MAGNATECH 427A Manual

6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA
Phone: [phone] E-Mail: [e-mail]
Fax: [phone] Web: www.Magnatechllc.com
OPERATING & MAINTENANCE
INSTRUCTION MANUAL
FOR
REDHEAD WELD HEADS
MODELS 427A (R-1), 428A (R-2), 429A (R-3)
FOR USE WITH
514 TUBEMASTER OR 515/516 PIPEMASTER
POWER SUPPLIES
Signature on File
7/18/2014
J.G. Emmerson
President
Date
Signature on File
7/21/2014
Tom Denner
Chief Mechanical Engineer
Date
Signature on File
7/21/2014
Jeffrey Schwirz
Product Engineer
Date

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
i
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
Copyright Notice
This manual and the information contained herein is the property of Magnatech, LLC. It is proprietary and shall not
be copied in whole or in part without the prior express written permission of Magnatech, LLC. Information and
instructions in the document are subject to change and Magnatech, LLC reserves the right to change specifications
and data without notice. This document is based on the latest design version at the time of publication. Some
deviations in actual operation, from this document, are possible depending on the production generation of a
particular machine.
Edition publication date –July 17, 2014. Copyright 2014 by Magnatech, LLC. All rights reserved.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
ii
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
CHANGE HISTORY
Revision
Change No.
Change Description
Date
Approvals
AA
D-10041
Updated format, Section 3.0 Reference Documents, 6.0
Component Inventory. Section 9.1Connect Weld Head to
Controller/Power Source and Section 9.2 Connect Gas.
Removed “Magnapulse” references and updated power
sources.
3/25/2014
JGE
AB
D-10060
Added "Governing Law" to Section 2.0. Updated Section 11.3
Tungsten Material & Ordering Information.
7/23/2014
JGE

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
iii
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
TABLE OF CONTENTS
1.0 TECHNICAL SUPPORT..................................................................................................................................1
2.0 MAGNATECH LIMITED WARRANTY FOR MODELS 427A, 428A & 429A ..................................................2
2.1 Magnatech Product Warranty Registration .................................................................................................................. 3
3.0 REFERENCE DOCUMENTS...........................................................................................................................4
3.1 Standards .................................................................................................................................................................... 4
3.2 Regulations (Repairs and Maintenance)...................................................................................................................... 4
4.0 SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF ARC WELDING EQUIPMENT ...........5
4.1 Important Notice........................................................................................................................................................... 5
4.2 Owner/Operator Obligations ........................................................................................................................................ 5
4.2.1 Safety Precautions (General)................................................................................................................................ 5
4.3 Shock Prevention......................................................................................................................................................... 6
4.3.1 Installation and Grounding of Electrically Powered Equipment............................................................................. 6
4.3.2 Torch and Work Cables......................................................................................................................................... 6
4.3.3 Power Source Output Terminals ........................................................................................................................... 6
4.3.4 Service and Maintenance...................................................................................................................................... 7
4.3.5 Fuse and Circuit Breakers..................................................................................................................................... 7
4.4 Burn Prevention ........................................................................................................................................................... 7
4.4.1 Protective Clothing ................................................................................................................................................ 7
4.4.1 Eye and Head Protection ...................................................................................................................................... 7
4.4.2 Hazards from Flying Sparks .................................................................................................................................. 7
4.5 Toxic Fume Prevention ................................................................................................................................................ 7
4.5.1 Weldments ............................................................................................................................................................ 8
4.5.2 Coated Weldments................................................................................................................................................ 8
4.5.3 Vessels that have contained toxic materials ......................................................................................................... 8
4.5.4 Welding Area......................................................................................................................................................... 8
4.6 Compressed Gas Cylinder Handling............................................................................................................................ 8
4.6.1 Cylinders ............................................................................................................................................................... 8
4.6.2 Pressure Regulators.............................................................................................................................................. 8
4.7 Equipment Warning Labels.......................................................................................................................................... 8
4.8 Inspection .................................................................................................................................................................... 8
4.9 Spares and Expendable Parts ..................................................................................................................................... 9
4.10 Safety Precautions in Normal Operation...................................................................................................................... 9
4.11 Turn Power Off Before Connecting/Disconnecting Cables .......................................................................................... 9
4.12 Always Stop Motors before Reversing......................................................................................................................... 9
4.13 Abrasive Grinding Dust will Cause Premature Wear ................................................................................................... 9
4.14 Be Cautious About Heat Damage to Head .................................................................................................................. 9
4.15 Do Not Expose System to Rain ................................................................................................................................... 9
4.16 Check to ensure that Weld Head Rotation will not be obstructed................................................................................ 9
5.0 SAFETY PRECAUTIONS..............................................................................................................................10
5.1 Symbol Usage............................................................................................................................................................ 10
5.1.1 Arc Welding Hazards........................................................................................................................................... 10
5.1.2 Electric Shock...................................................................................................................................................... 10
5.1.3 Hot Parts ............................................................................................................................................................. 12
5.1.4 Fumes and Gases ............................................................................................................................................... 12
5.1.5 Arc Rays.............................................................................................................................................................. 12
5.2 Welding...................................................................................................................................................................... 13
5.2.1 Flying Metal or Dirt .............................................................................................................................................. 13
5.2.2 Buildup of Gas..................................................................................................................................................... 14

