Miller Electric GPS-1000 User manual

November
1986
FORM:
OM-267E
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST,
P.O.
Box 1079
APPLETON,
WI
54912
USA
IMPORTANT
Read
and
understand
the entire
contents of this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and
these
instructions
are
for
use
only by
persons
trained
and
experienced
in the
safe
operation
of
welding equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you do
not
fully
understand
these
instructions.
Effective
With
Serial
No.
JF887698
MODEL
GPS-1
000
G
PS-i
500A
GPS-1500V
OWN
ERS
MAN
UAL
A1IHER
*Ltlpv
PRINTED IN
U.S.A.

LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi
tions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
Miller is
free
from
defect
in
workman
Ship
and
material
as
of
the
time
and
place
of
delivery by
Miller.
No
warranty
is
made
by
Miller with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others. Such
engines,
trade accessories
and
other items
are
sold
subject
to
the
warranties of
their
respective
manufacturers,
if
any
.
All
engines
are
warranted
by
their
manufacturer
for
one
year
from
date of
original
purchase,
except
Tecumseh
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components having
normal
useful
life of less
than
one
(1)
year,
such
as
spot
welder
tips, relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where failure
does
not
result from
defect
in
workmanship
or
material.
Miller shall be
required
to honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
within the
following
periods
from the
date of
delivery
of
Equip
ment
to the
original
user:
Arc
welders,
power
sources,
robots,
and
components
1
year
Load
banks
1
year
Original
main
power
rectifiers 3
years
(labor
-
1
year
only)
All
welding
guns,
feeder/guns
and
plasma
torches...
90
days
All
other
Millermatic
Feeders 1
year
Replacement
or
repair parts,
exclusive
of
labor
..
60
days
Batteries 6
months
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers risk and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
Appleton,
Wisconsin,
or
F.O.B.,
at
a
MILLER authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind will
be
allowed.
Upon
receipt
of notice of
apparent
defect
or
failure,
Miller shall instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN AND
ANY IMPLIED
WARRANTY,
GUARANTY OR
REPRESENTA
liON
AS
TO
PERFORMANCE,
AND ANY REMEDY FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE OR
COURSE
OF
DEALING,
INCLUDING
ANY IMPLIED
WARRANTY OF
MERCHANTABILITY
OR OF
FITNESS
FOR PARTICULAR
PURPOSE,
WITH RESPECT TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY MILLER IS
EX
CLUDED
AND
DISCLAIMED BY
MILLER.

L
1
&~~L

LIMITED
WARRANTY
*
EFFECTIVE:
OCTOBER
1,
1986
This
warranty
supersedes
all
previous
MILLER
warranties
and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
*
*
2.
r
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
!,
4.
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
(
5.
ULTIMATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
~
6.
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED AND
~
7.
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING EQUIPMENT
AND NOT FOR
CONSUMERS
OR
~,)
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
CONSUMER USE.
MILLERS WARRANTIES
DO
NOT
EXTEND
t~
t-
of
the date
of
such failure.
TO,
AND NO
RESELLER IS
AUTHORIZED
TO
EXTEND
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
r
submitted
by
the
original
user
within
the
foregoing periods.
~
~.
,~.
~
...~
~
~ ~
,,t

ERRATA
SHEET
After this manual
was
printed,
refinements
in
equipment
design
occurred. This
sheet
lists
exceptions
to
data
appearing
later
in
this manual.
**FirSt
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE MODEL
AND SERIAL
NUMBER WHEN ORDERING
REPLACEMENT
PARTS.
Dia.
**
Mkgs.
Part
No.
Replaced
With
Descnption
Quantity
2-1
2-4
2-
059
572
004 104
004259
120 496
099 044
048599
PLATE,
adapter-power
cord
CONTACTOR,
3P
110/120/220-240
(Eff
w/JH282902)
.
.
~COIL
..
1
1
1
2-
004 258
Deleted
4-27
009
139
Deleted
4-
601 375 Deleted
4-
030
691
Deleted
4-
604
288
Deleted
4-
083
719
Deleted
4-
031
640 Deleted
4-
601 375 Deleted
4-
031 683
Deleted
4-
4-
4-
4-
R2
TP1
083
640
014 425
092
624
071
624
083
640
Deleted
092
624
120
495
109
035
RESISTOR
(dia mkg changed)
(Eff w/JJ355208)
THERMOSTAT,
NC
(Part
of
transformer
assembly)
PANEL,
side
(Effw/JJ355208)
LABEL,
warning
panel
1
1
2

TABLE
OF CONTENTS
Section
No.
Page
No.

