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Section Description Page

Cylinder Exchange Policy 1

1 Gases, Gas Cylinders 2

2 Gas Welding and Cutting Equipment 4

3 Gas Welding and Brazing Consumables (Rods/Fluxes) 6

4 Gas Welding and Cutting Equipment – Ships Cabinet (Safety Charts) 8

5 AMEROX® Equipment Identification Guide 10

6 AMERARC™ Equipment Identification Guide 12

7 Arc Equipment – Ships Cabinet (Electrode Stores, Safety Chart) 14

8 Arc Welding Electrodes and Equipment Guide 15

9 Arc Welding Machines – Inverters I-400 MST, MIG Welding 18 WELDZALL System 19 Wire Feeder 20 Torch 21 I-300S 22 I-300 ACDC 23 I-150 Inverter 24 R-655 Rectifier 25

10 TIG Welding Equipment 26 TIG Welding Filler Metals (Rods) 27

11 Plasma Cutting Equipment 28

12 Arc Welding Equipment and Accessories 30

13 Gouging Torch 32

14 Central Gas Installation Systems (CGI) 34 Workshop Outlet Station 36

15 Refrigerants 37 Test and Charging Equipment 38 Refrigeration Products & Equipment 40

16 Work Safety Precautions 42

17 The GMAW / MIG Welding Process 43

Index 44

Product Policy IBC

AMEROX® Gas Welding & Cutting Products•Gases–Oxygen,Acetylene, Argon and Nitrogen•GasWeldingandCuttingEquipment•CentralGasInstallationSystems•GasWeldingandBrazingConsumables•ShipsCabinet

AMERARC™ Arc Welding Products•ArcWeldingMachinesandEquipment•ElectrodesandAccessories•PlasmaCuttingSystems•TIGWeldingEquipment, Consumables and Accessories•ShipsCabinet

Table of Contents

CYLINDER EXCHANGE POLICY SALES - EXCHANGE – REDEMPTION

NOTICE: The key elements of the cylinder policy are summarized below. This summary is intended as a quick reference and not a statement of policy. For full details as well as terms and conditions, please refer to the Drew Marine Delivery Receipt which shall apply for all transactions.

GENERAL

All cylinders are sold to the customer F.A.S. vessel at normal ports of storage. Complete ownership of the cylinder is transferred to the customer at that time and place.

Drew Marine will accept cylinders for exchange or for return which are marked Drew Marine, or which meet the following specifications.

Oxygen, Argon and Nitrogen BS 5045 and DOT 3 AA or UN/ISO 9809

Acetylene BS 5045 and BS 6061 or UN/ISO 3807

For further details, refer to the Gas and Refrigerant Cylinders Identification Guide WRP-59.

Drew Marine accepts no responsibility for non-standard cylinders being landed without prior consent in writing.

Drew Marine will provide normal cylinder maintenance including periodic hydrostatic inspection and recertification and replacement of worn top valves at no cost to the ship owner. The repair of any damages caused by misuse or improper handling by the customer or missing valve protection caps will be charged to the account of the ship owner.

Drew Marine will not accept for credit cylinders which have been subjected to arc burn, flame, fire or impact resulting in dents or gouges.

Oxygen, Acetylene, Nitrogen and Argon Cylinders

ALTERNATIVE 1 Vessel Returns Cylinders for Exchange

Empty cylinders returned from the vessel will be exchanged for an equal number of full cylinders supplied by Drew Marine. Customer is only invoiced for the contained gas.

ALTERNATIVE 2 Vessel Requires Additional Cylinders

If the number of empty cylinders returned is less than the number of full cyl-inders supplied to the vessel, the customer will be invoiced for the additional cylinders supplied as well as the contained gas product provided in all cylinders.

ALTERNATIVE 3 Vessel Desires to Return Excess Cylinders, and the:

A. Number of Returned Cylinders Equals the Number of Cylinders Purchased From Drew Marine DURING Preceding Twelve Months. If empty cylinders to be returned are more than the quantity of full cylinders supplied to the vessel, the customer’s account will be credited with a redemption value for excess cylinders returned equal to the original purchase price, less 0.1% for each day that the cylinder has been in the customer’s possession provided that the number of returned cylinders does not exceed fine number of cylinders which have been purchased from Drew Marine within the preceding twelve (12) months.

B. Number of Returned Cylinders Exceeds the Number of Cylinders Purchased from Drew Marine Prior to Preceding Twelve Months. Drew Marine will accept the cylinders and credit line customer’s account with a redemption value for the excess cylinders originally purchased from Drew Marine prior to the last twelve (12) months based on the original purchase price, less the following reduction schedule:

Reduction From Length of Possession Current Drew Marine List Price

1-2 years 50%

2-3 years 65%

3-4 years 70%

4-5 years 75%

5-6 years 80%

6-7 years 85%

7-8 years 90%

8- years and over 95%

C. Cylinders Presented for Redemption Were Not Originally Purchased from Drew Marine. Drew will credit the customer’s account for the return of excess cylinders in acceptable condition which were not originally purchased from Drew for an amount equal to fair market value.

LIMITATIONS ON RETURNS OF ALL CYLINDERS

Cylinders may be returned at any Drew primary port of storage as listed in the current Drew Port Directory.

In order to maintain a balanced cylinder stock, Drew reserves the right to designate alternate ports where cylinders can be returned.

IMPORTANT NOTICE: Drew Marine warrants that GOODS delivered hereunder meet Drew Marine’s specifications. This is Drew Marine’s sole warranty with respect to the GOODS. ALL OTHER WARRANTIES, OTHER THAN TITLE, EITHER EXPRESS OR IMPLIED, WHETHER ARISING UNDER LAW OR EQUITY OR CUSTOM OF TRADE, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXCLUDED FROM THIS AGREEMENT.

All statements information and data presented herein are believed to be accurate and reliable but are not to be taken as a guarantee express warranty or implied warranty of merchantability or fitness for a particular purpose, or representation, express or implied for which seller assumes legal responsibility and they are offered

solely for your consideration, investigation and verification. Statements or suggestions concerning possible use of this product are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patent.

Cylinder Exchange Policy

1

2

section

1AMEROX® Gases and Gas Cylinders

Residual Pressure ValvesThe Drew Marine AMEROX Cylinder label has always included the statement “RETURN WITH 1 BAR PRESSURE” as well as “Keep valve closed at all times when not in use.” These instructions are not always followed and occasionally cylinders are returned that have been exposed to salt water with the top valves open. Water inside a cylinder can result in serious internal corrosion, in the case of an oxygen cylinder, or a significant reduction in the capacity of an acetylene cylinder.

Starting in January 1996, Drew Marine has equipped every new permanent gas cylinder, and all other cylinders requiring valve replacement, with a new, unique top valve, that automatically closes when the cylinder pressure has dropped to about 1 bar, thus closing off the inlet and preventing the acci-dental entrance of water or moisture. The Drew AMEROX Residual Pressure Valve is ideally suited to the marine industry since it assures a significant increase in the level of safety of Drew-supplied cylinders and requires no change in the way our customers use the gases delivered in the cylinders. No special adapters are required, no special procedures need be followed.

Cylinders are potentially hazardous. Refer to the Safety Precaution Charts on page 9.

Cylinder Capacity (water) – Liters

Typical Weight/Cylinder Gross Weight – kg (lbs) with Valve and Cap Nominal Tare Weight – kg (lbs) TARE S (Acetylene only) (*)

Nominal Cylinder Dimensions Diameter – mm Height With Cap – mm

Valve Outlet Connection

Valve Type

Cylinder Color

Cylinder Approvals

Cylinder Retest Period

Acetone Content Acetylene Cylinder kg (lbs)

Cylinder Product Content Standards @ 15°C, 1ATU Cubic Meters Cubic Feet kg (lbs)

Cylinder Equilibrium Pressure After Filling @ 15°C BAR PSIG kg/CM2

Cylinder Test Pressure @ 15°C - BAR (PSI)

Cylinder PCN

Gas Charge PCN

Maximum Recommended Continuous Withdrawal Rate Per Cylinder, Liters/Hour

40.0 5.0 61.8 (136.2) 11.2 (24.6) 53.5 (118.0) 9.2 (20.2) – –

229 140 1350 590

Whitworth 21.8 mm 1/14 RH – Ext

Forged Brass with Nickel Bursting Disc

Blue – RAL 5009

BS 5045 Part 1:1976/1982 and DOT 3AA-2132

or UN/ISO 9809

5 years or specific country requirement

– –

6.23 0.75 220.0 26.0 8.3 (18.2) 1.0 (2.2)

147.0 147.0 2132.0 2132.0 150.0 150.0 250-263.0 (3815) 250-263.0 (3815)

0506016 0720012

0505018 0721010

N/A N/A

40.0 5.0 82.9 (182.8) 13.2 (29.0) – – 76.1 (167.8) TARE 11.3 (25.0)

229 140 1350 590

Whitworth 26.4 mm 1/14 RH Int

Forged Brass

Maroon – RAL 3011

BS 5045 Part 1:1976 /1982with Porous Massing to BS 6061

or UN/ISO 3807 / 9809

Visual inspection at each refill, 10-year mass inspection

12.5 (276) 1.6 (3.5)

6.23 0.73 220.0 26.0 6.8 (15.0)(**) 0.8 (1.8)

15.0 15.0 218.0 218.0 15.3 15.3

60-75.0 (1088) 60-75.0 (1088)

0507014 0722018

0504010 0723016

1000 125

OX 40 OX5 AC 40 AC5 CYLINDER TYPE

(*) TARE S for acetylene cylinders includes cylinder shell, neck ring, top valve, porous mass, acetone and saturation charge.(**) Some non-Drew marked cylinders may be limited to 6.3 kg filling weight.

section

1

3

TECHNICAL INFORMATION (Some cylinders may vary from these norms. Refer to cylinder shoulder stampings prior to refilling.)

* Filling pressures are reduced to 179 BAR, 2600 PSI, 183 kg/CM 2 with a proportional reduction in contents and price in some supply locations.

HEAVY-DUTY OXYGEN/ACETYLENE REGULATORSThe Drew Marine heavy-duty oxygen and acetylene regulators are designed for maximum performance when cutting, welding, heating and brazing. Major features include: a modular capsule seat assembly that simplifies maintenance; a spring-loaded relief valve to protect the operator as well as downstream equipment; ergonomic pressure adjustment knob with color coded name plate; and total design simplicity which minimizes failures and reduces maintenance time, fire resistant teflon seat, and maximum pressure limiting mechanism.

Acetylene RegulatorPCN 0546053

Oxygen RegulatorPCN 0547051

ApplicationsNITROGENNitrogen gas is inert and does not react with other substances, liquids or gases. It is an inexpensive, exceptionally pure and dry gas which is excellent for purging tanks and lines, removing moisture from refrigeration systems, blanketing dangerous cargo and cargo that may be ruined by oxidation. Nitrogen is not suitable for use as a shielding gas for welding. It can be used as a plasma gas in special applications of the plasma cutting process where oxidation of the cut surface must be kept to the absolute minimum.

Blanketing of cargo is accomplished by pumping nitrogen into the cargo area and displacing the atmosphere in the voids or vacant spaces. This inert blanket helps to prevent flammable cargo from burning or exploding and non-dangerous cargo such as wine, fruit juice or vegetable oils from spoiling due to oxidation.

ARGONArgon is an inert gas which is used as a shield-ing gas for the Tungsten Inert Gas (TIG) welding process. TIG welding may be used for welding stainless steel, aluminum and other alloys such as

Cylinder Capacity (water) – Liters

Typical Weight/Cylinder Gross Weight – kg (lbs) with Valve and Cap Nominal Tare Weight – kg (lbs)

Nominal Cylinder Dimensions Diameter – mm Height With Cap – mm

Valve Outlet Connection

Valve Type

Cylinder Color

Cylinder Approvals

Cylinder Retest Period

Cylinder Product Content Standards @ 15°C, 1ATU Cubic Meters Cubic Feet kg (lbs)

Cylinder Equilibrium Pressure After Filling @ 15°C* BAR PSIG kg/CM2

Cylinder Test Pressure @ 15°C – BAR (PSI)

Cylinder PCN

Gas Charge PCN

50.0

91.9 (202.6)81.2 (179.0)

2291655

Whitworth 24.32 mm 1/14 RH – Ext

Forged Brass with Nickel Bursting Disc

Green – RAL 6018

BS 5045 Part 1: 1976/1982 and eitherDOT 3AA/ICC 3AA/DOT E 10043

or UN/ISO 9809

5 years or specific country requirement

9.3327.0

10.7 (23.6)

1962843200

357 (5178)

0724014

0725012

50.0

98.3 (216.7)81.2 (179.0)

2291655

Whitworth 24.32 mm 1/14 RH – Ext

Forged Brass with Nickel Bursting Disc

Gray – RAL 7023

BS 5045 Part 1: 1976/1982 and eitherDOT 3AA/ICC 3AA/DOT E 10043

or UN/ISO 9809

5 years or specific country requirement

10.3364

17.1 (37.7)

1962843200

357 (5178)

0726010

0727018

N50 A50 CYLINDER TYPE

YORCALBRO and CUNIFER products. Argon produces a smooth, quiet arc and excellent cleaning action when welding aluminum and magnesium with AC high frequency TlG equipment.

NOTE: Nitrogen and Argon are available in most major ports. Consult your local Drew office for details.

GAS CONTROL EQUIPMENTNitrogen/Argon RegulatorPCN 9002015 (not shown)

Argon/CO2 Regulator w/FlowmeterPCN 9079014(not shown)

Blanketing RegulatorPCN 0694019 (not shown)

Nitrogen Regulator 170 Bar Outlet Pressure PCN 9002056(shown above)

AMEROX® Gases and Gas Cylinders

4

The AMEROX Gas Welding and Cutting Kit is especially designed to meet the highest standards of the worldwide marine indus-try and to perform under the most rigorous shipboard conditions.

All parts in the AMEROX Kit are fully inter-changeable with most existing equipment now onboard and assure top performance and reliability. Safety is always a prime consideration, from the nozzle mixing design of our cutting attachment, to the recommended flashback arrestors and backfire valves, which no welder should be without. One example is the chrome plating on AMEROX Blowpipes which is specifically applied in order to avoid spat-ter adherence and to reduce heat transfer and possible backfires.

Our products are designed to perform safely and reliably under the toughest conditions of shipboard use. They are supported with parts and service through the Drew Marine organization in all major ports throughout the world.

The AMEROX Gas Welding and Cutting Kit contains all the basic components required for manual gas welding, cut-ting and brazing onboard ship. The prod-uct code number for the complete kit is 523010. Kit components are listed here and may be ordered as individual replace-ment parts using the product code num-bers indicated.

Please refer to pages 10 and 11 of the cat-alog in order to choose the other system parts such as regulators, hoses, backfire valves, flashback arrestors and safety and protective equipment necessary to com-plete an installation.

NOTE: Blowpipes, nozzles, cutting attach-ments and torch handles may be fully interchangeable with existing parts now onboard. These existing parts may be worn or otherwise unsafe and therefore, should be replaced with new Drew equipment to avoid possible serious damage or injury.

Description PCNRegulator Quick Coupling, Pair 9037053Torch Handle Quick Coupling, Pair 9037059

AMEROX® GAS WELDING & CUTTING KIT, PCN 0523010

AMEROX® QUICK COUPLINGS FOR TWIN HOSE

AMEROX Quick Couplings provide a quick and convenient way to connect hoses and torch handles to the gas supply system and an equally convenient way to disconnect and store the equipment. The couplings are complete and attach directly to the hose and apparatus fittings. It is not necessary to install and secure hose sockets. Further, the upstream piece contains an integral shutoff valve to prevent the escape of the gas.

Regulator to Hose

Torch to Hose

KIT CONTENTSDescriptionTorch Handle – Complete with 3/8” sockets and nuts Welding Blowpipe 50 Liter/HrWelding Blowpipe 100 Liter/HrWelding Blowpipe 225 Liter/HrWelding Blowpipe 400 Liter/HrWelding Blowpipe 650 Liter/HrWelding Blowpipe 1000 Liter/HrWelding Blowpipe 1300 Liter/HrWelding Blowpipe 1650 Liter/HrCutting Attachment 90° Cutting Roller GuideCutting Circular Bar and CenterCutting Nozzle 3-10 mmCutting Nozzle 10-30 mmCutting Nozzle 30-60 mmCutting Nozzle 60-100 mmCleaning Needles SpannerSpare Parts Kit Carrying Case

0526014 0527012 0528010 0529018 0530015 0531013 0660010 0532011 0533019 0535015 0538019

0537011 0536013 0661018 0539017 0540014 0541012 0665010 0545014 0790015

PCN

section

2AMEROX® Gas Welding & Cutting Equipment

Gas and Welding Operator’s ChartSafety and Operating Instruction Booklet

5

Warning: Backflow check valves will not stop a flashback. Approved flashback arrestors should always be attached to the inlet connections of a welding torch handle or a cutting torch. The AMEROX Flashback Arrestor contains a sintered stainless steel filter element that arrests (quenches) a flashback originating at the torch. It also includes a built-in backflow check valve. However, in the event of repeated flashbacks, the arrestor element may become so overheated that the flashback is reignited and continues upstream through the hose to the regulator, resulting in an explosion.

Therefore, to prevent serious dam-age and possible injury, AMEROX Backfire Valves should be installed at the regulator. In case of backfire, these backfire valves will automati-cally stop the flow of gas in either direction, extinguish the backfire and relieve any excess pressure buildup in the hose.