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
iv
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
5.2.3 Electric and Magnetic Fields (EMF) .................................................................................................................... 14
5.2.4 Noise ................................................................................................................................................................... 14
5.2.5 Cylinders ............................................................................................................................................................. 14
5.3 Additional Symbols for Installation, Operation and Maintenance .............................................................................. 15
5.3.1 Fire or Explosion Hazard..................................................................................................................................... 15
5.3.2 Falling Equipment................................................................................................................................................ 15
5.3.3 Overuse............................................................................................................................................................... 15
5.3.4 Static (ESD)......................................................................................................................................................... 15
5.3.5 Moving Parts ....................................................................................................................................................... 15
5.3.6 Welding Wire....................................................................................................................................................... 15
5.3.7 Battery Explosion ................................................................................................................................................ 16
5.3.8 Moving Parts ....................................................................................................................................................... 16
5.3.9 Read Instructions ................................................................................................................................................ 16
5.3.10 H.F. Radiation ..................................................................................................................................................... 16
5.3.11 Arc Welding......................................................................................................................................................... 16
5.4 California Proposition 65 Warnings............................................................................................................................ 17
5.5 Principal Safety Standards......................................................................................................................................... 17
5.6 EMF Information ........................................................................................................................................................ 18
6.0 REDHEAD WELD HEAD COMPONENT INVENTORY ................................................................................19
6.1 Component Inventory................................................................................................................................................. 19
7.0 SPECIFICATIONS.........................................................................................................................................20
7.1 Tube and Pipe Size Range ........................................................................................................................................ 20
7.2 Speed Range............................................................................................................................................................. 20
7.3 Arc Gap Control ......................................................................................................................................................... 20
7.4 Torch Cross Seam Adjustment.................................................................................................................................. 20
7.5 Torch and Torch Cable Assembly.............................................................................................................................. 20
7.6 Filler Wire Feed Module............................................................................................................................................. 21
7.7 Weld Head Weight..................................................................................................................................................... 21
7.8 Clearance Requirements ........................................................................................................................................... 21
8.0 FUNCTIONAL DESCRIPTION......................................................................................................................22
8.1 Basic Weld Head Assembly....................................................................................................................................... 22
8.2 Weld Head Control Cable Assembly.......................................................................................................................... 22
8.3 Torch and Cable Assembly........................................................................................................................................ 22
8.4 Filler Wire Feed Module............................................................................................................................................. 23
8.4.1 Filler Wire Feed Module Assembly...................................................................................................................... 23
8.4.2 Wire Spool Mount Assembly ............................................................................................................................... 23
8.4.3 Filler Wire Conduit............................................................................................................................................... 23
8.4.4 Wire Aimer Mechanism ....................................................................................................................................... 23
9.0 WELD HEAD SET-UP/PREPARATION FOR WELDING .............................................................................24
9.1 Connect Weld Head to Controller/Power Source....................................................................................................... 24
9.2 Connect Gas.............................................................................................................................................................. 24
9.3 Adjusting the Clamp for a New Pipe Size .................................................................................................................. 26
9.4 Install Tungsten Electrode and Adjust Arc Gap ......................................................................................................... 28
9.5 Adjust torch Lead/Lag Angle...................................................................................................................................... 29
9.5.1 R-1 Lead/Lag Adjustments.................................................................................................................................. 29
9.6 R-2 and R-3 Lead/Lag Adjustment ............................................................................................................................ 31
9.7 Preparing the Workpiece ........................................................................................................................................... 32
9.8 Clamp Head on Pipe.................................................................................................................................................. 32
9.9 Adjust the Tension on the Torch Pivoting Arm........................................................................................................... 32

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
v
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
9.10 Install the Wire Spool ................................................................................................................................................. 32
9.11 Adjust Filler Wire Nozzle Position .............................................................................................................................. 33
9.12 Check Torch Cross-Seam Adjustment....................................................................................................................... 33
9.13 Pre-wrap the Torch Cable.......................................................................................................................................... 34
9.14 Recheck Arc Gap and Torch Centering ..................................................................................................................... 34
9.15 Purge the Gas Lines .................................................................................................................................................. 34
9.16 Start Welding ............................................................................................................................................................. 34
9.17 Welding/Downslope ................................................................................................................................................... 34
9.18 Unclamp Head ........................................................................................................................................................... 34