SECTION
1
-
SAFETY
RULES
FOR
OPERATION OF
ARC WELDING POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General Precautions
1
1
-3.
ArcWelding
7
1
-
4.
Standards
Booklet Index
11
SECTION
2
-
INTRODUCTION
2-1.
General
13
2
-
2.
Receiving-Handling
13
2
-
3.
Description
13
2-4.
Safety
13
SECTION 3
-
INSTALLATION
3-1.
Location
13
3
-
2.
Electrical
Input
Connections
14
3
-
3.
Weld
Output
Connections
15
SECTION
4
-
OPERATION
4
-
1.
Power
Control
Switch
17
4
-
2.
Overload
Protection
17
4-3.
Pilot
Light
17
4
-
4.
Meters 17
4 -5.
Volt-Ampere
Curve
17
4
-
6.
Duty
Cycle
17
SECTION
5
-
MAINTENANCE
5-1.
Fan
Motor
18
5
-
2.
Internal
Cleaning
18
5
-
3. Control Circuit Protection
18
SECTION
6
-
TROUBLESHOOTING

SECTION
1
-
SAFETY RULES
FOR
OPERATION
OF ARC
WELDING
POWER
SOURCE
SECTION
1
-
REGLES
DE
SECURITE
POUR
LE
FONCTIONNEMENT
DU
POSTE
DE
SOUDAGE
A
LARC
1-1.
INTRODUCTION
-
We
learn
by
experience.
Learning safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise.
Let the
experience
of others teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained. The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It is
wiser
to follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with these
procedures
as
applicable
to
the
par
ticular
equipment
used and
their
instruction
manuals,
for
personal safety
and for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in this
manual.
They
are
listed
in
the
Standards
Index
in
this manual.
ANSI Z49.1 is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
different
fumes,
gases,
and
radiation
levels.
In
addition
to
the
information
in
this
manual,
be
sure
to
consult
flux and
elec
trode
manufacturers
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A. Burn
Prevention
Wear
protective
clothing
-
gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety~toe
shoes. Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
1-1.
INTRODUCTION
-
Contrairement
a
lappren
tissage
de Ia
vie,
lapprentissage
de Ia
sØcuritØ
par
ox
pØrience
personnelle,
comme
lenfant
qui
touche
un
poŒle
chaud,
est
dangereux,
imprudent
at
inutile.
lnstruisez-vous
donc
de
lexpØrience
dautrui.
Des
mØthodes de
sØcuritØ issues
de
Iexperience
du
soudage
et
du
coupage
sont
dØcrites
dans
le
manuel. La
recherche,
le
progres
at
lexpØrience
dans
ce
domaine
ont
dØveloppØ
an
matØrial
fiable
at
des
mØthodes do
sØcuritØ
pour
linstallation,
le
fonctionnement
et
lentre
tien.
Des accidents
so
produisent
lorsque
le matØrial
est
inadequatement
utilisØ
ou entretenu.
La
raison
do
ces
mØthodes
de
sØcuritØ
peut
ne
pas
Œtre
toujours
donnØe.
Certaines
sont
fondØes
sur
Ia
sens
commun,
dautres
demanderont a
Œtre
expliquØes
par
des
livres
techni
ques.
II
est
plus
sage
de
suivre
los
regles.
Lisez
at
comprenez
ces
mØthodes
de
sØcuritØ
avant
dessayer dinstaller,
de
faire
fonctionner
ou
de
rØparer
lappareil.
Pour
votre
sØcuritØ
personnelle
at
celle
dautrui,
conformez-vous a
ces
regles
et
aux
manuels
dinstructions.
Manquer
dobserver
ces
mØthodes de sØcuritØ
pourrait
entrainer
des
blessures
graves
ou
mŁme
Ia
mort.
Quand
Ia sØcuritØ deviant
une
habitude,
le
matØrial
pout
alors
Œtre
utilisØ
en
toute
confiance.
Ces mØthodes
do
sØcuritØ
sont
divisØes
en
deux
sec
tions:
1
-
Precautions
gØnØrales,
communes
au
soudage
et
au
coupage
a
larc,
at
2
-
Soudage
a larc
(et
coupage)
(uniquement).
Normes de
rØfØrence:
Des
publications
des
normes
amØricaines
de
sØcuritØ
sont
aussi
a
votre
disposition
pour
dautres
modes
opØratoires plus complets
quo
ceux
du
present
manuel.
Elles
sont
donnØes
dans
lln
dex
des Normes de
ces
rŁgles
de
sØcuritØ. ANSI
Z49-1
est
Ia
plus
complete.
Les codes
do
IACNOR,
los
codes
provinciaux
et
municipaux
donnent
aussi
les
exigonces
pour
une
in
stallation,
une
utilisation
et
an
entretien
s~rs.
1-2.
PRECAUTIONS
GENERALES
Plusiours
procØdØs
du
soudage
a
Iarc,
des
Ølec
trodes
allies,
at
las
flux
peuvent
produire
des
vapeurs, gaz,
at
niveaux
do
rayonnoment
diffØrents. Pour
tout
rensoignomont
supplØmon
taire
a
ce
manual,
consultez
aussi
lea fabricants
des
electrodes
et
des
flux
af
In
dobtenir los
rensoignements
techniques
spØcifiques
at
los
mesures
do
precaution
concarnant laura
matØriaux.
A.
Prevention
des brOlures
Portez
des
vŒtements de
protection
-
des
gants
a
crispin
spØcialement
dØsignØs
pour
le
soudage,
un
casque
at
des chaussures
de
sØcuritØ. Boutonnez le
col
de
votre
chemise
at
les
pattes
de
vos
poches,
et
portez
des
pan-
talons
sans
revers
pour
Øviter
qua
des
Otincelles
et
du
laitier
ne
sy
introduisent.
Portez
un
masque
avec
lunettes
de
sØcuritØ
ou
avec
Øcrans
latØ-raux
de
protection,
des
lunettes
filtrantes
ou
des
couvre-lentilles
(proteges
par
an
verre
clair).
Pour Is
soudage
ou
le
coupage
(et
le
burinage),
il
est
OM-267
Page
1