Oxygen and Acetylene RegulatorsA vessel’s oxygen and acetylene supply is provided either by cylinders mounted securely in the workshop or from the preferred safer and more convenient Central Gas Installation Systems (see Section 14, page 34). In order to connect the torch handle to the cylinder supply and to provide safety protection, Flashback Arrestors and Backfire Valves must be installed.

Description PCNOxygen Cylinder Regulator 0547010Acetylene Cylinder Regulator 05460121/4” Twin Hose 20 M Assembled w/Fittings & Coupler 90970163/8” Twin Hose 20 M Assembled w/Fittings & Coupler 9098014Oxygen Cylinder Regulator, Heavy Duty 0547051Acetylene Cylinder Regulator, Heavy Duty 0546053

Description PCNFlashback Arrestor, Acetylene 0542010Flashback Arrestor, Oxygen 0543018Backfire Valve, Acetylene 0548026Backfire Valve, Oxygen 0549024

AMEROX AccessoriesAMEROX accessories are designed for the safety, comfort and convenience of a vessel’s engineer. Welding goggles in particular are vitally important to the safety and comfort of the user and Drew Marine pays particular attention to these requirements by providing a “flip front” system which allows the welding lenses to be flipped up out of the way. Eye protection is retained through secondary clear acetate lenses which always cover the eyes so long as the comfortable soft plastic goggles are worn. A small point perhaps, but an important one. All Drew welding products are designed with this attention to detail and user comfort and safety.

AMEROX Flashback Arrestors and Backfire Valves

Oxygen Content Gauge and Profile Washer (0-315 BAR) 0552019Acetylene Content Gauge and Profile Washer (0-40 BAR) 0550013Oxygen Working Gauge and Profile Washer (0-16 BAR) 0553017Acetylene Working Gauge and Profile Washer (0-2.5 BAR) 0551011Oxygen Regulator Washer (10/Pkg)* 0662016Acetylene Regulator Washer (10/Pkg)* 0663014 Oxygen Hose Joint 1/4” RH 0711011 Acetylene Hose Joint 1/4” LH 0712019 Oxygen Hose Joint 3/8” RH 0557019Acetylene Hose Joint 3/8” LH 0556011Hose Socket 3/8”* 0559015Hose Socket 1/4” R3/8”* 0667016Gouging Nozzle 0544016Multiflame Blowpipe 2500L/Hr 0534017Multiflame Blowpipe 5000L/Hr 0534041Socket Nut 3/8” RH* 0560012Socket Nut 3/8” LH* 0664012Nozzle Retainer Nut 9088015Hose Clamp (fits both 1/4” and 3/8”) (2/Pkg) 0666018O-Ring Set (6 pairs/Pkg) 0728016

Unless indicated otherwise, sold and packaged as individual items.* Included in Spare Parts Kit PCN 0545014

Parts & Accessories PCN

Other gas welding and cutting supplies and accessories such as gas rods, fluxes and gloves are listed elsewhere in this catalog. All are stocked at major ports throughout the world.

Oxygen Cylinder Regulatorwith Backfire Valve

Acetylene Cylinder Regulatorwith Backfire Valve

Torch Handle Torch Handle with Quick Couplings Attached

Hose with Quick Couplings Attached

Gas Welding Goggles (50 mm) Flip Front 0565012Colored Gas Welding Lens (50 mm) Shade 5 (5 pair) 0566051Cover Lens (50 mm) Acetate (5 pair) 0567059Gas Ignitor – Triplex 0568016Replacement Flints (4 Triple Flints/Card) 0693011Cylinder Trolley (Single Cylinder) 0570011Gas Welding and Cutting Safety Precautions Chart (see page 9) 9076051

Parts and Accessories (continued) PCN

Flashback Arrestor Cut-Away View

Direction of Gas Flow fi

Backflow Check Valve

FilterElement

Acetylene Cylinder Regulator, Heavy Duty

section

2AMEROX® Gas Welding & Cutting Equipment

6

AMEROX Silver Brazing RodsPackaged in individual sealed plastic tubes to assure factory freshness, these flux-coated, cadmium-free rods are provided in two popular alloys, SL60 and SL45.

AMEROX Gas Welding and Brazing RodsThese rods and coating are low-fuming, specially formulated to meet the demand-ing marine applications and are all user-friendly products. Flux coatings, where required, are selected for easy wetting of the workpiece and rapid cleanup, as well as a very low hygroscopic level.

Each rod is selected for the solution of a specific welding and brazing problem and is particularly useful on difficult jobs such as thin materials or special alloys or mate-rial combinations.

High density polyethylene tubing with clear screw caps assures highest quality at delivery, as well as resealability after initial use. Complete product description and application information is included on the package label.

AMEROX FluxesDrew Marine fluxes are designed to exactly match the characteristics of the brazing rods with which they are recommended for use. The flux removes the oxide layers which are present both prior to brazing and at elevated brazing temperatures. Fluxes also improve the flow of the melted braz-ing rod onto the base material. Since most fluxes are corrosive, it is best to remove any residual flux after the workpiece has cooled. More detailed instructions may be found in our Welding Handbook. Flux qual-ity is assured by the tough plastic jar and cap and moisture-proof seal.

AMEROX Silver Brazing Rods

AMEROX Gas Welding and Brazing Rods

AMEROX Fluxes

NOTE: All Drew Marine welding and brazing rods are cadmium-free.

AMEROX Cast Iron Welding Kit PCN 0523036 3.25 X 450 mmThe AMEROX CI Cast Iron Welding Kit con-tains flux and gas welding rods for making machinable welds in cast irons. The rods are a strong, nickel-iron alloy for making crack-resistant welds on all types of light-to-heavy-duty gray, malleable or white castings. Excellent for filling surface defects, building up worn or missing sections of castings.

section

3Gas Welding & Brazing Consumables

7

FOR JOINING

MILD STEEL

ALUMINUM

COPPER ALLOYS

STAINLESS

OTHER STEELS

(SEE HANDBOOK)

STEEL

COPPER ALLOYS

IRON FOR

WEAR-RESISTANT

BUILDUP

(SEE HANDBOOK)

ROD TYPE

MSMILD STEEL

ALALUMINUM

SILICON

SL60FLUX COATED

SILVER

SL45FLUX COATED

SILVER

BRFLUX COATED

BRONZE

WBFLUX COATED

WEARING BRONZE

DIAMETER/LENGTH

(mm X mm)

2.0 X 10003.0 X 1000

WT: 2.5 kg/Pkg

3.0 X 500WT: 0.5 kg/Pkg

2.0 X 500WT: 0.5 kg/Pkg

2.0 X 500WT: 0.5 kg/Pkg

2.0 X 5003.0 X 500

WT: 1.0 kg/Pkg

3.0 X 5005.0 X 500

WT: 1.0 kg/Pkg

RECOMMENDED FLAME FLUX

NeutralNo Flux Required

Excess AcetyleneAMEROX AF Flux

NeutralAMEROX SF Flux

NeutralAMEROX SF Flux

Slightly Oxidizing or Neutral

AMEROX BF Flux

NeutralAMEROX BF Flux

PCN

90110160705014

0707010

0574013

0575011

05760190577017

05780150579013

APPLICATIONINFORMATION

AMEROX MS is recommended for oxy-acetylene welding of low carbon steels (less than .20% carbon). Also suitable for TIG welding.

AMEROX AL is an aluminum silicon alloy designed for brazing of aluminum cast-ings and forging alloys. A clean work-piece is essential as well as close tem-perature control.

AMEROX SL60 is a cadmium-free high silver alloy used for brazing copper and stainless steel joints–particularly for food/water containers. It provides a good color match for stainless steel.

AMEROX SL45 is a cadmium-free medi-um silver alloy used for brazing steel, stainless and copper alloys where high capillarity is important.

AMEROX BR is a flux coated low-fuming bronze rod for joining and surfacing steel, copper, brass, bronzes and gray cast iron as well as galvanized steel.

AMEROX WB is a flux-coated bronze rod with excellent wear and seawater cor-rosion resistance for buildup of shafts, gears, cams, sliderails and certain bear-ing surfaces.

AMEROX® Gas Welding and Brazing Rods

section

3Gas Welding & Brazing Consumables

FLUX TYPE SIZE CONTAINER PCN WORKING TEMPERATURE RANGE °C

FOR USE WITH AMEROX® ROD

SF SILVER BRAZING FLUX 113 GM 0582016 500 - 800 SL60 and SL45

BF BRONZE BRAZING FLUX 250 GM 0584012 700 - 950 BR and WB

AF ALUMINUM BRAZING FLUX 200 GM 0586018 500 - 700 AL

AMEROX® Fluxes

8

AMEROX SHIPS CABINETThe AMEROX Welding and Cutting Ships Cabinet, full, is available for installation on new buildings or may be retrofitted into existing vessels. Each full cabinet includes rods, fluxes and accessories required for gas welding, cutting and brazing onboard.

Regulators, hose, backfire valves, flash-back arrestors, as well as the gas supply or central gas installation and cylinders, must be ordered separately.

An empty cabinet also is available when an owner wishes to order contents separately in order to satisfy special requirements.

AMEROX GAS WELDING CABINETFull – PCN 0717019Empty – PCN 0522012

CONSUMABLES LAYOUTSuggested products for spare positions are TIG (GTAW Gas Tungsten Arc Welding) rods. See page 27 for additional information.

Ships Cabinet

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4AMEROX® Gas Welding & Cutting Equipment

BOLT HOLE M 10

In order to provide the necessary gas supply (oxygen and acetylene) to fully equip a ship’s workshop and to supplement the basic equip-ment and consumables supplied in the AMEROX Ships Cabinet, the following additional items should be ordered:

1. A supply of gas cylinders sufficient for a normal voyage. The ratio is normally three oxygen cylinders to two acetylene cylinders.

2. Gas cylinder regulators and backfire valves for both oxygen and acetylene are required. The regulators mount directly to the cylinders; the backfire valves connect to the outlet of the respec-tive regulator.

3. Connecting hoses for oxygen and acetylene, either 1/4” or 3/8” twin hose assemblies with fittings assembled, 20 meters in length, quick couplings, and a pair of flashback arrestors at the torch end.

4. For a new building, a Central Gas Installation System provides the safest, most easily managed gas supply facility. The system consists of a manifold, pressure regulator, high pressure flexible hoses, brackets and cylinder storage racks for the appropriate number of oxygen and acetylene cylinders. The system is usually installed in separate, ventilated compartments on the main deck.

5. For a central gas installation, one oxygen and acetylene outlet station in the workshop, complete with low pressure regulator, pressure gauges and backfire valves.

9

Each full cabinet 717019 is shipped with the following equipment and supplies. Resupply is available at all designated ports. In addi-tion to the empty cabinet 522012, Welding & Cutting Handbook WP-10, Safety and Operation Instruction Booklet WRP-12, and the Gas Welding and Cutting Operators Chart WRP-17, the following standard equipment and consumables are included:

Description Quantity PCN Torch Handle 1 0526014Welding Blowpipe 50L 1 0527012Welding Blowpipe 100L 1 0528010Welding Blowpipe 225L 1 0529018Welding Blowpipe 400L 1 0530015Welding Blowpipe 650L 1 0531013Welding Blowpipe 1000L 1 0660010Welding Blowpipe 1300L 1 0532011Welding Blowpipe 1650L 1 0533019Cutting Attachment 90° 1 0535015Cutting Roller Guide 1 0538019Cutting Circular Bar 1 0537011Cutting Nozzle 3-10 mm 1 0536013Cutting Nozzle 10-30 mm 1 0661018Cutting Nozzle 30-60 mm 1 0539017Cutting Nozzle 60-100 mm 1 0540014Spare Parts Kit 1 0545014Spanner 1 0665010SF Silver Flux 1 0582016AF Aluminum Flux 1 0586018BF Bronze Flux 2 0584012MS 2.0 mm 2 9011016MS 3.0 mm 3 0705014BR 2.0 mm 2 0576019BR 3.0 mm 2 0577017WB 3.0 mm 2 0578015SL45 2.0 mm 1 0575011SL60 2.0 mm 1 0574013AL 3.0 mm 1 0707010Welding Goggles 1 0565012Gas Ignitor 1 0568016Cleaning Needles 1 0541012

Cabinet Contents

Drew Marine Cylinder Safety Smart Chart WRP-65 (500 x 800 mm)For copies of charts, contact your local Drew Marine Account Center.

Gas Welding and Cutting and Safety Precautions Chart(400 x 500 mm) PCN 9076051

section

4AMEROX® Gas Welding & Cutting Equipment

10

45. Welding Blowpipe 1650L 0533019 46. Multiflame Blowpipe 2500L 0534017 47. Multiflame Blowpipe 5000L 0534041 48. Spanner 0665010 49. O-Ring Set 0728016 50. Welding Goggles 50 mm Flip Front 0565012 51. Colored Welding Lens 50 mm SH5 0566051 52. Cover Glass 50 mm Acetate 0567059 53. Gas Ignitor Triplex 0568016 54. Replacement Flints – 4/Pkg 0693011 55. Cleaning Needles 0541012 56. Blowpipe/Cutting Attachment Nut 0798019 57. Hose Couplers, 3/8” BSP, Pair 0795015 58. Regulator Quick Coupling, Pair 9037053 59. Torch, Quick Coupling, Pair 9039059 60. Regulator Gauge Guard 0663097 61. Heavy Duty Cutting Torch 0554015

20

19

1. Cylinder OX 40 – Oxygen 0506016 2. RPV Type, Top Valve Oxygen 0501057 3. Oxygen Regulator, Washer 10/Pkg 0662016 4. Oxygen Regulator, Cylinder 0547010 5. Oxygen Content Gauge 0552019 6. Oxygen Working Gauge 0553017 7. Oxygen Backfire Valve 0549024 8. Hose Socket 3/8” 0559015 9. Hose Clamp – 2/Pkg 0666018 10. Twin Welding Hose 1/4” 20 M 9097016 Twin Welding Hose 3/8”, 20 M 9098014 11. Oxygen Hose Joint 3/8” RH 0557019 12. Acetylene Hose Joint 3/8” LH 0556011 13. Oxygen Hose Joint 1/4” RH 0711011 14. Acetylene Hose Joint 1/4” LH 0712019 15. Cylinder AC 40 – Acetylene 0507014 16. Top Valve Acetylene 0500018 17. Acetylene Regulator, Wash. 10/Pk 0663014 18. Acetylene Regulator – Cylinder 0546012 19. Acetylene Content Gauge 0550013 20. Acetylene Working Gauge 0551011 21. Acetylene Backfire Valve 0548026

22. Socket Nut 3/8” LH 0664012 23. Socket Nut 3/8” RH 0560012 24. Acetylene Flashback Arrestor 0542010 25. Oxygen Flashback Arrestor 0543018 26. Torch & Regulator Spare Parts Kit 0545014 27. Hose Socket 1/4”, R3/8” 0667016 28. Welding Torch Handle 0526014 29. Cutting Attachment 90° 0535015 (75° Available on Special Order) 30. Cutting Torch 75° Angle 0747016 31. Cutting Torch 180° Angle 0747024 32. Cutting Nozzle 3-10 mm 0536013 33. Cutting Nozzle 10-30 mm 0661018 34. Cutting Nozzle 30-60 mm 0539017 35. Cutting Nozzle 60-100 mm 0540014 36. Nozzle Retainer Nut 9088015 37. Gouging Nozzle 0544016 38. Welding Blowpipe 50L 0527012 39. Welding Blowpipe 100L 0528010 40. Welding Blowpipe 225L 0529018 41. Welding Blowpipe 400L 0530015 42. Welding Blowpipe 650L 0531013 43. Welding Blowpipe 1000L 0660010 44. Welding Blowpipe 1300L 0532011

58

58

58

58

10

15

16

17

5

6

9

3/8” to 1/4” Hose Joint

23 8

8 5722

57 27

27 23

22

3/8” to 3/8” Hose Joint

22

8 8

88

23 23

22

11

121/4” to 1/4” Hose Joint

23 27 27

2727

23

22 2214

13

To convert non-standard hose connections to Drew Marine standard, cut hose A and install fittings listed at B.

A

B

89

8

22

9

23

18

21

60

3

1

24

7

section

5AMEROX® Equipment Identification Guide

11

34

28

37

32

36

2956

33

46

47

43

39

4241

45

40

44

38

51 52

35

48

25

10

24

59

59

5959

61

49

26

31

30

53

55

54

50

section

5AMEROX® Equipment Identification Guide

12

1. Arc Welding Accessory Kit 0716029 2. AMERARC Arc Welding Ships Cabinet 0716011 3. Cable Drum with Crank 0605016 4. Cable Connector, Pair 0692054 5. Welding Cable (**) (Refer to cable selection chart) 35 mm2 (*) 0602012 50 mm2 (*) 0603010 70 mm2 (*) 0604018 6. Ground Clamp 600 AMP 0613019 Ground Clamp 200 AMP (for AMERARC I-140) 0613050 7. Safety Electrode Holder 400 AMP 0614017 Safety Electrode Holder 150 AMP (for AMERARC I-140) 0614058 8. Face Shield with Headband 0615015 9. Chipping Hammer 0627010 10. Wire Brush 0626012 Stainless Steel Wire Brush for TIG 0812017 11. Clear Glass (page 31) (not shown) --------12. Arc Welding Electrodes --------13. Dark Glass (page 31) --------14. Shatterproof Lens (page 31) --------15. Gloves 0616013 16. Apron 0618019 17. Gloves TIG Welding 0813015 18. Face Shield with Handle 908901319. Electrode Holder (Whip) Assembly, “Stinger” 061402520. Ground Clamp Cable Connector 0613027 *Refers to cable cross-sectional area in square mm.