10.0 WELD HEAD MAINTENANCE......................................................................................................................35
10.1 Cleaning..................................................................................................................................................................... 35
10.2 Torch Cable Replacement ......................................................................................................................................... 35
10.3 Water Cooler Maintenance/Flushing Procedure for Torch Cable .............................................................................. 35
10.4 Maintenance of Wire Feed Nozzle............................................................................................................................. 36
10.5 Adjusting the Chain Tensioner................................................................................................................................... 36
10.6 Maintenance of Torch Components........................................................................................................................... 36
11.0 TUNGSTEN...................................................................................................................................................37
11.1 Tungsten Diameter and Length ................................................................................................................................. 37
11.1.1 Tungsten Diameter.............................................................................................................................................. 37
11.1.2 Arc Gap to be used ............................................................................................................................................. 37
11.2 Tungsten Tip Angle and Flat Diameter to Be Used ................................................................................................... 37
11.3 Tungsten Material & Ordering Information................................................................................................................. 38
11.3.1 Tungsten Material................................................................................................................................................ 38
11.3.2 How to specify part number................................................................................................................................. 38
12.0 DEVELOPING WELD PROCEDURES/PROCESS PARAMETERS.............................................................39
12.1 Goal ........................................................................................................................................................................... 39
12.2 MECHANIZED VERSUS MANUAL: IMPLICATIONS TO WPS/PQR ....................................................................... 39
12.3 The Misconception of “Automatic” Pipe Welding ....................................................................................................... 40
12.4 Weld Development –5G............................................................................................................................................ 40
12.4.1 Type of Material................................................................................................................................................... 40
12.4.2 Joint Design and Fit-up Tolerance ...................................................................................................................... 40
12.4.3 Tungsten Geometry............................................................................................................................................. 41
12.4.4 Setting Tungsten Rotation Speed ....................................................................................................................... 41
12.4.5 Setting Current Level........................................................................................................................................... 41
12.5 Setting Filler Wire Speed ........................................................................................................................................... 42
12.6 Root Pass Procedure................................................................................................................................................. 42
12.7 Hot Pass Procedure................................................................................................................................................... 43
12.8 Fill Passes.................................................................................................................................................................. 43
12.8.1 Shield Gas Effects............................................................................................................................................... 43
12.8.2 Fit-up Requirements Maximum Wall Mismatch................................................................................................... 44
12.8.3 Tack Welding Programs...................................................................................................................................... 45
13.0 COMMON WELD DEFECTS: IDENTIFICATION AND PREVENTION........................................................47
14.0 ACRONYMS..................................................................................................................................................49

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
vi
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
APPENDICES
APPENDIX A BILL OF MATERIALS/DRAWINGS................................................................................................. A
A1. 427A, 428A, 429A Bill of Materials/Drawings (Common) ........................................................................................A–1
A2. 427A (R-1) Bill of Materials/Drawings ......................................................................................................................A–2
A3. 428A (R-2) Bill of Materials/Drawings ......................................................................................................................A–3
A4. 429A (R-3) Bill of Materials/Drawings ......................................................................................................................A–4
APPENDIX B WELD HEAD WIRING DIAGRAM ................................................................................................... B
LIST OF FIGURES
Figure 1 - Adjusting the Clamp for a New Pipe Size ....................................................................................................26
Figure 2 - Tungsten Electrode and Adjust Arc Gap......................................................................................................28
Figure 3 - Torch Lead/Lag Adjustments for ALL Redheads.........................................................................................30
Figure 4 - Mounting Locations, R-1 Head Only............................................................................................................30
Figure 5 - Mounting Locations R-1 Head Only (Pivoting Arm Assembly on Rotary Plant)...........................................30
Figure 6 - Filler Wire Aiming Adjustments....................................................................................................................34
Figure 7 - Example of Tack Weld Programs ................................................................................................................46
LIST OF TABLES
Table 1 - Component Inventory R-1 Model 427A.........................................................................................................19
Table 2 - Component Inventory R-2 Model 428A.........................................................................................................19
Table 3 - Component Inventory R-3 Model 429A.........................................................................................................19
Table 4 - Head Dimensions..........................................................................................................................................21
Table 5 - Radial Clearance ..........................................................................................................................................21
Table 6 - Recommended Tungsten Electrode Tip Geometry.......................................................................................29
Table 7 - Pivot Arm Pipe O.D.......................................................................................................................................31
Table 8 - Recommended Tungsten Diameter..............................................................................................................37
Table 9 - Recommended Arc Length ...........................................................................................................................37
Table 10 - Tungsten Tip Angle and Flat Diameter .......................................................................................................37
Table 11 - Tungsten Diameter .....................................................................................................................................38
Table 12 - Tip Diameter ...............................................................................................................................................38

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
vii
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
INTRODUCTION
This operation and maintenance manual is intended to provide general operating instructions in the use and care of
the Redhead line Weld Heads. This manual covers general instructions as well as assistance in weld procedure
development.