from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be handled
without
gloves.
Medical first
aid and
eye
treatment.
First
aid
facilities
and
a
qualified
first aid
person
should
be available
for
each
shift
unless
medical facilities
are
close
by
for
im
mediate
treatment
of
flash burns of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be used
by
per
Sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent them
with
adequate
ventilation
as
described
in
ANSI Stan
dard
Z49.1
listed 1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
cut)
may
produce
harmful concentrations
of
toxic fumes.
Ade
quate
local
exhaust ventilation
must
be
used,
or
each
person
in
the
area as
well
as
the
operator
must
wear an
air-supplied respirator.
For
beryllium,
both
must
be
us
ed.
Metals coated
with
or
containing
materials that emit
toxic fumes should
not be
heated
unless
coating
is
removed
from the
work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in the
space
if
downstream valves
have been
accidently opened
or
left
open.
Check
to
be
sure
that
the
space
is safe before
re-entering
it.
Vapors
from
chlorinated solvents
can
be
decomposed
by
the heat
of the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc can
also
decompose
trichloroethylene
and
per
chioroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
OBLIGATOIRE
do
proteger
ses
yeux
contre
lØnergie
de
rayonnement
et
los
Øclats
de
metal.
Romplacez
le
verre
protecteur
lorsquil
est
brisØ,
piquØ
ou
quil
a
recu
des
projections.
Voir
1.3A.2.
Evitez
de
porter
des habits
impregnØs
dhuile
ou
de
graisse.
Une
Øtincelle
pourrait
les
enflammer.
Ne
manipulez
jamais
sans
gants
un
metal
chaud
tel
que
des chutes
dØlectrode
et
des
piŁces
a souder.
Premiers soins
et traitement
des
yeux:
Tout
atelier
devrait
avoir
a
sa
disposition
un
poste
de
premiers
soins
ainsi
quune
personne
compØtente,
a
moms
quur,
ser
vice medical
ne
soit a
proximitØ
pour
soigner
immediate
ment
les brlures
des
yeux
et
de Ia
peau.
Portez des
bouche-oreilles
lorsque
vous
travaillez
au
plafond
ou
dans
un
espace
restreint.
Portez
un
casque
lorsque
dautres
personnes
travaillent
au
plafond.
Les
personnes
devant souder
ou
couper
ne
doivent
pas
employer
des
preparations
inflammablos
pour
lours
cheveux.
B. Prevention
des
gax
toxiques
Les
gaz,
les
vapeurs,
Ia
chaleur,
un
enrichissement
ou
un
manque
doxygŁne
peuvent
entralner
un
malaise,
une
maladie
ou
mŒme
Ia
mort.
RemØdiez-y
par
Ia
ven
tilation dØcrite dans Ia
Norme
ANSI
Z49.1
paragraphe
1
de
llndex
des
Normes.
NE ventilez
JAMAIS
a Iox
ygŁne.
En
soudant
ou en
coupant,
los
p10mb,
cadmium,
zinc,
mercure
et
beryllium
ou
autres
matØriaux
semblables
peuvent
crØer des
concentrations
nocives
de
gaz
taxi
quos.
On
doit avoir
recours
a
une
ventilation
aspirante
adequate
du
local,
ou
alors
toute
personne
sur
les
Ileux,
de
mŒme
que
le
soudeur,
doit
porter
un
masque
a ad
duction
dair.
On
doit
employer
los
deux
pour
lo
beryllium.
Les
mØtaux
enrobØs
ou
composes
do
matØriaux
Ømet
tant
des gaz
toxiques
no
doivent
pas
Œtro
chauffØs
a
moms
que
lenrobage
ne
salt tØ
do
Ia
surface a
travailler,
quo
le local
no
salt
bien
ventilØ,
ou
quo
to
soudour
no
porte
un
masque
a
adduction
dair.
No travaillez
dans
un
ospaco
rostroint
que
sil
est
bion
ventilØ
ot,
si
nØcessaire,
portez
un
masque
a
adduction
dair.
On doit
Øviter
los
fuites
do
gaz
dans
un
ospaco
rostroint.
Los
fuites do
gaz
on
grando
quantitO
peuvont
transformer
dangoreusoment
Ia
concentration
dox
ygeno.
Namonoz
pas
do
boutoillos
do
gaz
dans
un
ospace
rostreint.
En
quittant
un
ospace
restreint,
FERMEZ
to robinot
dalimentation
do
gaz
do
Ia
boutoillo.
Ainsi
on
pourra
rontror en
touto
sØcuritØ
dans
Ia
piŁce,
memo
si los
robinets
aval
ant
ØtØ
ouvorts
par
accident,
ou
si
on
los
a
laissØs
ouvertS.
Les
vapeurs
do
dissolvants chiorØs
peuvent
Œtro
dØcom
posØes
par
Ia chaleur
do
larc
(ou
de Ia
flammo)
et
former du
PHOSGENE,
gaz
trØs
toxique,
ot
dautres
produits
irritant les
poumons
et
los
yeux.
LØnorgio
ultra-violette do
larc
peut
aussi
dØcomposer
los
vapeurs
de
trichloroØthylŁne
et
de
porchloroØthylŁne
pour
former
du
phosgeno.
NE
SOUDEZ
PAS
ou
no
coupoz
pas
dans dos
ondroits
oC~
los
vapeurs
de
dissolvants
peu
vent
Œtre
attirØes
dans
IatmosphŁro
do
soudage
ou
do
OM-267
Page
2