**Welding cable is supplied in 25 meter lengths per carton and priced by the meter.

Description PCN

4

2

12

3

20

19

section

6AMERARC™ Equipment Identification Guide

1

13

1314

5

159

18

7

10

6

8

16

17

Maximum Distance from Welding Power Source to Welding LocationAmperage 1 Ft = .3048 M Ft 49 99 132 165 197 247 296 329 M 15 30 40 50 60 75 90 100 100 35* 35 35 50 50 70 150 35 50 50 70 200 35 50 70 250 50 70 300 50 350 50 400 70

WELDING CABLE SELECTION CHART

* Cable cross-sectional area in square mm.

2019

SAFETY WARNING It is extremely important to follow recommended safe practices while using welding equipment and consumables. Always wear suitable protection against ultraviolet and infrared radiation, including Face Shield with proper shade lens, goggles, and gloves. Always provide adequate ventilation to avoid exposure to harmful fumes and to avoid possible accumulation of explosive gases from a leak. For additional information, refer to the Drew Marine Welding & Cutting Handbook WP-10. The AMERARC Arc Welding Safety Placard (PCN 9076044) is recommended for the workshop.

section

6AMERARC™ Equipment Identification Guide

14

The AMERARC Arc Welding Ships Cabinet, full, is available for installation in new shipbuildings or may be retrofitted into vessels. Each full cabi-net contains a range of AMERARC electrodes in most popular types and diameters.

An empty cabinet also is available for those instances in which an owner wishes to order contents separately in order to satisfy special requirements.

AMERARC WELDING CABINETFull – PCN 0716011Empty – PCN 0601014

1 box 2 boxes 2 boxes 1 box 1 box 1 box 1 box 2 boxes 1 box 1 box 1 box 1 box 1 box 1 box 1 box 1 box 1 box 1 box1 each Welding & Cutting Handbook WP-10

EO PLUS EO PLUS EO PLUS ER PLUS ER PLUS ER PLUS LH PLUS LH PLUS LH PLUS LV PLUSLV PLUSTE ST ST NI60Nl99 Nl99 CH

2.5 mm3.25 mm4.0 mm2.0 mm2.5 mm

3.25 mm2.5 mm

3.25 mm4.0 mm

3.25 mm4.0 mm

3.25 mm2.5 mm

3.25 mm3.25 mm2.5 mm

3.25 mm 3.25 mm

Each full cabinet is supplied with the following popular AMERARC electrode types and sizes. Resupply is available at all designated ports.

AMERARC CABINET CONTENTS CHECKLISTPCN 9076044

LV PLUS3.25

LV PLUS4.0

LH PLUS2.5

LH PLUS3.25

LH PLUS3.25

LH PLUS4.0

CH3.25

EO PLUS2.5

EO PLUS3.25

EO PLUS3.25

EO PLUS4.0

EO PLUS4.0

ER PLUS2.5

ER PLUS3.25

ST2.5

ST PLUS3.25

NI992.5

NI993.25

NI603.25

TE3.25

ER PLUS2.0

section

7Arc Welding Equipment Ships Cabinet

15

Classification Society ER PLUS EO PLUS LH PLUS LV PLUSAmerican Bureau of Shipping Grade 2 Grade 2 3H-3Y 3YVdBF3M

Det Norske Veritas Grade 2 Grade 2 3Y, H10 3Y, H10

Lloyd’s Register Grade 2 Grade 2 3-3YH 3YMH15

Bureau Veritas Grade 2 Grade 2 3-3YHH 3YMH15

Germanischer Lloyd Grade 2 Grade 2 3YHH 3YH1O

DREW MARINE PRODUCT SPECIFICATIONS

DREW AMERARC ELECTRODE APPROVALS

PackagingAMERARC PLUS Electrode packages are also built for the marine environment. Many in the marine industry will recognize the unique plastic tube that stores our AMERARC PLUS welding electrodes. Polyethylene construction makes this heavy-duty container highly resistant to water and moisture – exactly the construction needed for shipboard use. The snap-on polypropyl-ene cap, sealed to the container when delivered, has a specially designed gasket to permit efficient resealing.

Drew Marine maintenance and repair electrodes are placed in a cardboard tray that is then vacuum-sealed in a resealable composite metal foil pouch. The pouch is packed in a square or rectangular high density, rigid multi-layer box and then shrink-wrapped for further protection. All parts of the package can be easily incinerated.

AMERARC COCR is packaged in two 1.1 kg pouches per box, typi-cally providing a sealed package for each repair. A temperature indicating crayon (302°C/575°F) is included to assure the proper preheat temperature.

AMERARC Arc Welding Electrodes are approved by major clas-sification societies. If an electrode is not listed, no approval code exists for its class. Copies of approval certificates are available on request.

ELECTRODE AWS ISO EN 499/1599ER PLUS A5.1: E6013 E 42 0 RR 12

E0 PLUS A5.1: E6012 E 38 0 RC 11

LH PLUS A5.1: E7018-H4R E 42 3 B 32 H5

LV PLUS A5.1: E7048-H8 E 42 3 B 15 H10

ST A5.4: E 316L-16 3581: E 19 17 3LR26 E 19 12 3 L R 12

TE A5.4 :E 312-16 E 29 9 R 32

Nl99 A5.15: E Ni-CI E Ni-BG 12

NI60 A5.15: E NiFe-CI E NiFe-1-BG 12

SN A5.6: E CuSn-A EL-CuSn-7

AB A5.6: E CuA1-A2

AL A5.3: E 4043 Al-4043A

SSM0 A5.4: E 309Mo L-16

COCR A5.13: E Co Cr-A

PIPE A5.1: E 6010 2560: E 433 4 C10 E 42 2C 25

ECEL A5.1: E 6011 2560: E 43 4 C10

EOHP A5.1: E 7024 2560: E 43 2 RR 110

CRMO A5.5: E 8018-B2 3580: E1CrMo B24

STV A5.4: E 316L-16 3581: E19.12.3 LR23

DP A5.4: E 2209-17

section

8Arc Welding Electrodes

16

AMERARC Ferrous Electrodes

AMERARC LV PLUS is a basic-type, low hydrogen electrode with outstanding operating characteristics in the vertical down position. AMERARC LV PLUS can be used at relatively higher amperages providing high welding speeds with low heat input – the result – enhanced productivity and low residual stress and deformation. Excellent mechanical properties make AMERARC LV PLUS well suited for welding structures subjected to high stress conditions and/or low temperature impact loading. AMERARC LV PLUS is recom-mended for welding ordinary and high strength ship plates of A-D quality, including high strength, low alloy steels. Tensile Strength: 500-640 N/mm2

AMERARC HF60 is a high hardness range hard facing electrode based on a high chromium carbide composite with a rutile coating. It is ideally suited for rebuilding surfaces that have been worn due to moderate impact and/or severe abrasion. The very high chrome content produces a dense, smooth, easily polished, wear resistant surface. The as-welded surface has a minimum of ripple for this purpose. AMERARC HF60 is an excellent choice for resurfacing worn machine parts, hatch coamings, grates, conveyor screws, shackles, buckets, rails and cat’s pawls.

AMERARC ST is a basic rutile type stainless steel electrode providing an 18 Cr, 12 Ni, 2 Mo weld deposit. It is suitable for welding austenitic steels of types AISI 316/316L Werkstoff 1.4404, 1.4401 and 1.4406 and similar standards. Operates well on both AC and DC positive polarity and has excellent out-of-position characteristics. Arc striking and restriking with AMERARC ST is easy and the electrode is free from short circuiting during welding. Slag removal is good and fillet welds have outstanding appearance. It is an extra low carbon type for highest corrosion resistance. Tensile Strength: 580 N/mm2 (Avg)

AMERARC STV is a specially formulated low carbon stainless steel electrode for joining titanium and niobium-stabilized 18/8 stainless steels. It is excellent for all positions of welding but excels in vertical down applications. The electrode produces a very smooth bead with good wetting resulting in a high quality weld deposit with a minimum of spatter and easily removable slag. AMERARC STV provides a smooth running arc, produces excellent welds in thin walled stainless steel piping and tanks in the vertical position. Tensile Strength: 560 N/mm2 (Avg)

1.5 2.0 X 300 0628034 40 - 80 4.1 2.5 X 350 0629032 50 - 110 4.8 3.25 X 450 0630039 80 - 150 AC/DC (+/-)

4.4 2.5 X 350 0631037 45 - 80 4.7 3.25 X 350 0632035 75 - 110 4.8 4.0 X 350 0633033 105 - 150 AC/DC (+/-)

4.3 2.5 X 350 0993015 45 - 80 4.6 3.25 X 350 0993023 75 - 110 4.5 4.0 X 350 0993031 105 - 150 DC (+)

4.5 2.5 X 350 0994013 25 - 75 4.5 3.25 X 350 0994021 35 - 125 4.5 4.0 X 350 0994039 50 - 160 AC/DC (+)

6.3 4.0 X 450 0995128 140 - 190 6.1 5.0 X 450 0995136 180 - 230 5.7 6.3 X 450 0995144 220 - 280 AC/DC (+)

4.1 2.5 X 350 0634031 65 - 110 4.0 3.25 X 450 0635039 100 - 140 4.1 4.0 X 450 0636037 140 - 200 AC/DC (+/-) (Vertical Down) 5.1 3.25 X 450 0637035 130 5.0 4.0 X 450 0638033 190 AC/DC (+)

4.3 3.25 X 350 0817025 90 - 110 AC/DC (+)

4.5 3.25 X 350 0996019 110 - 140 4.5 4.0 X 350 0996027 160 - 200 AC/DC (+)

1.5 2.5 X 300 0639023 50 - 80 1.7 3.25 X 350 0640020 70 - 120 AC/DC (+)

2.2 2.5 X 300 0997017 60 - 80 2.2 3.25 X 300 0997025 90 - 110 AC/DC (+)

1.7 1.6 X 300 0816043 25 - 45 2.2 2.5 X 300 0816019 40 - 80 2.2 3.25 X 350 0816027 65 - 120 2.2 4.0 X 350 0816035 90 - 150 AC/DC (+)

FOR WELDING

MILD STEEL NORMAL

CONDITIONS

MILD STEELUNDER

HIGH STRESS

HARD FACING

AUSTENITICSTAINLESS

STEEL

APPLICATION INFORMATIONELECTRODETYPE

AMERARC ER PLUS is a heavily coated rutile electrode used in all positions on AC or DC with positive or negative polarity. Arc action is particularly stable even when welding with low open circuit voltage trans-formers. Bead appearance is smooth and flat, and slag removal is easy. AMERARC ER PLUS electrodes have excellent wetting action and produce shallow penetration making it suitable for thin metal welding as well as butt, fillet and outside corner welds. Tensile Strength: 490-600 N/mm2

AMERARC EO PLUS is a general purpose mild steel electrode that can be used in all positions. When used at lower current levels (shallow penetrations), it is superior for welding thin sections, joints with poor fit-up or for bridging gaps. The weld bead is smooth in appearance, wetting and fill are excellent. Slag is easily removed. AMERARC EO PLUS is especially easy to use for vertical down welding. Striking and restriking is easy, even on low voltage transformers. AMERARC EO PLUS is used for general mild steel fabrication in all positions, for tack welding most rusty or galvanized plates and for ordinary ship’s plates of A-, D- and E-Quality. Tensile Strength: 480-580 N/mm2

AMERARC LH PLUS is a basic coated general purpose electrode with controlled low hydrogen well-suited for a broad range of general welding and repair applications. The superior mechanical properties of the weld metal make AMERARC LH PLUS a superior choice for applications with higher stress levels due to base metal chemistry or joint configuration. The coating produces a good weld bead appearance with a stable arc. The iron powder content of the coating produces a high deposition rate and metal recovery rate of 120%. Superior welding performance in the vertical up position. AMERARC LH PLUS is well-suited for welding ordinary and high strength ship’s plates of A-, D- and E-Quality and also for galvanized plates. Tensile Strength: 550 - 610 N/mm2 PLUS

ER PLUSGENERALPURPOSE RUTILE

EO PLUSGENERAL PURPOSE ORGANIC

LH PLUSLOW

HYDROGENELECTRODE

HF38MID-RANGE

STSTAINLESS

STEEL

LV PLUSLOW

HYDROGENVERTICAL

DOWN

AMERARC HF38 is an intermediate range hard-facing electrode with mechanical work-hardening properties well suited to applications combining high compressive loading and abrasion with excellent resistance to impact loading. The hardness of the weld deposit is Rc33-41/HBN 310-380. The weld deposit is machinable and can be flame cut. AMERARC HF38 is well suited to repair hatch cover rails and rollers, sheaves and winches and components of bulk carrier unloading gear. It is also an excellent choice for build up of severely worn areas prior to the application of AMERARC HF60.

AMERARC PIPE is an all-position cellulosic electrode producing an exceptionally smooth, evenly rippled weld bead with light slag and a high quality weld deposit. The arc is stable over a wide range of current and is forceful, providing good control in all positions including vertical down applications. Penetration is deep, producing highly ductile, sound root welds free of defects. AMERARC PIPE electrodes are recommended for welding pipe, pressure vessels, tanks with plain or galvanized surfaces and general shipboard maintenance. Tensile Strength: 520 - 535 N/mm2

AMERARC EOHP PLUS is a heavily coated, iron powder electrode providing high deposition rates for flat (downhand) and horizontal welding with good weldability and superior mechanical properties. The elec-trode easily produces equal leg fillets with smooth bead appearance and self-cleaning slag. Features include increased penetration with minimal root porosity in the recommended welding positions. The electrode is easy to control. AMERARC EOHP PLUS is ideal for making high speed horizontal fillet, butt and lap welds on mild plate and structural steels such as decking, hatch covers, etc. Tensile Strength: 480 - 570 N/mm2

AMERARC ECEL is an all-position cellulosic electrode, producing an exceptionally smooth, excellent quality weld deposit with very light slag. The forceful arc is easy to control, has good stability even at low current and freezes quickly. The penetration is deep, producing highly ductile, sound root welds, free from porosity and lack of fusion. The coating generates a large volume of shielding gas to eliminate porosity and problems associated with dirt and oil contamination. AMERARC ECEL electrodes are used for welding mild steels such as ASTM A-36,-283,-284,-285,-515,-516, and ABS Hull and Boiler steel. Typical applications include pressure vessels, fabricated structures, piping, tanks and general shipboard maintenance. Tensile Strength: 520 - 535 N/mm2

HF60HIGH

HARDNESS

STVVERTICAL DOWN

PIPEDEEP

PENETRATION ALL POSITION

ECELALL POSITION

EOHP PLUS

HIGHPERFORMANCE

WT.(kg/PK)

DIA/L(mm X mm)

PCN RECOMMENDEDAMPERAGE

SSMOMOLYBDENUM

STAINLESSSTEEL

AMERARC SSMO is a highly alloyed rutile coated molybdenum stainless steel electrode suitable for welding in all positions with AC or DC. The slag is self-releasing, revealing a weld bead of exceptionally smooth contour without undercut or cold lap. The higher chromium and nickel content in combination with the molybdenum provides exceptional corrosion resistance of the weld deposit. AMERARC SSMO is especially well suited for welding or repairing stainless clad steel plates where corrosion resistance of the weld metal is critical. It is ideal for joining or repairing stainless steel piping, heating coils and fittings in stainless steel cargo tanks. Tensile Strength: 650 N/mm2 (Avg)

section

8Arc Welding Electrodes

17

AMERARC TE is recommended for welding medium and high carbon hardenable steels, machine components, tools, springs and other steels of unknown composition. It is highly tolerant of base metal dilution and is generally free of hot cracking tendencies. AMERARC TE may also be used for welding dissimilar steels or under conditions where high temperature scaling resistance is important. The electrode operates well on both AC and DC positive polarity, has good slag removal and the finished weld bead may be polished to a hard high gloss surface with excellent wear characteristics. AMERARC TE is not recommended for welding cast irons or for repairing engine valves. Tensile Strength: 830 N/mm2 (Avg)

AMERARC COCR is a cobalt, chromium, tungsten alloy electrode with superior resistance to wear, erosion and impact at high temperatures. The metal core is fully alloyed assuring specified deposit composition if coating is chipped. AMERARC COCR is well suited for repairing/refacing engine valves and valve seats, pump rotors and corrosive fluid valve elements. Tensile Strength: 890 N/mm2 (Avg)

AMERARC Nl99 is a low slagging, high nickel electrode especially designed for cold welding of cast irons to produce crack-free, machinable welds in all positions. The unique coating produces a pulsed arc providing good penetration through surface skin and contaminants for a porosity-free weld without overheating and avoiding stress cracks. Preheating is not usually required. AMERARC Nl99 can also be used for welding cast irons to other metals such as steel, stainless steel, clad steel and copper-based metal alloys. Tensile Strength: 350 N/mm2 (Avg)

AMERARC Nl60 is a lower nickel alloy than the AMERARC Nl99 companion electrode. It has excellent operating characteristics with very low slagging and will operate on either DC positive or AC welding power. AMERARC Nl60 is recommended for welding cast iron where color matching is important or where large cavities must be filled. Always use the lowest possible amperage and weld for short time periods intermittently in order to reduce heat-induced stresses and the pos-sibility of cracking. For heavy sections, preheating to 300°C is advisable. Peening between passes to reduce residual stresses is recommended and the work should be covered or blanketed in order to produce a slow cooling rate. The electrode may also be used to weld malleable cast iron and for welding iron to steel. The deposit is machinable. Tensile Strength: 520 N/mm2 (Avg)