The Redhead line of orbital pipe Weld Heads is designed for either autogenous welding, or for applications requiring
additional filler wire. The mechanical arc length control maintains a uniform arc gap even on out-of-round pipe.
There are three models of Weld Heads in the Redhead line, designated R-1 (427A), R-2 (428A), and R-3 (429A).
The Redheads can be operated off of virtually any of Magnatech's control/power supply models including:
Tubemaster Power Source (water cooling module required)
Pipemaster Power Source (water cooling module required)
The appropriate hookup cables and accessories will be provided for each of the various power source alternatives
After receiving your system, please take the inventory of parts using the Packing List, or see Section 6.0, Component
Inventory.
READ AND OBSERVE WARNINGS BEFORE PROCEEDING WITH INSTALLATION!
ATTENTION: ALL FASTENERS ON THIS WELD HEAD ARE METRIC

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
1
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
1.0 TECHNICAL SUPPORT
Now that you have purchased a Magnatech product, our goal is to provide prompt service and technical
support. If technical assistance is needed following equipment delivery, please contact us and our staff will
take every measure to resolve the issue.
U.S. Headquarters:
Magnatech, LLC
6 Kripes Rd. PO Box 260
East Granby, CT 06026-0260
General E-Mail: [e-mail]
E-Mail: [e-mail]
Tel: [phone]
Fax: [phone]
Service & Parts:
Bryan Kirkland - Manager - Manufacturing & Service, Ext. 14, [e-mail]
Technical Support (U.S.):
Scott Wright - Weld Lab Supervisor –Technical Support, Ext. 28, [e-mail]
Jeremy Nettleton - Manager –Technical Sales, Ext. 17, [e-mail]
Jeff Schwirz - Sr. Technician –Design Engineering, Ext. 23,[e-mail]
Yuchi Liu –Controls Engineer, Ext. 38, [email protected]om
Welding Development Assistance/Problem Solving:
Jeremy Nettleton - Manager –Technical Sales, Ext. 17, [e-mail]
Service & Technical Support - Europe, Middle East, India:
Magnatech International b.v.
Tel: +(31) 321-38-6677
Fax: +(31) 321-31-4165
E-Mail: [e-mail]

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
2
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
2.0 MAGNATECH LIMITED WARRANTY FOR MODELS 427A, 428A & 429A
Effective July 2014
GENERAL:
Magnatech warrants equipment that it manufactures to be free from defects from material and workmanship under normal use and service for the periods defined
below. This Warranty shall apply to the Original Purchaser only, and is not transferable. All warranty time periods start on the date that the equipment was
delivered to the original retail purchaser. Our sole obligation under this warranty is limited to repairing or replacing the defective part or parts, which in our
judgment show evidence of such defects. All warranty repair work shall be accomplished at the factory and Magnatech assumes no obligation to perform
warranty service at a customer's facility. This warranty is given in lieu of and to the exclusion of any and all other warranties, express or implied. Specifically,
and without limiting the generality of the above disclaimer, Magnatech disclaims any warranty of merchantability or fitness for any particular purpose as to any
and all goods sold to the Buyer (whether for the ultimate use of the Buyer, or any other person) pursuant to the purchase order, contract or in connection
therewith.
COVERED COMPONENTS:
A. 1 Year –Parts and Labor B. 6 months
All Magnatech Power Sources/Controllers Switches
All Model Water Coolers (with exception of Pump)
All Weld Heads C. 3 months –Parts and Labor
Torch cable assemblies
Relays
Batteries
EXCLUDED COMPONENTS:
Magnatech Limited Warranty shall not apply to:
1. Equipment Supplied Not Manufactured by Magnatech. With respect to standard equipment supplied by Magnatech as part of a complete welding system,
Magnatech extends the same warranty as offered by the individual manufacturer of this standard equipment if any. In many instances such items are
warranted directly by the manufacturer, and Magnatech may, from time to time, inform the customers of such warranty coverage; however, Magnatech does
not guarantee the accuracy of completeness of its information regarding such warranties.
2. Expendable Items. This warranty does not cover certain items considered expendable and certain high wear items offered herein. Expendable items consist
of welding torch components, wire feed conduits, motor brushes, fuses, bulbs and filters.
