintain this
temperature by moving it in and out of the
flame. Once the weld is started dip the rod
into the puddle, the rod will melt and build
up the weld so that the top is rounded
instead of concave. Remember, welding rod
is necessary on all double joints and once
the you become an experienced welder,
you will prefer to use rod on all welds,
regardless of how thin the steel to be welded.
3.2mm
10
Fig. 8
6.4mm
Welding - Practices and Exercises
Gas welding is not a difficult art. The following
exercises of torch movement are good practice,
and make subsequent welding easy
Exercise 1
Using a small welding nozzle and correct pressures
(Table above). Point the flame directly onto the
steel (3.2mm stock recommended) with the flame
cone just above the metal surface. When a
puddle begins to form, slowly move the torch
back and forth to move the puddle across the
-6-
-7-
Fig. 9
Fig. 10
60º
30º
Fig. 11
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