TEHIGH

CHROME-NICKEL

COCRCOBALT

CHROMIUM

NI99HIGH

NICKEL

NI60NICKELIRON

FOR WELDING

COPPER BASEALLOYS

andJOINING

DISSIMILAR METALS

SEE HANDBOOK

ALUMINUM

GOUGINGELECTRODENOT FOR WELDING

ELECTRODE TYPE

SNTIN

BRONZE

ABALUMINUM

BRONZE

ALALUMINUM

CHCHAMFERING

GOUGING

DIA/LT(mm X mm)

3.25 X 350

3.25 X 350 3.25 X 350

3.25 X 350

WT(kg/PK)

1.9

1.8

0.8

2.8

RECOMMENDED AMPERAGE

100 - 150DC (+)

90 - 125DC (+)

80 - 130DC (+)

160 - 180AC/DC (-)

PCN

0648024

0646028

0647026

0649022

APPLICATION INFORMATION

AMERARC™ Non-Ferrous Electrodes

AMERARC SN is a tIn-bronze electrode recommended for joining copper base alloys to them-selves or to steel or cast iron. It may also be used for welding cast iron without preheat where machining after welding is not required and for cladding of steels and other material and for filling cavities. AMERARC SN is used with DC positive polarity only. Avoid working temperature range of 400-600°C due to risk of hot shortness. Tensile Strength: 420 N/mm2

AMERARC AB is an aluminum-bronze electrode intended for building up or joining copper base alloys or for welding copper base alloys to steel. May also be used for buildup of cast iron using normal precautions for this crack-sensitive material. AMERARC AB deposits exhibit high strength and are highly resistant to abrasion and wear. As on all copper welding, preheating is advisable. Best results obtained in flat or horizontal position with DC positive. Tensile Strength: 690 N/mm2

AMERARC AL is an aluminum-silicon electrode suitable for welding cast or extruded aluminum alloys of relatively heavy thickness. Typical applications are repair of aluminum castings or architectural or decorative components. AMERARC AL is used with DC positive polarity only. The electrode exhibits high burn-off rates and high welding speeds and therefore for starts and on heavy sections preheating may be required. The residual slag is corrosive and should be completely removed following welding. Tensile Strength: 235 N/mm2

AMERARC CH is specifically designed for gouging out cracks, or back gouging of welds and for joint preparation. Its thick, specially-developed coating produces a strong plasma and gas jet which removes the material melted by the arc. AMERARC CH may be used for gouging most engineering materials such as steel, stainless cast iron and many non-ferrous metals. The resulting grooves are smooth and even and welding may follow immediately after gouging except on stainless steel, which should be thoroughly cleaned prior to welding. Either AC or DC negative polarity may be used. The electrode should be struck perpendicular to the work and then pointed in the direction of travel at an angle of approximately 20 degrees to the perpendicular. Travel speed of l00-150 CM/Min should be maintained. AMERARC CH can also be used for cutting and piercing holes. Good ventilation in closed areas is recommended.

AMERARC CRMO is a basic coated, extra low hydrogen electrode with major alloying elements of chromium and molybdenum. A limited carbon content reduces the possibility of cracking when welding the alloy steels for which this electrode is intended. These steels include 1/2% Cr - 1/2% Mo, 1% Cr - 1% Mo, 11/4% Cr - 1/2% Mo, which are typically used in high pressure boilers and power piping with a maximum service temperature of 550°C. AMERARC CRMO is ideally suited for welding creep and hydrogen resistant CrMo steels. The electrode provides high welding speed and deposition rate and easily removed slag. Tensile Strength: 550 - 520 N/mm2

CRMOCHROME-MOLY LOW HYDROGEN

DPDUPLEX

STAINLESS STEEL

1.7 2.5 X 300 0919011 50 - 80 1.7 3.25 X 350 0919029 70 - 100 (+/-)

4.5 2.5 X 350 0815011 65 - 95 4.5 3.25 X 350 0815029 90 - 140 (+/-)

1.7 3.25 X 350 0641028 65 - 120 AC/DC (+/-)

2.2 3.25 X 350 0814013 80 - 110 2.2 4.0 X 350 0814021 100 - 150 AC/DC (+)

1.7 2.5 X 300 0642026 30 - 70 2.1 3.25 X 350 0643024 55 - 110 AC/DC (-)

1.9 3.25 X 350 0644022 70 - 110 1.9 4.0 X 350 0645020 90 - 130 AC/DC (+)

ELECTRODETYPE

WT.(kg/PK)

DIA/L(mm X mm)

PCN RECOMMENDEDAMPERAGE APPLICATION INFORMATION

AMERARC DP is a duplex stainless electrode for welding and cladding of austenitic/ferritic stainless steels. The nitrogen-based weld metal is resistant to chloride-containing medias. Also, the AMERARC DP has high strength and good overall welding characteristics to combine with the excellent corrosion resistance. In the as-welded condition, the deposits have between 30%-50% ferrite and welding conditions should be used that will result in this same structure. Tensile Strength: 800 N/mm2

STAINLESS STEEL

ALLOYSTEELS

HARDENABLE STEELS

COBALT CHROMIUM

HIGH TEMPERATUREHIGH IMPACT

CAST IRONand

CAST IRON TO

OTHER STEELS

section

8Arc Welding Electrodes

18

MIG WELDING I-400 MSTThe AMERARC I-400 MST arc welding machine is an inverter type arc welder with 400 amps output for use with constant current (CC) and constant voltage (CV) welding operations. The MST model is ideal for welding with all the major shipboard welding processes:

• Shielded Metal Arc Welding (SMAW-Stick) with all types and sizes of electrodes

• CarbonArcGouging(CAC-A)withgougingrodsupto9mm(3/8”)

• Gas Tungsten Arc Welding (GTAW-TIG), with lift or scratch starting with current as low as 5 amps

And with a wirefeeder...

• Gas Metal Arc Welding (GMAW-MIG) using the short spray technique with 0.9 mm (0.035”) solid wire or the spray arc technique with 1.3 mm (0.052”) wire

• Flux-Cored Arc Welding (FCAW) with cored wires up to 2.4 mm (3/32”)

Welding with any process is easy. The operator simply selects a pro-cess, sets his current or voltage, and starts his job. Programmable controls allow for maximum flexibility, offering either machine or remote control of electric power and contactor. The MST allows adjustments for hot starting, hot current and arc control in the SMAW mode, inductance and material selection for GMAW, and pulse and slope controls for GTAW. Five welding programs can be saved for standard applications.

The AMERARC I-400 MST weighs only 29 kg so it is not difficult to take the machine to the work area, avoiding long cable lengths and both the associated voltage drops and safety concerns due to cables strewn about the ship.

The MST accepts any power configuration: 208/330/460 volts, 1/3 phase, 50/60 Hz. The proper input voltage can be selected by simply adjusting a switch; no tools are required. If the machine is accidentally connected to improper voltage, SMART LOGIC1 technology prevents the machine from damage.

The I-400 MST is equipped with a 14 pin receptacle for powering & operating a 24 or 110 volt AC wire feeder for GMAW and FCAW.

ACCESSORY EQUIPMENTDrew Marine offers several accessory items with the AMERARC I-400 MST. For GMAW/FCAW, the F4 wire feeder and Number 4 MIG torch, with associated spare parts as outlined in this section. A hand held Spool Gun and Controller, especially well suited for aluminum GMAW is also available.

AMERARC I-400 MST Multipurpose Inverter Arc Welding Machine

SPECIFICATIONSRated Output Amps 400A Volts 44V Duty Cycle 25% @ 400A 60% @ 300A Output RangeAmps 5 – 400AVolts 10 – 36VMaximum OCV 80 OCVInput Hz 50/60 Hz

DimensionsWidth 8.25 in/220 mmLength 16.5 in/420 mmHeight 16.9 in/430 mmWeight 64.2 lb/29.2 kg

LOAD CHARACTERISTICSInput 400A 300A NO50/60 Hz 36V 32V Load230V 3 phase 55A 37A 1.3A460V 3 phase 27A 18A 0.6AKW 16.9 KW 11.3 KW 0.3 KWKVA 21.9 KVA 14.6 KVA 0.5 KVA

HOW TO ORDERDescription PCNI-400 MST CC/CV 400 Amp Inverter Arc Welding Machine 208/230/460 Volt, 1/3 ph, 50/60 Hz 0600123

section

9AMERARC™ Arc Welding Machines

1 Registered trademark of Thermadyne Corporation

19

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9AMERARC™ WELDZALL System - Gas Metal Arc Welding (MIG)

AMERARC™ WELDZALL SYSTEM

DESCRIPTIONThe AMERARC™ WELDZALL SYSTEM consists of a self-contained GMAW (MIG) welding torch and wire feeder, and a 24 volt power converter. The torch and feeder, more commonly known as a spool gun, allows Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) of a number of metals that are considered hard to weld using more traditional means like “stick” or Shielded Metal Arc Welding (SMAW).

The AMERARC™ WELDZALL SYSTEM uses 100 mm spools of wire electrode, in diameters from 0.6 to 1.2 mm (0.023 to 0.045 inches). Common alloys like 4043 and 5356 Aluminum, Cunifer, 309 and 316 stainless steel, as well as mild and low alloy steels are readily available, although the most dramatic results are generally shown in aluminum welding.

The GMAW and FCAW processes are generally familiar to the ship repair community, but for most shipboard maintenance, startup expense was prohibitive. Now the technology is available in an afford-able but durable package. The system is easy to use that an everyday ship’s welder can perform repairs usually assigned to a riding or shore crew with specialized equipment.

FEATURES• 175ampoutputcapacity

• 14-pinconnector

• 15.2metercableandgashoseassembly

• Large,easytogriphandleandtriggerassembly

• Integratedwirespeedcontrolpotentiometer mounted in the handle

• Aircooleddesign

• Completewithspares

BENEFITS• Capacitytoweldallmaterials

• CompatiblewithAMERARC™MST400arcwelding machine and most common competitive machines

• Allowstheweldertogettothework

• Controlwhilewearingnormalsafetyequipment

• Speedadjustmentatthegun-notripsbackandforth to the arc welder

• Noneedforaliquidcoolingsystem

• Everythingneededtoweldisincluded,alongwith 90 days’ spares

HOW TO ORDER Description PCN AMERARC WELDZALL SYSTEM 0601105AMERARC WELDZALL SEASTOCK KIT 0601113Flowmeter Regulator 9079014Gas Hose Assembly 0792011To complete the system specify the proper welding gas. For aluminum welding, argon 20-liter 0727059For steel and stainless steel, argon gas mixture 20-liter 0727729

Voltage Converters for other Arc Welding Machines are available. Please consult your Drew Marine Account Executive.

SPECIFICATIONSSpool Gun Weight 1.3 kg (2.9 lbs)Spool Gun w. 15.2m (50ft) Cable 13.2kg (29lbs) Rated Output 175 ampsWire Speed 0 0-38 mm/sec (0-900 inches/min)Wire Diameters 0.6 – 1.2 mm (0.023 – 0.045”)

PACKAGING CONSISTS OF:1 spool gun and 15.2 meter cable1 24 volt AC to DC converter/control box10 0.9 mm (0.035”) contact tips10 1.1 mm (0.045”) contact tips10 1.2 m (3/64”) contact tips2 nozzles1 diffuser1 liner package1 0.9 mm drive roll1 1.1/1.2 mm drive roll1 gas valve tool1 drive roll tool

24-volt control unit included with the AMERARC WELDZALL SYSTEM

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section

9AMERARC™ Gas Metal Arc Welding (MIG)

MODEL F4 WIRE FEEDERDESCRIPTIONThe AMERARC Model F4 Wire Feeder is a heavy-duty, 4-roll drive feeder providing excellent performance for gas metal arc welding (GMAW/MIG) and flux cored arc welding (FCAW). The F4 Wire Feeder is used with the AMERARC I-400 MST inverter power sourc-es when using the machines in the CV (Constant Voltage) mode.

The F4 Feeder works on a 24-volt circuit provided through the welder control cable. Optional 3-meter and 6-meter control cables are available to extend the feeder operation at convenient distances from the welder. Included with the feeder are gas purge and wire jog switches.

The Feeder is equipped with contactor control, voltage and wire speed controls, gas solenoid, drive rolls for 0.9 mm and 1.2 mm wire, guide tube and 2.2 meter control cable and gas hose. Wire speed range of 1-20 meters per minute, with the digital meter for display of wire feed speed and voltage provides accurate control of feed speeds for the modes of GMAW welding, including: short circuit, globular, spray and pulsed spray.

SPECIFICATIONSInput Power (from Power Source) 24V AC, 5A, 50/60 Hz, 1-pHWire Feed Speed Range 1-20 meters/minute (50-750 IPM)

Wire Sizes Accommodated:Hard/Soft 0.6-1.6 mmCored 0.9-2.4 mm

Width 230 mmHeight 240 mmLength 540 mmWeight 13.6 kg

Supplied with 0.9/1.2 mm drive rolls and guide tube for solid wire. Accessory Parts Kit including knurled drive for pressure rolls for cored wire welding.

View showing F4 Wire Feeder atop MST 400 Welder with welding torch connected.

Close-up view showing 4-roll drive system with indexed pressure guides for adjusting wire feed tension.

HOW TO ORDER Description PCNMIG F4 Wire Feeder 0892019Wire Feeder Spares Kit 0892035Wire Feeder Jumper Cable 0780016 (from machine to Feeder)Flowmeter Regulator 9079055Inert Gas Hose 0792011Extension Cable 9 M/18 M (to operate OR Feeder remote from welding machine)

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SPECIFICATIONSTotal Weight 6 kg (14 lbs.) Length Hose & Cable 4.5 M (15 ft.)

Rating 400 amps at 60% duty cycle with CO2 gas shielding De-rate torch when using cored wires or gas mixtures.

MIG Torch Spare Parts Kit

Wire Feeder Spare Parts Kit

HOW TO ORDER Description PCNAMERARC 400 AMP Torch 0892027Torch Spare Parts Kit 0892043consists of: Item Quantity Nozzles 8 Tips 50 Diffusers 12 Insulators 20 Trigger Assembly 1 Liner 2 MIG Pliers 1 Conductor Tube 1

MODEL 400 AMP MIG TORCH

DESCRIPTIONThe AMERARC 400 Amp is an air-cooled welding torch with EURO-MAG connection for use with the AMERARC F4 wire feeder. It comes equipped with nozzle, contact tip and liner for 0.9 mm (0.035 in.) diameter wire.

The “goose-neck” style torch is rated at 400 amps, 60% duty cycle using CO2 gas. The torch hose and cable length is 4.5 M (15 ft). Torch and cable connections include four (4) integrated assemblies for feeding: gas, wire, arc welding power and power for the torch trigger to control wire feed. For operator safety, the torch trigger switch is controlled by a low voltage AC circuit sup-plied by the feeder.

Nozzle Insulator

Nozzle

Trigger

Liner

Gas Diffuser

Contact Tip

View showing part of AMERARC 400 AMP Torchwith parts.

ACCESSORIESDrew Marine can provide all the accessories for MIG welding, including gases and an assortment of solid and flux cored wires, in several diameters and spool sizes. Assortment includes high qual-ity steel, stainless steel, aluminum and copper alloys.

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9AMERARC™Gas Metal Arc Welding (MIG) with I-400 MST Welder

22

HOW TO ORDERPrimary Voltage PCN208/230-460 0596058

ACCESSORIESRemote Foot Current Control 0599094Remote Hand Switch, Torch-Mounted 0599078Remote Hand Amp Control, Torch-Mounted 0599086

FEATURES•Advancedstate-of-the-artinvertersystemprovideslightweight, high efficiency and outstanding reliability

•Precisecurrentadjustment,arccurrentcontrol,hotstartand line voltage compensation provides optimum quality of welding

•Easy-Link™, Smart Logic, and Thermal Overload Protection insure the absence of failures

•VoltageReductionDeviceallbuteliminatestheriskofshockinthe welding circuit

•MeetorexceedIEC60974-1(CE),NEMA,CSA,andIP23S standards including the 10 minute water spray

DESCRIPTIONThe AMERARC I-300S welding machine is a highly efficient, light-weight and reliable, constant current (CC) inverter arc welder. The rugged, compact and very portable case, with carrying handle make it well-suited for shipboard maintenance and repair activities.

The machine operates on single- or three-phase, 50/60 Hz supply voltages and supplies 300 amps of direct current at 40% duty cycle, (250 amps at 60% duty cycle). A high quality arc is assured, even at a minimum of 5 amps for precision TIG (Gas Tungsten Arc Welding welding, using the LIFT-TIG operating mode. The machines also have excellent arc characteristics for all STICK (Shielded Metal Arc Welding) welding applications and are ideal for handling electrode sizes of 1.6 - 5 mm. To power TIG controls, use the available 14 pin receptacle.

APPLICATIONSThe AMERARC™ I-300S inverter arc welding machine is an especially well-suited to shipboard use because of its low weight and inverter technology design. These features allow carrying the machine to the work area, eliminating the need for long cable lengths that affect the quality of the arc and create hazards as they are strewn about the ship.

Inverter technology offers other advantages in addition to mobility. The circuitry responds so quickly to arc changes (up to thousands of times a second) that the operator achieves the best advantage of all electrode types, regardless of weld position or current level within the required current range. For example, welders easily control or “whip” the rod to direct the weld puddle when welding at high amperages. This action speeds up the weld, while still obtaining a quality weld joint. Some additional advantages of inverter technology include: the machines are not affected by line voltage changes up to 10%, and they perform very effectively using less than 2O-3O% power than conventional welding machines.