3. Modification And Misuse. This warranty does not apply to products which have been modified in any way by any party other than Magnatech; nor to products
which have not been installed and operated in accordance with applicable industry standards; or to products which have been used other than under usual
conditions for which they are designed; nor to products that have not received proper care, protection and maintenance under supervision of competent
personnel.
UTILIZATION FOR INTENDED PURPOSE ONLY:
The Tubemaster, Pipemaster, and Pipeliner systems are intended to be used SOLELY for GTAW or GMAW/FCAW orbital welding applications. Any other use is
deemed to be “not for the intended purpose” and the manufacturer shall not be liable for any damage resulting there from.
Utilization for the intended purpose includes:
• observance of all instructions in the operating manual
• performance of all prescribed inspection and maintenance work
Magnatech products are intended for purchase and use by commercial/industrial users and persons trained and experienced in the use and maintenance of
welding equipment.
PERFORMANCE OF WARRANTY REPAIRS –LOCATION:
Magnatech’s obligation under this warranty shall be limited to the repair or replacement, at its option, of any goods or any components or parts thereof sold by
Magnatech to Buyer that prove to be defective upon Magnatech’s examination. Returned goods shall be delivered F.O.B. Magnatech’s plant, East Granby,
Connecticut, at Buyers risk and expense.
DISCLAIMER:
Magnatech shall not be otherwise liable for any damages including but not limited to incidental damage, consequential damage, or special damages, whether
such damages result from negligence, breach of warranty, or the result of repair and replacement activity, including, but not limited to any losses due to downtime
or loss of use. Magnatech shall not be held liable for any lost profit or other damage, delay or loss which may result directly or indirectly from the adjustment,
alteration, repair, maintenance, operation, or interruption thereof, of any said equipment.
There are no warranties of fitness for any particular purpose of said equipment or any other warranties (expressed, implied or statutory) concerning the
performance capabilities thereof. Magnatech shall not be liable for any consequential, indirect or incidental losses or damages incurred as the result of any
breach of warranty or as a result of any repair or replacement activity, including, but not limited to any losses due to down time or loss of use. Magnatech shall
not be liable for any losses, injuries or damages sounding in tort, whether for the negligence of Magnatech or its agents, officers or employees or in a strict
liability theory.
To the extent permitted by law, the remedies provided herein are the sole and exclusive remedies. In no event shall Magnatech be liable for direct, indirect,
special incidental or consequential damages (including loss of profit), whether based on contract, tort, or any legal theory.
Any express warranty not provided herein and any implied warranty guaranty or representation as to performance, and any remedy for breach of contract tort or
any other legal theory which, but for this provision might arise by implication, operation of the law, custom of trade or course of dealing including any implied
warranty of merchantability or fitness for particular purpose, with respect to any and all equipment furnished by Magnatech is excluded and disclaimed by
Magnatech.
GOVERNING LAW:
The terms of this Warranty shall be construed in accordance with the laws of the State of Connecticut and the Country of the United States of America. Any
dispute or controversy which cannot be resolved by mutual agreement shall be brought exclusively in the courts of the State of Connecticut. The parties hereto
consent to the jurisdiction and venue in said court and waive any objection to such venue.
✔
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✔

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
3
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
2.1 Magnatech Product Warranty Registration
Please complete following information and mail/fax/email to Magnatech. This will allow us to ensure correct
replacement parts are supplied, service bulletins reach the correct person and provide a contact person for
service.
Date Purchased:
Company Name:
Contact Name:
Dealer:
Address:
City:
State:
Zip:
Email:
Phone:
Fax:
UPGRADE/SERVICE
Contact Name:
Address:
City:
State:
Zip:
Email:
Phone:
Fax:
Product Name:
S/N:
Product Name:
S/N:
Product Name:
S/N:

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
4
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
3.0 REFERENCE DOCUMENTS
Referenced standards and regulations may be purchased from the originating organization (AWS, ANSI,
NFPA, etc.). See also Section 5.5, Principle Safety Standards for ordering information.
3.1 Standards
AWS F3.M/F3.2
Ventilation Guide for Weld Fume
ANSI Z49.1
Safety in Welding, Cutting, and Allied Processes
ANSI/ISEA Z87.1
American National Standard for Occupational and Educational Personal Eye
and Face Protection Devices
ASTM F2412
Standard Test Methods for Foot Protection
ASTM A106/A106M
Standard Specification for Seamless Carbon Steel Pipe for High-Temperature
Service
AWS F4.1
Safe Practices for The Preparation Of Containers and Piping for Welding and
Cutting
OSHA Standard 29 CFR, Part
1910, Subpart Q
Welding, Cutting And Brazing
NFPA 51
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work
NFPA 70
National Electrical Code
CGA P-1
Safe Handling of Compressed Gases in Cylinders
CSA W117.2
Safety in Welding, Cutting and Allied Processes
Miller 215 994
Guidelines for Gas Tungsten Arc Welding (GTAW)
DHHS (NIOSH)
Publication No. 94-110
Applications Manual for the Revised NIOSH Lifting Equation
3.2 Regulations (Repairs and Maintenance)
Any repairs to the Controller or power source are only to be made by the factory, or a licensed electrician.
In the course of any service, the following regulations must be observed (as a minimum):
ANSI/IEC 60974-1
Arc Welding Equipment –Part 1: Welding Power Sources
VBG 4, 5
National Regulations for Safety and Accident Prevention
VBG 15, 33/49
Welding, Cutting and Allied Processes
VDE 0701-1
Repair, Modification and Inspection of Electrical Appliances; General
Requirements
VDE 0702-1
Repeat Tests on Electrical Appliances

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
5
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
4.0 SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF ARC WELDING EQUIPMENT
4.1 Important Notice
The nature of the GTAW process creates some potential hazards. In accordance and compliance with the
international safety regulations, the "exclamation symbol" indicates that this equipment is to be considered
"Hazardous" UNTIL an operator has been made aware of these potential hazards by READING THIS
MANUAL.
The "lightening flash" symbol indicates that there are potential electrical hazards. The display of these
symbols make it the OPERATOR'S RESPONSIBILITY TO INSURE THAT HE HAS READ AND/OR BEEN
MADE AWARE OF ALL OF THE SAFETY RELATED ITEMS CONTAINED IN THIS MANUAL.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING, OPERATING OR
SERVICING MAGNATECH EQUIPMENT OR AUXILIARY EQUIPMENT SUPPLIED AS PART OF THE
WELDING SYSTEM.
4.2 Owner/Operator Obligations
4.2.1 Safety Precautions (General)
The owner/operator must ensure that people working with the system:
Are familiar with the basic regulations on workplace safety and accident prevention and who have
been instructed in how to operate the equipment.
Have read and understand` the sections on safety and the warnings contained in this manual.
Keep a copy of the instruction manual at the welding location at all times.
Insure that the workplace and the equipment are always kept clean (see Section 10, Weld Head
Maintenance).
Only operate the power supply if all the protective features are fully functional. Before switching
the power to the system “ON”, ensure that no one will be injured.
At least once per week, check the system for any damage that may be visible from the outside, and
check that all the safety features work correctly.
Use only original parts purchased from the manufacturer.
Welding products and welding processes can possibly cause serious injury or death, and damage to other
equipment if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices are outlined in the ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes. See
Section 5.0, Safety Precautions for other guides and publications for what you should learn before operating
this equipment.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
6
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
4.3 Shock Prevention
Bare conductors or terminals in the output circuit, or ungrounded, electrically live equipment can fatally
shock a person. To protect against shock, have a competent electrician verify that the equipment is
adequately grounded, do not make contact with terminals and parts that are electrically HOT.
Always disconnect the AC power plug before removing the top or bottom panels of the Controller to avoid
electrical shock and the possibility of shorting or grounding the electrical circuitry.
Always disconnect primary power to the power source before removing panels. Do not remove panels from
the power source until the maintenance manual has been read and fully understood, as there may be lethal
voltage present even after the primary power is disconnected. Heed all installation instructions and
warnings given in the Power Source Manual.
Be sure that the 115V line providing electrical service to the Controller is properly grounded. Do not use
"cheater" adaptors to enable the three-prong connector provided to be installed in a two-prong receptacle
without a ground.
The body's electrical resistance is decreased when wet, permitting dangerous currents to flow through the
body. Do not work in damp area without being extremely careful. Stand on dry rubber mats or dry wood
and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry.
4.3.1 Installation and Grounding of Electrically Powered Equipment
Electrical equipment must be installed and maintained in accordance with NFPA 70, National Electrical
Code, and local codes. A power disconnect switch must be located at the equipment. Check equipment
nameplates for voltage and phase requirements. If only 3-phase power is available, connect single-phase
equipment to only two wires of the 3-phase line. DO NOT CONNECT the equipment-grounding conductor
(lead) to the third live wire of the 3-phase line as this makes the equipment frame electrically HOT, which
can cause fatal shock.
Be sure that all external electrical connections are clean and tight. In particular, the ground-to-work clamp
must make a good electrical contact to assure minimum voltage drop. Adhere to the power source
manufacturer's grounding recommendations. Check for gas and water leaks immediately following cable
hook-up before system is first operated.