AMERARC I-300S Inverter Arc Welding Machine

SPECIFICATIONS

NOTE: IT IS STRONGLY RECOMMENDED (required by many marine regulations) that the primary cable be connected to a fused safety switch using fuses rated as listed above to permit complete electrical shutdown of the arc welder when not in use for maintenance, and to protect other circuits in case of overload in the arc welder branch circuit. A fused safety switch cannot be used to guarantee protection of the arc welder in case of a short circuited secondary. Duty cycle is defined as the cumulative percentage of any ten (10) minute period during which the arc welder can be operated at the specified current without overheating.

For additional specifications, details and technical data, contact your Drew Marine Account Executive for a Product Data Sheet.

Rated Duty Output Primary Current at Input VoltageOutput Cycle Voltage Phase 208 230 460 kW kVA300 40% 32 3 45 41 21 12.0 16.0250 60% 25 3 35 32 16 9.4 12.6No Load -- -- 3 1.4 1.3 0.7 0.3 0.5250 40% 30 1 76 68 -- 9.4 15.7200 60% 28 1 44 40 -- 5.4 9.0No Load -- -- 1 2.5 2.2 -- 0.3 0.5

DIMENSIONS: Metric EnglishWidth 210 mm 8.3 in.Height 420 mm 16.5 in.Length 450 mm 17.7 in.Weight 20.0 kg 44.0 lbs.

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9AMERARC™ Welding Machines

23

HOW TO ORDERPrimary Voltage PCN208/230-460 0886160

ACCESSORIESRemote Foot Current Control 0599094Remote Hand Switch, Torch-Mounted 0599078Remote Hand Amp Control, Torch-Mounted 0599086

SPECIFICATIONS

For additional specifications, details and technical data, contact your Drew Marine Account Executive for a Product Data Sheet.

DESCRIPTIONThe AMERARC 1-300 ACDC special purpose welding machine is a constant current (CC) inverter arc welder that offers both DC and adjustable frequency AC. The AMERARC 1-300 ACDC machine also features wave balance adjustment for precision TIG welding of aluminum with advanced embedded microprocessor technology. This control of the wave form changes the amount of time spent on DCEP (cleaning) and DCEN (penetration) parts of each cycle, increas-ing arc stability. The rugged, compact and very portable unit makes it well- suited for shipboard maintenance and repair activities.

The machine operates on single- or three-phase, 50/60 Hz supply voltages and supplies 300 amps of direct current at 25% duty cycle, (250 amps at 40% duty cycle). A high quality arc is assured, even at a minimum of 5 amps for precision TIG (Gas Tungsten Arc Welding) welding. The machines also have excellent arc characteristics for all STICK (Shielded Metal Arc Welding) welding applications and are ideal for handling electrode sizes of 1.6 - 5 mm. To power TIG controls, use the available 14 pin receptacle.

APPLICATIONThe AMERARC™ I-300 ACDC inverter arc welding machine is especially well-suited to shipboard use because of its light-weight and inverter technology design. These features allow carrying the machine to the work area, eliminating the need for long cable lengths that affect the quality of the arc and create hazards as they are strewn about the ship.

Inverter technology offers other advantages in addition to mobility. The circuitry responds so quickly to arc changes (up to thousands of times a second) that the operator achieves the best advantage of all electrode types, regardless of weld position or current level within the required current range. For example, welders easily control or “whip” the rod to direct the weld puddle when welding at high amperages. This action speeds up the weld, while still obtaining a quality weld joint. Some additional advantages of inverter technology include: the machines are not affected by line voltage changes up to 10%, and they perform very effectively using 20-30% less power than conventional welding machines.

AMERARC I-300 ACDC Inverter Arc Welding Machine

FEATURES•Advancedstate-of-the-artinvertersystemprovideslight-weight,high efficiency and outstanding reliability.

•Precisecurrentadjustment,arccurrentcontrol,hotstartandline voltage compensation as well as high-frequency starting, slope and pulse controls, provide optimum quality of both SMAW (STICK) and GTAW (TIG) welding.

•EASY-LINK™, SMART LOGIC™, and thermal overload protection insure the absence of failures. Voltage reduction device all but eliminates the risk of shock in the welding circuit.

•MeetorexceedIEC60974-1(CE),NEMA,CSA,andIP235standards including the 10-minute water spray.

DIMENSIONS: Metric EnglishWidth 210 mm 8.3 in.Height 420 mm 16.5 in.Length 450 mm 17.7 in.Weight 24.0 kg 53.0 lbs.

Rated Duty Output Primary Current at Input VoltageOutput Cycle Voltage Phase 208 230 460 kVA kw300 36% 32 3 47 41 21 17 12.8250 40% 30 3 37 32 16 13.5 10No Load -- -- 3 1.4 1.1 0.7 0.5 0.13250 25% 32 1 96 87 -- 20 12200 40% 30 1 71 64 -- 14.8 8.9No Load -- -- 1 2.5 1.8 -- 0.5 0.13

*460 volt machine cannot be operated on single phase primary supply.

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9AMERARC™ Welding Machines

24

section

9AMERARC™ Welding Machines

AMERARC I-150 Arc Welding Machine

AMERARCTM I-150 Inverter Arc Welding Machine

FEATURES• Autoadaptivearcforcecontinuouslymeasuresthearc

voltage to adjust welding power. This optimizes arc stability with-out the risk of electrode sticking and minimizes spatter.

• Reliableinvertertechnologyprovidesalightweight, portable welding system.

• Steplessweldingcurrentadjustmentfrom4-150ampsoutput.

• Automaticoverloadprotectionshutsthemachinedownifthedutycycle rating is exceeded.

• Linevoltagecompensationautomaticallymaintainstheoutputcurrent level in spite of input voltage variations of + 10%.

• Choiceofsoft/crisporLIFT-TIGweldingmadebytoggleswitch.

• MeetsIEC974-1regulationandIP23/Fprotection,CE approved. (EN 60974-1).

DESCRIPTIONThe AMERARC I-150 Inverter Arc Welding Machine is a constant cur-rent arc welding rectifier providing 140 amps welding current at 55% duty cycle, 105 amps at 100%. Open circuit voltage is 48 volts. The AMERARC I-150 machine can be connected to any 230 volts + 15%, single-phase, 50/60 Hz supply providing 20 amps. The control includes compensation for line voltage variations up to 10% while welding. The machine weighs 6.7 kg (13 lb.) and measures 150mm x 225mm x 315mm (6.0 x 9.0 x 12.5 in.) and is supplied with a shoulder strap for carrying. Also included with the package are a 3m welding cable with electrode holder and a 3m ground cable with ground clamp and two male connectors.

The AMERARC I-150 Arc Welding Machine provides two modes of operation, controlled by a toggle switch, one for stick electrode welding (SMAW) and the other for LIFT-TIG welding (GTAW) without high frequency. The unit has thermal overload protection indicated by a warning light on the control panel. The machine produces an extremely stable DC welding current which is adjustable by a single potentiometer control on the panel.

APPLICATIONSThe AMERARC I-150 Arc Welding Machine is best suited for routine shipboard maintenance and repairs utilizing the stick welding process (SMAW) with electrodes up to 4.0mm diameter and also TIG welding (GTAW) of mild and stainless steels using argon shielding gas without high frequency stabilization. The arc is started using the LIFT-TIG feature by contacting the cold tungsten electrode to the workpiece with the argon gas flowing. Lift the torch several mil-limeters off the work and the arc is established immediately and TIG welding can proceed. No electrode contamination will occur if the electrode is cold at the start. The short circuit current is limited to approximately 5 amps thus no heating occurs.

The exceptionally smooth and well regulated output results in high quality welds with excellent appearance using AMERARC SSMO, AMERARC STV or AMERARC ST electrodes on stainless steel.

SPECIFICATIONSInput: 230 volts + 15%, single-phase, 50/60 Hz up to 20

amps

Power at Rated Outputs Duty Cycle

Output @ 20° C Input Power

140 amps @ 25.8V 35% 4.4KW

105 amps @ 24.2V 100% 3.0KW

Output Range: 5-150 amps

Open Circuit Voltage: 48 volts DC

Size and WeightDimensions

150mm x 225mm x 315mm

(6.0 x 9 x 12.5 in.)

Weight

6.7 kg (14.8 lb.)

HOW TO ORDERAMERARCTM I-150 inverter arc welding machine

(PCN 0595308) with welding and ground cables, with installed

electrode holder and ground clamp with two male connectors.

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FEATURES•Fullwave,three-phasesiliconrectifier

•Continuouscurrentadjustmentfrom60-815ampsatthepanel or with optional remote control

•Arcforcecontroladjustsshortcircuitcurrent,and

includes “Hot Start.”

•Idealarccharacteristicsforall-positionstickweldingwithall types of electrodes

•Linevoltagecompensation

•Protectivecircuitsguardagainstdamageresultingfromover loads or surges

•Corrosionprotectionisprovidedbydippingandtotallyenclosed control circuit compartment

DESCRIPTIONThe AMERARC R-655 arc welding machine is a heavy-duty, con-stant current/constant voltage three-phase rectifier ideally suited for all shipboard repair and maintenance activities. The machine provides an extremely smooth, ripple-free direct current that can be easily controlled to accomplish the most difficult SMAW weld-ing tasks. The arc starting current can be adjusted to eliminate striking and restriking problems, as well as electrode sticking. In the constant voltage made, the R-655 can be made mated to a wire feeder for GMAW/ FCAW welding.

APPLICATIONSThe AMERARC R-655 arc welding machine is a true multipur-pose power source, allowing all common arc welding processes: SMAW, GMAW, FCAW, and CAG (carbon arc welding). The machine is especially well-suited for use with low hydrogen and stain-less steel electrodes and also for all “out-of-position welding.” Electrodes up to 6.3 mm (1/4” inch) diameter can be used to produce high-quality welds efficiently. The machine provides a stable arc at low current levels for welding with small diameter electrodes. The R-655’s high output power in the constant current mode is also ideal for carbon-arc gauging (CAG). In the Constant Voltage mode, the R-655 may be used as a GMAW (MIG) power-source, with the addition of a wire feeder.

AMERARCTM R-655 DC Rectifier Arc Welding Machine

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9AMERARC™ Welding Machines

SPECIFICATIONSInput (60 Hz, 3φ) Voltage: 220 440 575

Rated Output

Amps Volts Duty Cycle, %

650 44 100

815 41 60

Maximum Open Circuit Voltage (OCV): 68 Volts

Height: 700 mmWidth: 565 mmDepth: 965 mmNet Weight: 327 kg

HOW TO ORDER Description PCNAMERARC R-655 DC Rectifier 0597023

NOTE: IT IS STRONGLY RECOMMENDED (required by many marine regulations) that the primary cable be connected to a fused safety switch using fuses rated as listed above to permit complete electrical shutdown of the arc welder when not in use for maintenance, and to protect other circuits in case of overload in the arc welder branch circuit. A fused safety switch cannot be used to guarantee protection of the arc welder in case of a short-circuited secondary.

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resistant welds than those made with the shielded metal arc welding methods. In addition, since no flux is required welding is applicable to a wide variety of joint types. Further, corrosion due to flux entrapment cannot occur, and expensive post-welding cleaning operations are not needed. The entire welding action takes place without spatter or sparks. Fusion welds can be made in nearly all metals such as alumi-

The Gas Tungsten Arc Welding process is a very popular choice for joining met-als of thicknesses less than 4 mm, where high quality, spatter-free welds with supe-rior appearance or corrosion resistance are desired.

The welds are protected from atmospheric contamination by shielding gas, resulting in stronger, more ductile, and more corrosion-

num, stainless steel, magnesium alloys, nickel and nickel-base alloys, copper, sili-con-copper, copper-nickel, brasses, silver, phosphor bronze, plain carbon and low-alloy steels, cast iron, and others. The pro-cess is also used for welding combinations of dissimilar metals, and for applying hard facing and surfacing materials to steel.

The Drew Marine flex neck TlG torch is excellent for the marine environment, offer-ing quality and long life, along with a simple design that is easy-to-use and adaptable to all shipboard situations. The torch comes complete with cable, gas hose, heat shield and backcap.

The Drew Marine TIG Accessory Kit, provides an assortment of collets, holders and caps for various welding operations. Additional parts are shown on the chart on next page. Argon gas, tungsten electrodes and regulator with flowmeter must be used with a suitable power source such as the 300S, 400MST or 300 ACDC inverter arc welding machines.

The AMERARC I-300 ACDC is ideally suited for TIG welding of all metals.

TIG ACCESSORY KITPCN 0521014

The TIG ACCESSORY KIT includes a starting supply of the most commonly used torch accessories.

Description PCN3 Collets 1.6 mm 0800012

3 Collets 2.4 mm 0800020

1 Long Back Cap 0811019

1 Collet Body 1.6 mm 0801010

1 Collet Body 2.4 mm 0801028

2 C5 Ceramic Cups 0802026

2 C6 Ceramic Cups 0802034

2 C7 Ceramic Cups 0802042

1 Heatshield 0810011

Pure tungsten electrodes are customarily used while welding aluminum. The 2% thoriated variety is usually preferred for all other applications.

TIG ACCESSORIES PCN

0.5 x 180 mm Pure Tungsten* (10/Pkg) 05240181.0 x 180 mm Pure Tungsten (10/Pkg) 05240261.6 x 180 mm Pure Tungsten (10/Pkg) 05240342.4 x 180 mm Pure Tungsten (10/Pkg) 05240423.2 x 180 mm Pure Tungsten (10/Pkg) 05240590.5 x 180 mm 2% Thor Tungsten* (10/Pkg) 05250161.0 x 180 mm 2% Thor Tungsten (10/Pkg) 05250241.6 x 180 mm 2% Thor Tungsten (10/Pkg) 05250322.4 x 180 mm 2% Thor Tungsten (10/Pkg) 05250403.2 x 180 mm 2% Thor Tungsten (10/Pkg) 0525057TIG Torch, Flex Head, 200 amps, 7.6 M Hose and Cable 0515017Accessory Kit, TIG 0521014Wire Brush, Stainless Steel for TIG 0812017Gloves, TIG Welding 0813015Gas Hose Assembly, TIG 0792011Jumper Cable, TIG 0780016Argon/Co2 Regulator with Flowmeter 9079014

* Other Tungsten types available on request.

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10AMERARC™ TIG Welding Equipment

27

BACKCAP TORCH SERIES HEATSHIELD COLLET COLLET BODY CUP (NOZZLE)

ALUMINA CUPA4 6.4 mm 0804014A5 7.9 mm 0804022A6 9.5 mm 0804030A7 11.1 mm 0804048A8 12.7 mm 0804055

CERAMIC CUPC4 6.4 mm 0802018C5 7.9 mm 0802026C6 9.5 mm 0802034C7 11.1 mm 0802042C8 12.7 mm 0802059

COLLET BODY1.6 mm 08010102.4 mm 08010283.2 mm 08010364.0 mm 0801044

COLLET1.6 mm 08000122.4 mm 08000203.2 mm 08000384.0 mm 0800046

GAS LENS 1.6 mm 0839011 2.4 mm 0839029

ALUMINA CUPAG6 9.5 mm 0837015

ALUMINA CUPSA4 6.4 mm 0809014SA5 7.9 mm 0809022SA6 9.5 mm 0809030

HEATSHIELD0810029

COLLETSee Above for Parts Numbers

HEATSHIELD0810011

BACKCAPLONG

0811019

BACKCAPMEDIUM

08110027

BACKCAPSHORT

0811035

CERAMIC CUPSC4 6.4 mm 0807018SC5 7.9 mm 0807026SC6 9.5 mm 0807034

COLLET BODYSHORT

1.6 mm 0806010 2.4 mm 0806028

COLLETSHORT

1.6 mm 0805012 2.4 mm 0805020

HEATSHIELD0810011

STANDARD

STANDARD GAS LENS

SHORT

Drew PCN 0515017 includes the 200 Amp torch with control valve, short backcap, heatshield, gas hose and electrical cable.

NOTE:REDUCE CONTINUOUS DUTY RATING BY 25% WHEN USING SHORT COLLET, WITH SHORT COLLET BODY.

AMERARC™ TIG RodsDrew filler metals for TIG welding are specifically alloyed to produce superior deposit quality and ease of use with Argon gas shielding. Refer to the Drew Marine Welding & Cutting Handbook WP-10 for additional details.

FOR TIG WELDING

YORCALBRO

ALUMINUMMAGNESIUM

CUNIFER

ALLOYSTEELS

STAINLESSSTEEL

ELECTRODE TYPE

ABTALUMINUM

BRONZE

ALTALUMINUM

MAGNESIUM

CNTCOPPER NICKEL

CRTCHROMIUM

MOLYBDENUM

SSTSTAINLESS

STEEL

SMTSTAINLESS

STEEL

DPTDUPLEX STAINLESS STEEL

DIA/LT(mm X mm)

2.4 X 1000

3.0 X 1000

2.4 X 1000

2.4 X 1000

1.6 X 10002.4 X 1000

1.6 X 10002.4 X 1000

2.5 X 1000

WT(kg/PK)

1.5

0.5

2.0

2.5

2.5

2.5

2.5

PCN

0708018

0710013

0709016

0824012

08180150818023

08380130838021

0937013

AMERARC DPT is a duplex stainless filler rod for welding and cladding of austenitic/ferritic stainless steels. The nitrogen bearing weld metal is resistant to chloride-containing medias. Also, the AMERAC DPT has high strength and good overall welding characteristics to combine with the excellent corrosion resistance. In a welded condition, the deposits have between 30/50% ferrite.

APPLICATION INFORMATION

AMERARC ABT is a specially formulated TIG rod which is used for joining and surfacing aluminum bronzes, particularly high manganese alloys and YORCALBRO, as well as other copper alloys and steel using the TIG process.