If a grounding lead (conductor) is part of the power supply cable, be sure to connect it to a properly
grounded switch box or building ground. If not part of the supply cable, use a separate grounding lead
(conductor). Do not remove a ground prong from any plug. Use correct mating receptacles. Check ground
for electrical continuity before using equipment.
4.3.2 Torch and Work Cables
Inspect cables often for damage to insulation. Replace or repair cracked or worn cables immediately. Do
not use a welding current in excess of rated cable capacity, as the cable will overheat.
4.3.3 Power Source Output Terminals
Do not touch output terminals or make contact with machine while equipment is operating.
Note: All Magnatech manufactured power sources completely shield the output terminals when the Torch
Cable is connected.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
7
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
4.3.4 Service and Maintenance
Shut OFF all power at the disconnect switch or line breaker before inspecting or servicing the equipment.
Unplug the input power cord. If the equipment is wired directly to an electrical box, lock the switch OFF (or
remove line fuses) so that power cannot be turned ON accidentally. Disconnect power to equipment if it is
to be left unattended or out of service.
4.3.5 Fuse and Circuit Breakers
Replace fuses and circuit breakers with equivalent sizes.
4.4 Burn Prevention
The welding arc emits high-energy radiation in the infrared and ultraviolet range. This energy penetrates
lightweight clothing and is reflected from light-colored surfaces. The arc rays can injure the eyes
permanently and burn the skin, just as in “sunburn”. Never look at an electric arc without eye protection.
4.4.1 Protective Clothing
Wear gloves, suitable long sleeved shirts/jackets, safety shoes, welding helmet, and other articles needed
to shield the skin and to prevent injury from arc burns. Wear earplugs if welding overhead or in a confined
space. Wear a hard hat if others are working above you.
4.4.1 Eye and Head Protection
Protect your eyes and head by wearing a welding helmet fitted with a double lens; use a clear lens outside
and a colored, welding filter inside. Use at least a number 10 filter. If welding over 100 amps, use a number
12 filter.
Always lower the helmet before striking the arc. Wear safety glasses with side shields under the helmet to
protect the eyes from flying particles and side arc flashes when the helmet is up.
Protect the eyes of other people in the area by use of opaque, non-reflecting and nonflammable screens
around your welding station. Allow good air circulation, especially at floor level. Do not permit anyone to
view the arc unless he uses a correct hand shield, or helmet.
4.4.2 Hazards from Flying Sparks
Move all combustible objects well away from the welding location. Welding must NEVER be performed on
pipes that have been used for transmission of flammable gases, fuels, mineral oils etc.
4.5 Toxic Fume Prevention
Breathing the fumes created during welding or cutting can cause illness or death if adequate ventilation is
not provided. Provide ventilation in accordance with ANSI Z49.1, Safety in Welding, Cutting, and Allied
Processes.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
8
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
Some fume sources are:
4.5.1 Weldments
Metals containing lead, cadmium, zinc, mercury and beryllium can produce harmful toxic fumes when
welded or cut. Arc welding of stainless steels can produce hazardous fumes. Adequate local exhaust
ventilation must be used for the operator and persons in the area.
4.5.2 Coated Weldments
Do not weld on pipes or tubes that have coatings that emit toxic fumes when heated.
4.5.3 Vessels that have contained toxic materials
Vapors from chlorinated solvents can be decomposed by the arc to form the highly toxic gas called
PHOSGENE or other damaging products. The ultraviolet radiant energy of the arc can also decompose
trichloroethylene and perchloroethylene vapors to form PHOSGENE. Do not weld or cut unless such
containers have been thoroughly cleaned following AWS F4.1, Safe Practices for The Preparation Of
Containers and Piping for Welding and Cutting.
4.5.4 Welding Area
Do not weld in locations close to chlorinated vapors coming from degreasing, cleaning or spraying
operations. The heat and rays from the arc react with the vapors to form highly toxic PHOSGENE. Work in
a confined space only if it is being adequately ventilated, and if ventilation is not adequate, wear an air-
supplied respirator (see AWS F3.2M/F3.2, Ventilation Guide for Weld Fume).
4.6 Compressed Gas Cylinder Handling
Follow precautions below and those outlined in CGA Standard P-1, Safe Handling of Compressed Gases in
Cylinders.
4.6.1 Cylinders
Handle carefully to prevent damage. Keep away from welding cables or other electrical circuits. Use only
cylinders with name of gas marked on them; DO NOT rely on color identification. Close valves on empties
and return promptly. Secure cylinders so they cannot be knocked over. Keep temperature below 55º C
(130º F).
4.6.2 Pressure Regulators
Use the correct regulator for the gas and cylinder being used. Remove any suspected faulty regulator and
return to manufacturer's service center for repair.
4.7 Equipment Warning Labels
Inspect all precautionary labels on the equipment.
4.8 Inspection
Frequently inspect all components for damage.
Check the Controller, Head and power source frequently for damage, and immediately replace any
components that are not in perfect condition.
Do not make alterations or modifications to the Weld Head, Controller, or power supply without first getting
permission from the manufacturer.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
9
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
4.9 Spares and Expendable Parts
Use only original spares and expendable parts. With parts purchased from other suppliers, there is no
certainty that these parts have been designed and manufactured to cope with the operation and safety
requirements that will be made of them.
When ordering spare parts, please give the exact description and the relevant part number, as given in the
spare parts list. Please also give the serial number of your machine.
4.10 Safety Precautions in Normal Operation
Only operate the power supply if all its protective features are fully functional. Before switching power on to
the power supply ensures that nobody can be injured. At least once a week, check the power supply for any
damage that may be visible from the outside, and check that the safety features all function correctly.
4.11 Turn Power Off Before Connecting/Disconnecting Cables
Turn the Main Power Switch of both Controller and power supply off before connecting or disconnecting any
cables to prevent possible damage to the electrical circuitry.
4.12 Always Stop Motors before Reversing
Do not snap reverse motors. Switch motor to the "OFF" position before reversing direction. Fast reversing
can reduce motor power and shorten life.
4.13 Abrasive Grinding Dust will Cause Premature Wear
Avoid grinding in the vicinity of the Weld Head. Grinding dust is extremely abrasive and should not be
allowed to contact Weld Head and controls.
4.14 Be Cautious About Heat Damage to Head
Do not allow the Weld Head to remain on preheated pipe when not actually welding.
4.15 Do Not Expose System to Rain
Do not allow the Weld Head to be exposed to rain.
4.16 Check to ensure that Weld Head Rotation will not be obstructed
Ensure that the rotation of the Weld Head will be unobstructed by adjacent structure, pipes, etc. If a doubt
exists, jog the Head around prior to striking an arc and carefully observe for interference

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
10
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
5.0 SAFETY PRECAUTIONS
The following section is referenced from Miller 215 994, Guidelines for Gas Tungsten Arc Welding (GTAW).
5.1 Symbol Usage
DANGER! –Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
Notice –Indicates statements not related to personal injury
Indicates special instructions
This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT
PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
5.1.1 Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in Section
5.5, Principle Safety Standards. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During Operation, keep everybody, especially children, away.
5.1.2 Electric Shock
ELECTRIC SHOCK CAN KILL
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded
equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection
Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent
any physical contact with the work or ground.
Do not us AC output in damp areas, if movement is confined, or if there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
11
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
Electric Shock (cont’d)
Additional safety precautions are required when any of the following electrically hazardous
conditions are present: in damp locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or
when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For
these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant
voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit
voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do
not work alone!
Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout
input power according to OSHA 29 CFR 1910, 147 (see Section 5.5, Principle Safety Standards).
Properly install and ground this equipment according to its Owner’s Manual and national, state, and
local codes.
Always verify the supply ground –check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet,
When making input connections attach proper grounding conductor first –double-check
connections.
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
Frequently inspect input power cord for damage or bar wiring –replace cord immediately if
damaged –bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a
different machine.
Do not touch electrode holders connected to two welding machines at the same time since double
open-circuit voltage will be present.
Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit
according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as
practical.
Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
Do not connect more than one electrode or work cable to any single weld output terminal.
Disconnect cable for process not in use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input
power
Turn off inverter, disconnect input power, and discharge input capacitors according to instructions
in Maintenance Section before touching any parts.

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
12
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
5.1.3 Hot Parts
HOT PARTS CAN BURN
Do not touch hot parts bare handed.
Allow cooling period before working on gun or torch.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to
prevent burns.
5.1.4 Fumes and Gases
FUMES AND GASES CAN BE HAZARDOUS
Welding procedures and gases. Breathing these fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes
and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.
Always have a trained watch person nearby. Welding fumes and gases can displace air and lower
the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of
the arc can react with vapors to form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the
coating is removed from the weld area, the area is well ventilated, and while wearing an air-
supplied respirator. The coatings and any metals containing these elements can give off toxic
fumes if welded.
5.1.5 Arc Rays
ARC RAYS CAN BURN EYES AND SKIN
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face
and eyes when welding or watching (see ANSI Z49.1, Safety in Welding, Cutting, and Allied
Processes and ANSI/ISEA Z87.1, American National Standard for Occupational and Educational
Personal Eye and Face Protection Devices listed in Section 5.5, Principle Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to
watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or
wool) and foot protection.