AMERARC CRT is recommended for TIG welding alloy steels of type -1/2% Cr 1/2% Mo, 1% Cr - 1/2% Mo, 1-1/4% Cr - 1/2% Mo commonly used in high pressure boilers and power piping. Argon backup is recommended for the most critical applications.

AMERARC ALT is for TIG welding of aluminum magnesium alloys containing up to 3 percent mag-nesium. It has good corrosion resistance.

AMERARC SST is ideally suited for welding most marine stainless steels including overlays. Piping, tanks, valves and fittings are typical applications. Argon backup is recommended to prevent internal corrosion.

AMERARC SMT with higher levels of chromium and nickel is especially well suited for welding stainless steel pipe on LNG carriers and for other applications requiring superior corrosion resistance, including repairs of stainless steel-clad tanks.

AMERARC CNT is recommended for TIG welding many copper-nickel alloys such as 70/30 and also for overlaying other metals to improve sea water corrosion resistance.

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10AMERARC™ Torch Head & Accessories TIG Welding Equipment

28

DESCRIPTIONThe AMERARC XL PLUS Series Air/Nitrogen Plasma Cutting Systems is especially well-suited for marine applications. The machine is based on inverter technology, providing an exceptional degree of reliability and low weight for portability. The 1O2XL Plus model is available, rated for cutting 25mm thick material under all conditions and 45mm under specific conditions (lower speed). The machine can be operated from any primary input from 208 to 460 vac +1- 10%, single or three phase, 50 or 60 Hz.

The AMERARC Plasma machine can be used to cut any metal that is electrically conductive. All steels, stainless steels, cast irons, aluminum, and copper alloys can be cut easily, quickly and cleanly. The combined effect of a high intensity arc and a hot, high velocity plasma gas results in a very clean, high speed cut. Most surfaces require only minimum cleanup and have sharp, well defined edges. Piercing, beveling and gouging can also be done with ease.

APPLICATIONSThe plasma cutting process is especially recommended for:•Routinemaintenanceonboardchemicalcarriersandotherves-

sels that have stainless steel, aluminum or other alloys not easily cut by conventional oxy-acetylene process.

• Maintenance and repair on vessels where metal cutting mustbe carried out in areas having little or no ventilation, where acetylene fuel gas or oxygen leaks would present a major safety problem.

•Routine maintenance on vessels that are restricted by the charterer to only a few gas cylinders onboard.

•Majorsteel renewalprogramsonvesselsoperating inareasofthe world where the supply of larger quantities of oxygen and acetylene cannot be assured.

AMERARC Plasma Cutting System

FEATURES•Two-YearWarranty-Assuranceofhighreliability.

•IncreasedOutput-Forratedcuttingthicknessathigherspeeds.

•ImprovedTorchDesign:

- Torch Leads - Enclosed in a one-piece, heavy-duty flexible cable. This provides durability and handling ease.

- ATC1 cable connectors allow simple torch replacement, ability to add extensions up to 24 meters (70 feet).

- Operator Friendly Handle - For ease and comfort, including trigger latch.

•Standardsapproval-CanadianStandardsapproval;certified to comply with standard CSA 22.2, No. 60.

•TipSaverCircuit-Consumablepartslastlonger.

•SmartStart1 (Auto Pilot) - Minimizes machine recycling, restarts quickly.

•SmartLogic1 (Over Voltage Protection) - Will not power on unless correct input.

•UniversalInputPower-Versatile-simplechange,withpropercable and plug units can be used with 208-460, 1/3 phase, 50/60 Hz.

•TRUEGUARD1 roll bar provides easy transportation and protects the front and rear of the power supply for unmatched durability.

•Portable-Goesanywherethere’scuttingtobedone.

•Highqualityairfilterincluded.Helpspromotemaximumlife of parts and good cut quality.

•IP-23CProtectionCertified(WaterSprayTest)-rugged, durable for marine use.

•7.6M/15.2MTorchLeads-selectpackagetosuitneeds.1 Registered trademark of Thermadyne Corporation.

NOTE: Initial shipments of the AMERARC PLUS series of plasma cutting systems include the standard kit of consumable parts, plus a “Sea Stock” of parts for the special needs of ships stores. Contents of the kits, including a schematic, are illustrated on next page.

section

11AMERARC™ Plasma Cutting Equipment

29

TSL-100 TORCH - Innovative Design/Patented Electrode Locking Mechanism

The new electrode is easy to install, no tools are required. The result is precise tip and electrode alignment, providing more efficient operation and improved parts life. This, together with the new trigger latching feature and extended tip for maximum viewing of cut, provides more on the job time for greater operating efficiency.

Torch Package - 6.1 meter length PCN 0931098

Torch Package - 15.2 meter length PCN 0931106

CONTENTS OF SEA STOCK KIT Description PCN QTY.

Electrode 0980178 25

Shield Cup 0980186 3

Tip-l00 Amp 0980160 50

Standoff Cutting Guide 0980202 1

Start Cartridge 0980194 3

ADAPTER KITS

Adapter kits for the Model SL-100 Torch are available to convert many competitive as well as earlier Drew Marine cutting systems to the new torch design. The conversion is quite simple and results in an ideal way to gain the benefits of innovative torch design and lower cost consumables at reasonable cost.

AMERARC™ PLASMA CUTTING SYSTEMS

DESCRIPTIONHigh quality cutting and gougingSeverance CuttingOutput Current, continuously variableDuty CycleTorch ModelPlasma GasGas PressureGas Flow

DIMENSIONS:HeightWidthLengthWeight

1O2XL PLUS25 mm45 mm15-100 amps40 10A, 100% @ 65ASL-100Air/Nitrogen4.8 bar (70 psig)212 1pm (450 scth)

380 mm (15 in)305 mm (12 in)760 mm (30 in)28 kg (62 lbs)

INPUT POWER: AMPS

208 - 460 VAC (± 10%), 1/3 Phase, 50/60 Hz

Voltage 1O2XL PLUS208 96.1-phase230 87, 1-phase460 22A, 3-phase

Plasma Cut Filter

How To Order

AMERARC P102XL PLUS

DESCRIPTIONAMERARC P1O2XL PLUS (with 6.1M torch)SL 100 Torch and Leads, 6.1 MSL 100 Torch and Leads, 15.2 MP1O2XL Sea Stock KitPlasma Cutting Guide KitP1O2XL Electrode (5)P1O2XL Tip (10)P1O2XL Start CartridgeP1O2XL Shield CupP1O2XL Start Off GuidePlasma Cut FilterFilter First StageFilter Second Stage

P1O2XL PLUS0980145093109809311060980152093108009801780980160098019409801860980202077101507710230771031

C u t t i n g G u i d e K i t

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11AMERARC™ Plasma Cutting Equipment

30

Ground Clamp

Ground Clamp Whip

Electrode Whip (Stinger)

Safety Electrode Holder

AMERARC AccessoriesFor personal safety during welding or when handling hot metal, AMERARC welding gloves and aprons offer maximum protec-tion. Gloves should be replaced if they show signs of cracking or embrittlement. For safety, protection and convenience, AMERARC Arc Welding accessories are recommended for the personal use of all welders.

Description PCNWelding Cable 35 mm2 0602012Welding Cable 50 mm2 0603010Welding Cable 70 mm2 0604018Cable Drum with Crank 0605016Electrode Whip (Stinger) 0614025Cable Connector, Pair 0692054Ground Clamp 600 AMP 0613019Safety Electrode Holder 400 AMP 0614017Ground Clamp Whip 0613027

A full range of auxiliary equipment is offered to complement and match AMERARC Arc Welding Machines and AMERARC consumables.

Cable Connector, Pair(accommodates each size cable)

Cable Drum with Crank. Ground Clamp, Safety Electrode Holder and Cable Are Available Separately.

The following chart compares Drew Marine cable sizing (mm2 of conductor area) to other cable standards.

Welding Cable Comparison Chart

mm2 CIRCULAR MILS AWG SIZE 26.7 52,620 #3 33.6 66,360 #2 35.0* 69,072 – 42.4 83,690 #1 50.0* 98,675 – 53.5 105,600 1/0 67.4 133,100 2/0 70.0* 138,145 – 85.0 167,800 3/0 95.0 187,483 107.2 211,600 4/0

*Drew standard sizes 35, 50 and 70 mm2

Apron

Gloves

Chipping Hammer

Brush

Maximum Location Distance from Welding Power Source to Welding Amperage 1Ft = .3048 M Ft 49 99 132 165 197 247 296 329 M 15 30 40 50 60 75 90 100 100 35* 35 35 50 50 70 ** 150 35 50 50 70 200 35 50 70 250 50 70 300 50 350 50 400 70

WELDING CABLE SELECTION CHART

* Cable cross-sectional area in Square mm.** Consult your Drew representative for unlisted cable ratings.

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12Arc Welding Equipment and Accessories

31

Description PCN

Welding Gloves 0616013Gloves, TIG Welding 0813015Welding Apron 0618019Wire Brush 0626012Wire Brush, Stainless Steel 0812017Chipping Hammer 0627010Face Shield with Headband* (Flip Front) 0615015Face Shield with Handle* 9089013Auto Darken Face Shield 0617011Glass, Clear 2” x 4 1/4” (10) 0688053Lens, Clear Shatterproof 2” x 4 1/4” (10) 0797052Dark Glass SH8 2” x 4 1/4” (5) 0682055Dark Glass SH9 2” x 4 1/4” (5) 0683053Dark Glass SH10 2 “x 4 1/4” (5) 0684051Dark Glass SH11 2” x 4 1/4” (5) 0685059Dark Glass SH12 2” x 4 1/4” (5) 0686057Dark Glass SH13 2” x 4 1/4” (5) 0687055Lens, Clear, Shatterproof 60 x 110 mm (10) 0796054Glass, Clear 60 x 110 mm (10) 0625055Dark Glass SH8 60 x 110 mm (5) 0619058Dark Glass SH9 60 x 110 mm (5) 0620055Dark Glass SH10 60 x 110 mm (5) 0621053Dark Glass SH11 60 x 110 mm (5) 0622051Dark Glass SH12 60 x 110 mm (5) 0623059Dark Glass SH13 60 x 110 mm (5) 0624057

*Uses 2” x 4 1/4” size clear and dark glass. Faceshields are each shipped with a shade 10 dark glass.

Auto Darken Face ShieldThe AMERARC Auto Darken Face Shield is a com-plete face shield with fully adjustable headband and the most advanced auto-darkening welding filter available. The filter automatically turns dark the instant (within 1/2000 second) the arc is struck and returns to the light condition 0.2 seconds after the arc is broken. In either the light or dark condition, the filter provides ultraviolet/infrared protection to shade 16. The unit is solar powered and requires no replacement batteries. It contains one lithium battery (10-year life) to insure operation in total darkness.

The auto darken Face Shield enables the welder to strike the arc at precisely the spot where it must be struck to eliminate the risk of arc burns, which is especially critical in stainless steel welding. It also eliminates the risk of arc flashes when welding in confined, out-of-position locations or while tack welding.

DREW Non-DREW Type Lens 2” X 4 1/4” 60 X 110 mm Face Shield Face ShieldClear Glass “Waster” Plate 0688053 0625055Shade 8 Dark Glass Under 0682055 0619058Shade 9 Dark Glass 200 0683053 0620055Shade 10 Dark Glass* Amps 0684051 0621053

Shade 11 Dark Glass 200 0685059 0622051Shade 12 Dark Glass to 0686057 0623059 400 Amps

Shade 13 Dark Glass Over 0687055 0624057

Clear Shatterproof Lens 0797052 0796054* Shade 10 supplied as standard with Drew Marine Face Shield. Final shade decision must be made by engineer using equipment.

WELDSIDE

EYESIDE

1

2

3

3

2 1

Face Shield with Headband Auto Darken Face Shield

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12Arc Welding Equipment and Accessories

32

SHIPBOARD APPLICATIONThe AMERARC Gouging Torch is an effective metal removal tool for fabrication jobs on ships in shipyards or in any instance where it is necessary to improve productivity and profitability. This gouging torch decreases the amount of time spent on weld removal, backgouging, edge preparation, defect repair and many other metal removal jobs. The AMERARC gouging torch can be used on all common metals. Arc gouging with the AMERARC torch is fast, and it causes little to no deformations because the heat input is so low.

OPERATING FEATURES•ImprovedTorchAirFlow Increases efficiency of air supply which provides for a faster removal operation.

•NewFour-BarrelAirNozzle Optimizes air flow to the arc. Efficiently cleans slag from groove edge.

•OptimizedAirFlowtoControlNoise Allows torch usage in areas where noise cannot exceed 115 decibels. Permits torch usage at lower air pressure and flow to obtain acceptable grooves.

•Air-AssistPositiveAirShut-Off Minimizes air supply unit cycling on and off. Permits torch usage when air supply is marginal.

•ImprovedCableElectricalConduction Decreases heat build up in cable and torch and improves cable service life.

•InsulatedConnectionBootandHook-UpKit Increases ease of torch hook-up. Virtually eliminates the possibility of arcing when contacting electrically hot parts.

FEATURES AND BENEFITS•Natural150TorchAngle-improvesoperatorcomfort

•3600SwivelCable-decreasescabletwist&strainonoperator

•PositiveGripHandle-increasesoperatorcomfort&easein positioning the torch

•ReducedWeight-reducescable&torchweighttominimizefatigue

•HighQualityCableHose-offershighheat&abrasionresistance

•RuggedConstruction-providesprotectionfortheharshenvironment

TECHNICAL SPECIFICATIONS

Accepts •PointedCarbons(4mmto13mm) •FlatCarbons(10mmand16mm)

Maximum Current: 1250 Amps

Compressed Air •Pressure:5.6kg/cm’(80psi*)

•FlowRate:0.8m3/min(28cfm)

Torch and Cable Weight •2.4kg(5.4lbs)

Description Part No.Complete Torch 01-082-002

1. Insulators and Screws 94-433-183 2. Upper Insulator (N/A) N/A 3. Lower Insulator (N/A) N/A 4. Lever and Screw 94-476-066 5. Valve Bonnet 94-104-016 6. Bonnet Wrench 94-960-001 7. Bonnet Only 94-104-012 8. Spool and 0-Rings 94-801-011

Description Part No.

9. 0-Ring (2 required) 94-710-036 10. Spool Only 94-801-010 11. Upper Arm 94-048-088 12. Head and Screw 94-378-368 13. Torch Body 94-103-206 14. Hinge Pin 94-632-094 15. Spring 94-800-077 16. Handle 94-370-163

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13AMERARC™ Gouging Torch

Torch Assembly Replacement Parts

33

Description Part No.Complete Hook-Up Kit 94-463-045

1. Male Gouging Connector 94-170-181 2. Cable Boot Cap 94-105-027 3. 4 WPC-R Connector 94-251-427 4. Pigtail Air Supply Hose 94-396-205

Description Part No.

7.11 (2.1 m) Cable Assembly 70-084-207

10’ (3 m) Cable Assembly 70-084-210

1. Retainer Screw 94-170-182

2. 0-Ring See Above

3. Connector See Above

4. Spring Washer 94-940-104

5. Flat Washer 94-940-103

6. Swivel Sleeve (N/A) N/A

7. Clamp (2 Required) 98-167-010

8. 7(2.1 m) Conductor 96-130-263

8. 10 (3 m) Conductor 96-130-261

9. 7(2.1 m) Cover 94-171-274

9. 10(3m)Cover 94-171-274

10. Insulating Boot 94-105-014

11. Female Connector 94-170-150

TECHNIQUES FOR SPECIFIC METALS

Carbon Steel

This material can be easily gouged or cut using DCEP (reverse polarity). Normal conditions use a 35° electrode to work angle with a maximum of 7 (178 mm) electrode stickout. The air blast is always positioned between the electrode and workpiece.

Stainless Steel

These alloys can be easily gouged using the same techniques as described in carbon steel.

Aluminum

The electrode stickout should be no more than 3 (76 mm). Be careful not to touch the electrode to the work surface, as a carbon deposit will occur. The finish of the groove/cut will require a stainless steel brush to remove the black oxide (oxides not carbon) from the area. Recommend using DC Copperclad1 electrodes on DCEP (reverse polarity). If this doesn’t work well, then switch to DCEN (straight polarity).

Gray, Ductile and Malleable Cast Iron

These materials require a special operating procedure when attempting to gouge with CAC-A. It is recommended that the current range for gouging be 1000 amps or higher. This also requires using 1/2fl (12.7 mm) diameter carbons or larger. Attempts to gouge with smaller carbons will deposit refractory slag (gray crystalline surface) resulting in little or no gouging progress while burning up carbons.

Copper Base Alloys

Heat dissipation due to high conductivity of

these materials makes them more difficult

to cut or gouge than carbon steel. Use DC

electrodes with DCEN (straight polarity) at the

maximum amperage rating of the electrode.

ORDERING INFORMATIONDescription PCNTorch w/1 0 ft. Cable 0580010

Electrode Types/50 Pieces per BoxDC Copperclad Round PCN

5 mm x 300 mm 0581018

6 mm x 300 mm 0583014

8 mm x 300 mm 0585010

10 mm x 4 mm x 300 mm 0585119

16 mm x 5 mm x 300 mm 0585127

CURRENT REQUIREMENTS

Carbon Diameter 5 mm 6 mm 8 mm 10 mm flat 16 mm flat

Minimum Amps 200 300 350 450 800

Maximum Amps 250 400 450 600 1000

1 Registered trademark of Thermadyne Industries, Inc.

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13AMERARC™ Gouging Torch

Hook-Up Kit and Parts Cable Assembly and Replacement Parts

34

Drew Marine Central Gas Installation (CGI) Systems comply with the requirements of the Norwegian Maritime Directorate (NMD) and the DNV (Det Norske Veritas) for new buildings or upgraded gas supply systems.

Drew Marine CGI systems are engineered especially for the marine environment. They provide a high level of safety as well as convenience of operation and flexibility. These features are high-lighted in the following brief description of the new “MANY-FLOW” CGI System.

The CGI MANY-FLOW System uses a unique, unit-body, 3-gas-control that accommodates two or three cylinder inputs, each with integral check valve. The MANY-FLOW System provides a simple method to customize the CGI system to meet the need of any ship. In the event expansion is required, additional component sets may be ordered.

Drew Marine also provides the necessary pipeline pressure regula-tion, through deck fittings, operational safety placards and venting and workshop outlet stations, for any requirement the owner, shipyard or naval architect may specify. Our engineering staff at Whippany or specialists at regional centers are prepared to assist in the design, specification and installation, as well as testing, of any standard or special custom need. Consult with your Drew Marine Account Executive for full details.

ON DECKA typical oxygen central installation includes cylinders, manifold and piping, rigidly secured to a bulkhead in order to prevent the possibility of unsafe condition in a seaway. Oxygen and acetylene systems may be mounted together in the same room if the total number of cylinders, both on line and in reserve storage, does not exceed eight (8). The Norwegian Marine Directorate requires that if the total of oxygen and acetylene cylinders exceeds eight, that separate rooms must be provided. In either case, for safety, vent-ing from the outlet on the manifold regulator must be provided to a safe area outside the storage location.

AMEROX CGI Systems

Three-cylinder CGI oxygen manifold shown with CGI regulator, vent, pipeline and pipe clamps.

The following major CGI Systems are available from stock in Rotterdam, Singapore, and Yokohama. Spare parts and service are available at most major ports.

Description PCNBasic Gas System with RackAcetylene 2-cylinders with Racks 9082025Acetylene 3-cylinders with Racks 9082033Acetylene 2 plus 2-cylinders with Racks 9082124Acetylene 3 plus 3-cylinders with Racks 9082132Acetylene 1-cylinder with Rack 0511015

Oxygen 2-cylinders with Racks 9080029Oxygen 3-cylinders with Racks 9080037Oxygen plus 2-cylinders with Racks 9080128Oxygen plus 3-cylinders with Racks 9080136Oxygen 1-cylinder with Rack 0508012

Outlet Station Including Backfire ValvesWith Cabinet, Complete 0517013Without Cabinet 0739013Cabinet Only 0514019Cabinet, Left-hand Hinge 0514027CGI PartsRegulator (CGI), Acetylene 0518011Regulator (CGI), Oxygen 0741018Flexible Hose Assembly, AC 0787012Flexible Hose Assembly, OX 0783010

Cylinder Rack AssembliesRack Assembly, 1 cylinder 9041013Rack Assembly, 2 cylinder 9042011Rack Assembly, 3 cylinder 9043019

Other ComponentsPipe Bushing, Through Deck (19.5-28.5 mm) 9008013Pipe Clamp (21.3 mm) 9006017Outlet Connection Assembly*/ AC, Socket Weld 9060013Outlet Connection Assembly*/ OX, Socket Weld 9061011Outlet Connection Assembly*/ AC, Butt WeldOutlet Connection Assembly*/ OX, Butt WeldPlacards: (Also available in Spanish) Oxygen 9076028 Acetylene 9076010 Outlet Station 9076036

* Optional items, pipeline connection fittings to connect to J.l.S. pipe standards where required by shipyard.

Complete systems for other combinations of cylinders, as well as other gases such as nitrogen, are available on request. Engineered systems for blanketing cargo tanks and boilers are also available.

CAUTION: CHEMICALS OR OTHER FLAMMABLE MATERIALS SHOULD NEVER BE STORED IN THE CYLINDER COMPARTMENTS.

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14Central Gas Installation Systems

35

Approved and specially designed clamps and bush-ings support the piping system through decks and bulkheads.

Reverse flow check valves in the acetylene and oxygen manifolds provide isolation of the individual cylinders at all times and additional protection during changeover.

Outlet stations offer optimum control and protection for gas welding and cutting in the workshop. The system includes an adjustable low pressure reg-ulator, delivery pressure gauge and backfire valve for each gas – acetylene and oxygen.

Relief vent valves, which are required by most agencies, are an important safety feature. The manifold system requires only one adjustable, high pressure regulator which is preset for maximum delivery pressure.

Retaining racks, with easy-to-detach clamps and bushings, keep cyl-inders well secured while under way.

The cylinders are connected by a manifold system (individual inlet connection valves and flexible high pressure hoses) for easy switching of cylinders on/off line. Each cylinder is isolated by a non return check valve. A cylinder can be connected directly to the system as supplied by Drew or most other suppliers.

For the utmost in safety, 40-litre acetylene cylinders are kept in a separate compartment. The system operates similarly to the oxy-gen system. No special tools or keys are required to operate the system.

The main workroom is fully equipped with

equipment, accessories and consumables

to perform arc welding and gas cutting and

welding; an outlet station which houses and

protects oxygen and acetylene regulators;

arc welding machine and cable, welding

table, AMEROX® and AMERARC™ Ships

Cabinets which provide secure storage for

the welding consumables, and personal

protective safety gear.

t

The oxygen cylinder central compartment is sized to meet the cylinder storage requirements of the vessel. It provides secure storage of welding gas cylinders onboard and ready access for the exchange of cylinders in port.

Locate one or more

satellite stations

wherever welding

may be required on a

frequent basis – such

as the ramp deck.

The satellite station

is equipped with an

outlet station, ships

cabinet, arc and/or

gas welding gear and

protective clothing.

A Central Gas Installation (CGI) System consists of various components, allowing the controlled withdrawal of a gas from cylinders through a specially vented regulator to a low pressure piping system. For a single cylinder, the system includes the regulator, outlet coil, mounting bracket, main shutoff valve, high pressure inlet hose, and outlet connection fitting, for both the oxygen and the acetylene cylinder. Optional racks to secure the cylinders may or may not be included. Specify by the product code number. For multiple cylinder supply, additional compo-nents include a high-pressure manifold with individual manifold valves with non return (check) valves to isolate each individual cylinder. The Drew Marine Central Gas and Welding Outlet Station System is engineered to meet specific needs aboard ship. These systems provide safe and efficient operation under all conditions.

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14Central Gas Installation Systems

36

All Drew Marine AMEROX equipment, including Central Gas Installation Systems, comply with the requirements of the Norwegian Maritime Directorate. The shipyard is, of course, responsible for the installation of the system including the pipeline between the deck storage room and workshop. Drew specialists are available in major shipbuilding areas to advise and assist the shipyards in designing each installation to a specific owner’s requirements. Pipeline clamps and through-deck bushings are available as standard components.

The selection of a central gas installation system of appropriate size and proportion should be based on the minimum capacity required to satisfy the equipment onboard, with sufficient standby storage capacity for typical voyages. For example, a minimum of two AC 40 acetylene cylinders are required, on line, to supply one 1650 liter welding blowpipe. The oxygen manifold capacity should be 1.5 to 2 times the acetylene capacity. Thus, a 2 AC + 3 OX or a 2 AC + 4 OX system is indicated.

AMEROX CGI Systems FULLY CERTIFIED

Each workshop outlet station is equipped with backfire valves (oxygen and acetylene), as well as pressure adjusting regulators and pressure gauges, to provide an optimum and safe gas supply at the point of use.

Two or more outlet stations can be supplied from one CGI system. Drew Marine Central Engineering can design special systems tailored to a vessel’s needs.

A workshop should also include as a minimum:AMEROX® Ships CabinetAMERARC Ships CabinetAMERARC Arc Welding MachinesGas and Arc AccessoriesSafety Equipment

Workshop Outlet Stations

5-Liter Cylinders with Backpack Frame PCN 9013012

For added personal safety and convenience, Drew Marine offers a system of 5 liter water capacity oxygen (OX5) and acetylene (AC5) cylinders mounted in a convenient, lightweight backpack. This portable gas welding, brazing and cutting system allows complete flexibility and ready access to all areas of a vessel while retaining all the technical advantages of the normal 40 liter system and the marine certified AMEROX equipment range. Available in selected ports. (Cylinders sold separately)

Consult with your Drew Marine Account Executive or Marketing Specialist for a complete system specially designed for your new building needs.

SAFETY WARNINGIt is extremely important to follow recommended safe practices while using welding equipment and consumables. Always wear suitable protection against ultraviolet and infrared radiation, including face shield with proper shade lens, goggles, and gloves. Always provide adequate ventilation to avoid exposure to harm-ful fumes and to avoid possible accumulation of explosive gases from a leak. For additional information, refer to the Drew Marine Welding Handbook WP-10. The AMERARC Arc Welding Safety Placard (PCN 9076044) is recommended for the workshop.

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14Central Gas Installation Systems

37

A-22

AMERFROST A-134a refrigerant is the ozone-friendly, chlorine-free hydrofluoro-carbon (HFC) that has become the new industry standard for use with medium-temperature appliances. Ideal for retrofit-ting CFC-12 systems, it can be used in most marine systems utilizing water-cooled condensers and reciprocating, screw, or centrifugal compressors. It is suitable for A/C and refrigeration systems with evapo-rator/diffuser temperatures above -23°C (-10°F).

Refrigerant Charge (Refills in kg)PCN: 0830019

AMERFROST A-22 Refrigerant is the lead-ing HCFC refrigerant for all types of ship-board refrigeration and A/C systems. With a boiling point of -40.8°C @ 1 ATM, it is particularly useful for applications that employ reciprocating compressors.

The outstanding properties of AMERFROST A-22 refrigerant permit using smaller equip-ment than is possible with other refriger-ants. The result is space savings onboard the vessel.

Refrigerant Charge (Refills in kg)PCN: 0651019

The leading medium and low temperature HFC refrigerant is used for both retrofitted and new refrigeration and A/C systems. It can be used in most marine water-cooled condensers and reciprocating compressors. This non-ozone-depleting refrigerant is a good replacement for A-22.

AMERFROST A-404A has a boiling point of -46.1°C (-51°F) @ 1 ATM*. Although a blend, this refrigerant has a relatively small temperature glide.

Refrigerant Charge (Refills in kg)PCN: 0829012

*Bubble point temperature

AMERFROST A-404AREFRIGERANTHYDROFLUOROCARBON BLEND

AMERFROST A-22REFRIGERANTCHLORODIFLUOROMETHANE

AMERFROST A-134AREFRIGERANTETHANE, 1,1,1, 2-TETRAFLUORO

Blend

56.0

64.8 45.0 (100)

23.8

2561370

Medium Blue

DOT BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

Blend

56.0

71.852.0 (115)

23.8

2561370

Chocolate Brown

DOT BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

Blend

56.0

71.345.0 (100)

26.3

2561370Rose

DOT BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

Blend

56.0

64.845.23.8 (100)

2561370Teal

DOT 4BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

CF3CH2F

56.0

76.8 (169.2)57.0 (125)

23.8

2561370

Sky Blue

DOT BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

Chemical Formula

Cylinder Capacity (Water) (L)Typical Weight kg (LB) Gross w/valve & cap Net Empty Dimensions (mm) Diameter Height with capColor

Cylinder Approval

VALVEOutlet ConnectionType

REFRIGERANTNominal PurityStabilityToxicity

Technical InformationA-404A A-410A A-507A-407CA-134a

Drew Marine reserves the right to refuse acceptance or exchange of a damaged, contaminated or otherwise unserviceable cylinder.

CHCIF2

56.0

76.8 (169.2)57.0 (125)

23.8

2561370

Light Green

DOT 4BA/BW 300/400

CGA 6681.030” x 14 NGO

Liquid/Vapor

99.8%ExcellentVery Low

section

15Refrigerants, Test and Charging Equipment

For use in marine refrigeration and air con-ditioning systems. A non-ozone-depleting replacement for A-22.

AMERFROST A-407C has a boiling point of -46.3°C (-46°F) @ 1 ATM*. This refrigerant has a moderately high temperature glide.

Refrigerant Charge (Refills in kg)PCN: 0571019

AMERFROST A-407CREFRIGERANTHYDROFLUOROCARBON BLEND

AMERFROST A-410A is a non-ozone- depleting refrigerant developed for use in new equipment and systems. It can be used in marine air conditioning and refrigeration systems.

AMERFROST 410A is a high pressure, high capacity refrigerant. Although a blend, this refrigerant exhibits no temperature glide. The boiling point of AMERFROST 410A is -52.7°C (-62.90°F) @ 1 ATM*.

Refrigerant Charge (Refills in kg)PCN: 0572017

AMERFROST A-410AREFRIGERANTHYDROFLUOROCARBON BLEND

The leading medium and low temperature HFC refrigerants are used for both retrofitted and new refrigeration and A/C systems. They can be used in most marine water-cooled condensers and reciprocating compressors. These non-ozone- depleting refrigerants are good replacements for A-22.

AMERFROST A-404A and AMERFROST A-507 have boiling points of -46.1°C (-51°F) @ 1 ATM.*

Refrigerant Charge (Refills in kg)PCN: 0808016

*Bubble point temperature

AMERFROST A-507REFRIGERANTHYDROFLUOROCARBON BLEND

PROPERTIES AND PRECAUTIONS

PROPERTIES OF AMERFROST REFRIGERANTS

STABILITYAMERFROST refrigerants are generally stable and non-corrosive.

NON FLAMMABLENone of the AMERFROST refrigerants is flammable or explosive.

LUBRICANT-COMPATIBLE AMERFROST refrigerants are fully compat-ible with lubricating oils commonly used in refrigeration systems.

LOW TOXICITYAMERFROST refrigerants are very low in toxicity.

PRECAUTIONSAs with all shipboard chemicals, certain basic precautions should be taken in order to avoid unnecessary risks or accidents. If in doubt, contact Drew Marine.

1. Always be sure to provide adequate ventilation wherever the possibility of a refrigerant leak exists. Refrigerant gases can displace air from an enclosed space and cause suffocation.

2. Avoid highly elevated temperatures where decomposition occurs. Toxic by-products are formed.

3. Never store cylinders in sun or in areas with ambient temperatures above 60°C.

4. Do not abuse cylinders. Do not drop or use cylinders as rollers. Do not lift a cylinder by its valve or valve cap. Keep protective cap on the cylinder when not connected to a refrigerant system.

5. Avoid contact of refrigerant with skin. It is low in toxicity but can cause freezing or frostbite because of low temperature.

6. Avoid contamination of cylinders through introduction of liquids or vapors from the refrigerant system into the cylinder.

7. Do not apply open flame to cylinder.

8. Close valve after use and when empty.

SALES EXCHANGE REDEMPTION

GENERAL:All cylinder deliveries are F.A.S. vessel at normal Drew Marine ports of storage.

Refrigerant Cylinders which Drew Marine will accept are limited to the following:

DOT/ICC 4BA 300 400 4BW 300 400

Drew Marine accepts no responsibility for non-standard cylinders being landed without prior consent in writing.

REFRIGERANT CYLINDERS:

ALTERNATIVE 1. VESSEL RETURNS CYLINDERS FOR EXCHANGE

Empty cylinders returned from the vessel will be exchanged for an equal number of full cylinders supplied by Drew Marine. Customer is invoiced only for the con-tained refrigerant.

ALTERNATIVE 2. VESSEL REQUIRES ADDITIONAL CYLINDERS

If the number of empty cylinders returned is less than the number of full cylinders supplied to the vessel, the customer will be invoiced for the additional cylinders as supplied as well as the contained refriger-ant product provided in all cylinders.

ALTERNATIVE 3. VESSEL DESIRES TO RETURN EXCESS REFRIGERANT CYLINDERS

Drew Marine will credit the customer’s account for the return of acceptable excess refrigerant cylinders which were origi-nally purchased from Drew Marine at the original purchase price of the cylinders. If excess refrigerant cylinders returned were not originally purchased from Drew Marine, credit will be issued for an amount based on fair market value.

CYLINDER EXCHANGE POLICY

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15Refrigerants, Test and Charging Equipment

38

39

RECOVERY/RECYCLING/RECLAMATION

The Montreal Protocol and environmental regulations in most countries now mandate the recovery of refrigerant from a system prior to beginning service work. While most marine systems contain receivers capable of containing the entire system charge and that can be isolated from the rest of the system, it may still be necessary to have recovery equipment onboard to meet current requirements. In addition, with the rising costs of all refrigerants, it makes good economic sense to recover as much refrigerant as possible and recycle it back into the system, rather than replac-ing the charge with new refrigerant.

In addition to a recovery machine and charging manifold, recovery cylinders are necessary. These cylinders can be used for temporary storage, or for landing used refrigerant for reclamation. Drew Marine offers 56-liter 45-kg capacity recovery cylinders with dual port/dual valve connections in many ports. 12-liter 10-kg capacity recovery cylinders are also available in select ports. Drew Marine is also coordinating a reclamation program in several ports to help maintain an adequate, ongoing source of supply of R22 for the future, to help keep the marine industry’s costs more stable.

For all refrigerant handling, use and recovery/reclamation questions, contact your Drew Marine representative.

section

15Refrigerants, Test and Charging Equipment

REFRIGERATION RECOVERY MACHINE• Powerful1HP(0.8kW)oil-lessreciprocatingrecoverycompressor•Exceptionalcompressor,condensingandcoolingsystemsallowfastrecoveryinhigh temperature environments•Automaticlow-pressureshut-offfeatureturnsunitoffwhenrecoveryiscompleted•SuitableforallHCFCandHFCrefrigerants•Capacity:0.22kg/min.vapor,7kg/min.liquid

PCN Description 0882036 Refrigeration Recovery System 120 V 0882044 Refrigeration Recovery System 220 V 0882069 Recovery Repair Kit CR700 110/220

DUAL STAGE VACUUM PUMP •Dualvoltagedesignoperateson110Vor220V•6cubicfeetperminutecapacity Motor: 1/2 HP (.4 kW) Frequency: 50/60 Hz RPM: 1440@50Hz - 1730@60Hz Voltage: 110-220/ 220/240 VAC Internal Start: Yes Capacitor-Thermal: Yes Overload Protector: Yes Oil Capacity: 0.9 liter Dimensions: 430 mm x 145 mm x 265 mm Shipping Weight: 13.7 kg

PCN Description 0704024 Refrigeration Vacuum Pump 6CFM (9 liters/min.)

REFRIGERATION CHARGING SCALE •Highcapacity100kg/220lbrefrigerantscale•CalibratedtostrictNISTstandards•Removablemetalscaleplatform•LargehighresolutionLCDreadoutw/6°(1.8m)coilcord•Accuracyto.015%ofreading•Operates60continuoushoursontwo9ValkalinebatteriesFully enclosed and removable metal scale platform enables use of product in or out of the protective case. The ergonomic hand-held remote controller incorporates a 6 ft coil cord, a hanging hook and is backed with a magnet for attaching to metal surfaces. Full mechanical and visual overload protection. Accuracy: .015% of Reading Resolution: ±10g/(±1/4oz) Platform Size: 223 mm x 223 mm (8 3/4” x 8 3/4”) Weight: 2.55 kg/5.6 lb Operating Temp: -10° C to 50° C/-4° F – 156° F

PCN Description 0129511 Refrigeration Charging Scale

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15Refrigerants, Test and Charging Equipment

40

ELECTRONIC REFRIGERANT LEAK DETECTION •State-of-the-artColdCathodeDiode(CCD)sensortechnology•ForusewithallCFC/HFC/HCFCrefrigerants•75hourbatterylife(3“C”batteries)

PCN Description 0820028 Automatic Electronic Leak Detector 0820036 Spare Sensor

ACCESSORY ITEMS PCN Description 0129503 AC Ratchet Wrench, 4-way, N1000 0658015 Manifold System with Case, R12,R22,R502 0658023 Manifold System with Case R134A,R404A,R507 0698011 Gauge, Compound Blue - R12,R22,R502 0698029 Gauge, Compound Blue - HFCs 0699019 Gauge, Pressure Red - R12,R22,R502 0699027 Gauge, Pressure Red - HFCs 0700014 Charging Hose, Blue 1/4” X 60” (1.5 m) 0701012 Charging Hose, Yellow 1/4” X 60” (1.5 m) 0702010 Charging Hose, Red 1/4” X 60” (1.5 m) 0703018 Charging Hose, Black 3/8” X 60” (1.5 m) 0129529 Infrared Thermometer •Simpleone-handedoperation,laserpointsighting •°C/°Fselectability 0129537 Electronic Vacuum Gauge •Handles400PSIofpositivepressure •1/4”standardrefrigerantconnectors •Includesadapter 0655011 Valve Adapters 1/4” (4/Set)

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15Refrigerants, Test and Charging Equipment

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42

section

16

WORK SAFETY PRECAUTIONS 1. Always secure cylinders with racks, clamps or chains in an upright position during storage, transportation or use. Do not use rope.

2. Always keep the cylinder cap securely mounted on the cylinder during storage, movement or road transportation.

3. Never lift a cylinder by its valve or cap or with slings, chains or magnets. A net or an approved cradle or platform is recommended.

4. Never hammer, pry or wedge a stuck or frozen cylinder top valve to open and never use a wrench/spanner. If valve will not open by hand set cylinder aside and notify Drew Marine.

5. Do not drop cylinders.

6. Do not allow grease, oil or other combustible material to touch any part of a cylinder. This is particularly critical with oxygen cylinders.

7. Never strike an arc on a cylinder or expose a cylinder to high tempera- tures from oxy-acetylene flame from a torch or any other source.

8. Cylinders must be stored and used at less than 130°F (54°C).

9. Keep acetylene cylinders well separated from oxygen cylinders during storage. Six meters (20 feet) is a minimum separation unless a fire- proof barrier is erected. Provide adequate ventilation at all times. Never store cylinders with combustible materials (oil, acids or chemicals).

10. For safety, cylinder maintenance of any kind should only be carried out by authorized personnel designated by Drew Marine. Any cylinder which has a defect should be marked and set aside unused and returned to Drew Marine at the earliest opportunity.

11. Always return cylinders with some positive gas pressure. Be sure valves are closed after use in order to avoid contamination.

12. Cylinders should be used only to contain gas. They are not to be used as rollers, braces props or work platforms. Avoid any condition which might dent, nick or otherwise damage the cylinder shell.

13. Only qualified persons should handle, transport and use cylinders. No attempt should be made to transfill gas between cylinders or to mix gases.

14. Use only correct and approved regulators and regulator connections and other equipment in welding and cutting service with Drew Marine supplied welding gas cylinders.

15. Refer to WRP-12 - Drew Marine Safety and Operating Instruction Booklet for additional details.

WARNINGOxygen under pressure may react violently in contact with oil, grease or other combustible materials. Do not use oil on any welding or cutting equipment.

Pure acetylene forms dangerously explosive compounds with copper. Do not use fittings in contact with acetylene which have a copper content greater than 65 percent.

Many materials that will only char or smolder in air will flare up in the pres-ence of oxygen-rich atmosphere, e.g . clothing, gloves, cigarettes, pipes. etc. Therefore, do not allow oxygen to permeate such articles.

Never use oxygen to blow dirt or dust away from clothing.

Oxygen leaks can be as dangerous as fuel gas leaks!

Inert gases pose a serious health hazard by their ability to displace oxygen in a confined (non-ventilated) area. In absence of air in a confined area, occupants face the threat of asphyxiation and death after a very short time of exposure.

It is essential that adequate positive ventilation be provided wherever inert gases are being stored or used. Furthermore, every possible precaution should be taken to make sure that all connections of inert gas systems are tight without any leakage.

NOTICE: Drew Marine reserves the right to refuse acceptance or exchange of damaged, contaminated or otherwise unservice-able cylinders.

FOR SAFETY ONBOARD, SOME SAFETY PROCEDURES TO REMEMBER1. BEFORE USE, READ AND FOLLOW INSTRUCTIONS IN THE SAFETY AND INSTRUCTION BOOKLET WRP-12. ADDITIONAL COPIES ARE AVAILABLE UPON REQUEST.

2. Never allow oil or grease on any regulator or top valve. The combination of oxygen at high pressure with the lubricant can cause a violent explosion.

3. Be sure all gas connections are tight. Leaks are potentially hazardous. If in question, use soap and water solution to check for leakage.

4. Never use oxygen to blow off chips or clean clothing. It’s not air and can cause injury.

5. A torch is not a hammer. For your safety, don’t use it as one.

6. Open cylinder valves slowly and when changing cylinders clean the valve with a short blast of gas to remove any foreign material before mounting regulator.

7. Acetylene is potentially hazardous when combined with copper. Use only brass or steel in contact with acetylene.

8. Never strike an arc on gas cylinders.

9. Protect your eyes.

10. Only use approved AMEROX® equipment and parts.

11. Always close top valves tightly before removing cylinder regulators, even when the cylinder is empty, and replace the valve protection caps.

Work Safety Precautions

43

section

17

INTRODUCTIONThe gas metal arc welding process, commonly referred to as GMAW or MIG, is widely used in a number of forms in industry and throughout the world. Most variations of the process are used extensively in the shipbuilding industry. Most recently, interest has developed in the application of the process for major repairs and steel renewal onboard. Drew Marine has complete packages available to meet the needs of ship owners/managers planning such projects.

THE PROCESSThe GMAW/MIG process uses a bare electrode in the form of a coil of wire, the end of which is automatically fed into an arc between the end of the wire and the base metal. The wire is fed into the arc at a constant speed set at the wire feeder control by the operator. A continuous gas shield (which may be inert or chemically active gas) surrounds the arc to protect the molten base metal. The welding current is carried by a flexible cable to the contact tip at the end of the torch where it is transferred to the wire. The shield-ing gas flows to the torch through a hose to the gas nozzle.

In the MIG process, the arc length is determined by the arc voltage, which is set by the operator. If the arc length increases due to a higher melting rate, the welding current decreases automatically to reduce the arc length. The opposite occurs if the arc length decreases due to a lower melting rate. This is a very important characteristic of the constant CV, type of arc welding machine preferred for this process.*

*An alternate system, with more limited applications, uses a con-stant current, CC, arc welding machine and an arc voltage sensing wire feeder. The feeder adjusts the wire feed speed to maintain the desired arc voltage.

There are several significant variations of the process such as the flux cored arc welding process (FCAW), which uses a “hollow” or tubular wire with a small amount of flux in the center to improve the welding characteristics such as deposition rate and vertical or overhead performance. Many variations of shielding gas mixtures are used depending upon the metal(s) to be welded and the pro-cess parameters. In some cases, sufficient flux is provided in the core to eliminate the need for a gas shield. This type of wire is sometimes referred to as an “air wire.”

The typical GMAW welding package consists of an arc weld-ing machine, a wire feeder which may be a part of the welding machine in some cases, a torch with an integral hose, cable and casing/liner assembly, a supply of shielding gas (cylinder), a flow-meter regulator and a spool of welding wire of the required alloy composition and diameter.

WIRE FEEDER/TORCHThe wire feeder includes a spindle to mount the wire spool, an adjustable constant speed motor and drive roll assembly to pull the wire off the spool and feed it into the casing/liner assembly of the torch, a gas solenoid to start and stop the flow of shielding gas and digital display of the selected wire feed speed. The torch assembly includes a gas hose to carry the shielding gas to the torch and a flexible cable to conduct the welding current to the contact tip at the end of the torch. At the contact tip the current is transferred to the wire and a replaceable liner, sized to match the wire diameter, in the casing.

Basic elements of GMAW (MIG) Process

Basic elements of the Flux Cored (FCAW) Process

The GMAW / MIG Welding Process

Acetylene 2 Acetylene Cylinder-5 Liter 2

Acetylene Cylinder-40 Liter 2Aluminum Brazing Rod (AL) 7Aluminum Bronze Electrode (AB) 17Aluminum Electrode (AL) 17Approvals, CGI 32Approvals, Electrodes 15Apron 12, 13, 30Arc Welding Machines 18, 22-25Argon 3Argon/CO2 Regulator with Flowmeter 3Argon Cylinder-50 Liter 3Arrestors, Flashback 5, 10, 11Auto Darken Faceshield 31

Backfire Valves 5 Backpack-5 Liter Cylinders 36

Blowpipes, Multiflame 2500/5000 5, 10, 11Blowpipes, Welding 4, 10,11Bronze Brazing Rod (BR) 7Bronze (Wearing) Brazing Rod (WB) 7Brushes, Wire 12, 13

Cabinet, Ships-Arc 12, 14 Cabinet, Ships-Gas 8, 9

Cable, Arc Welding 30Central Gas Installations (CGI) 32Chamfering Electrode (CH) 17Check Valves, Backflow, (see Flashback Arrestors) 5Chipping Hamm er 30Clamp, Hose 5Classifications, Electrodes 15Connector, Cable 30Cutting Attachment 4Cylinder Policy 1Cylinder Racks 32Cylinder, Technical Data 2, 3Cylinder Trolley 5

Drum, Cable 30 Delivery Terms 42

Electrode, Aluminum (AL) 17 Electrode, Aluminum Bronze (AB) 17

Electrode, Approvals 15Electrode, Boiler Tube (CRMO) 17Electrode, Chamfering (CH) 17Electrode Classifications 15Electrode, Cobalt Chrome (COCR) 17Electrode, Hard Facing (HF38, HF60) 16Electrode, High Tensile (TE) 17Electrode Holder, Safety 12, 13Electrode, Low Hydrogen (LH) 16Electrode, Low Hydrogen (LV) 16Electrode, Nickel Iron (Nl 60) 17Electrode, Nickel (Nl 99) 17 Electrode, Stainless (ST, STV) 16Electrode, Stainless (SSMO) 16Electrode, Steel (EO, EOHP) 16Electrode, Steel (ER, ECEL, PIPE) 16Electrode, Tin Bronze (SN) 17Exchange Policy 1Electrode Packaging 15

A

B

C

D

E

Face Shields 31 Flashback Arrestors 5, 10, 11

Flints, Gas Ignitor 5, 10, 11Flux, Aluminum Brazing 6, 7Flux, Bronze Brazing 6, 7Flux, Silver Brazing 6, 7

Gauges, Content 5 Gauges, Working 5

Glass, Clear Shatterproof (Faceshield) 31Glass, Dark (Faceshield) 31Gloves 30Goggles 5Ground Clamps 12, 13, 31Gases, Technical Data 2, 3Gouging, Torch 32

Handle, Torch 5 High Tensile Electrode (TE) 17

Hose Clamps 5Hose Joints 5Hose, Twin 5Hoses, Flexible, CGI 34

Ignitor, Gas Triplex 10, 11 Inverter, Arc Welding Machines 18, 22-24

Inverter, Plasma Cutting Machines 28

J.l.S. Standard (CGI Couplings) 34

Kit, Welding and Cutting 4 Kit, Spare Parts 4, 30

Lens, Clear, Goggles 50 mm 5 Lens, Colored, Goggles 50 mm 5

Lens, Shatterproof (Faceshield) 32Low Hydrogen Electrodes (LH, LV) 16

Manifolds 34 MIG Welding Machine 18, 19

MIG welding torch and wire feeder, 21

Needles, Cleaning 10, 11 Nickel Electrode (Nl 99) 17Nickel-Iron Electrode (Nl 60) 17

Nitrogen 3Nitrogen/Argon Regulator 3Nitrogen Cylinder-50 Liter 3Nozzle, Cutting 4, 10, 11Nozzle, Gouging 5, 10, 11

Outlet Stations (CGI) 36Oxygen 2

Oxygen Cylinders-5 Liter 2Oxygen Cylinders-40 Liter 2

F

G

H

I

J

K

L

M

N

O

Packaging, Electrodes 15 Packaging, Gas Rods 6, 7

Plasma Cutting Systems 28

Quality Assurance, Electrodes 15 Quick Couplings 4, 5, 10, 11

Regulator, Acetylene (CGI) 32 Regulator, Acetylene (Cylinder) 3, 5, 10

Regulator, Argon/CO2 with Flowmeter 3Regulator, Nitrogen/Argon 3Regulator, Nitrogen Blanketing 3Regulator, Oxygen (CGI) 32Regulator, Oxygen (Cylinder) 3, 5, 10Rods, Gas Aluminum (AL) 7Rods, Gas Bronze (BR) 7Rods, Gas Silver (SL60, SL45) 7Rods, Gas Steel (MS) 7Rods, Gas Wearing Bronze (WB) 7

Safety and Operating Instructions 2 Safety Electrode Holder 12, 13

Safety Precautions 2, 9, 14, inside back cover 34Ships Cabinet, Arc 12, 14Ships Cabinet, Gas 8, 9Silver Brazing Rods (SL45, SL60) 6, 7Socket Nuts 5Spare Parts Kit 4, 10, 11Stainless Electrodes (ST, SSMO) 16Steel Brazing Rods (MS) 7Steel Electrode (EO, ER) 16

TIG Rods, Aluminum (ALT) 27 TIG Rods, Aluminum Bronze (ABT) 27

TIG Rods, Boiler (CRT) 27TIG Rods, Stainless Steel (SST, SMT) 27TIG Welding Equipment 26, 27Tin Bronze Electrode (SN) 17 Top Valves, Cylinders 2Trolley, Cylinder 5Twin Hose 5

Ultimate (Tensile) Strength 16, 17

Valve (Top), Cylinder, Standards 2, 3 Valve, Residual Pressure, 2

Washer, Regulator 5 Welding Apron 12, 13, 30

Welding Electrodes 16, 17Welding Machines, Arc 18-25Wire Brushes 12, 13

YORCALBRO, TIG Welding 27 Zinc Coated Cylinder, OX40,

OX5, N50, A50 2, 3

P

Q

R

S

T

U

V

W

XYZ

Index

For full policy statement on terms and conditions, refer to the

reverse side of the delivery receipt.

Delivery of Drew Marine products is made at no charge in the

primary ports of storage listed in the current Service Directory

on an F.A.S. vessel basis. Special handling, launch deliveries or

deliveries outside primary ports are subject to additional charges.

Contact your local Drew Marine representative for details.

Advance notice may be required for delivery from primary ports

of storage to outports. Deliveries to outports are subject to

additional charges.

See Worldwide Price Book for details of availability of gases. If

a price is listed, the product is normally available in the primary

port of storage and can be delivered with advance notice to out-

ports with delivery charges applied. Oxygen (OX40) and Acetylene

(AC40) cylinders and refills are normally available at all DREW

WELDING PRODUCTS primary ports of storage. Other gas products

such as nitrogen (N50), argon (A50) and 5-liter (portable) oxygen

(OX5) and acetylene (AC5) cylinders and refills are available only

at ports where prices are indicated in the current price book.

Every reasonable effort is made to maintain adequate stock of

material in all ports where Drew Marine is represented. No liability

of any kind will be accepted or acknowledged in the event that

materials are unavailable at a particular time in a given port.

Except for returnable cylinders, no merchandise will be accepted

for return and credit unless approved by an authorized Drew

Marine representative at Drew Marine’s sole discretion. Damaged or partial containers, obsolete merchandise, modified equipment and products held by the customer for over one year are not returnable. A restocking fee will be charged for all returns.

In order to assure product quality, the contents of gas cylinders are not returnable for credit.

Product Policy