energy
can
penetrate
to
atmospheres containing
even
minute
amounts
of
trichloroethylene
or per
chioroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire and
explosion
are:
combustibles reached
by
the
arc,
flame,
ftying
sparks,
hot
slag
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35 feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
yen
tilators.
If
the
work
cannot
be
moved,
move
com
bustibles
at
least
35
feet
away
out
of reach of
sparks
and
heat;
or
protect
against
ignition
with suitable and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(or
cut).
Walls,
ceilings,
and
floor
near
work
should be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within 35
feet
b.
appreciable
combustibles
are
further
than 35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35
feet
may
expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have been taken.
After
work
is
done,
check
that
area
is free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has first
been
cleaned
as
described
in
AWS Standard
A6.O,
listed
3
in
Standards
index.
This includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
corn-
coupage
et
o~i
lØnergie
de
rayonnemont
peut
pØnØtrer
dans des
atmospheres
contenant
des
quantitØs
memo
minuscules
de
trichloroØthylŁne
ou
de
per
chloroØthylŁne.
C.
Prevention
des incendies
et
des
explosions
Les
causes
dincendie
et
dexplosion
sont
les
com
bustibles
atteints
par
(arc,
Ia
flamme,
les
Øtincelles,
le
laitier
chaud
ou
los
matØrlaux
chauffØs,
le
mauvais
emplol
des
gaz
comprimØs
et
des
bouteilles ainsi
que
los
courts-circuits.
Sachez
que
les
Øclats dØtincelles
ou
Ia
chute
du
laitier
peuvent
sinfiltrer
dans
les
fissures,
le
long
des
tuyauteries,
par
les fenŒtres
et
les
portes
et
par
los
couvertures
des
murs ou
du
sol,
sans
que
le soudeur
portant
des
lunettes
ne
les voie.
Les
Øtincelles
ot
les
scones
peuvent
voler
jusqu
35
pieds.
Pour
prØvenir
los incendies
et
les
explosions:
Veillez
a
co
quo
votre
appareil
soit
propre
et
en
Øtat
de
marche,
dØnuØ
dhuile
et
de
graisse,
et
de
particules
do
metal
sur
les
piŁces
Ølectriques
qui
pourraient
entrainer
des
courts-circuits.
Si
des
combustibles
se trouvent
a
proximite,
no
soudez
pas,
ne
coupez pas.
Sipossible,
dØplacez
votre
travail
loin
des combustibles.
Evitoz
les ateliers do
peinture
au
pistolet,
les
cuves
dimmersion,
les
entrepts,
les
yen
tilateurs.
Si
cela nest
pas
possible,
placez
los
com
bustibles
a
au
moms
35
pieds
des Øtince(les
et
de
(a
chaleur
et
protØgez-Ies
des
Øtincelles
avec
des
couver
tures
ou
des
Øcrans
protecteurs
adØquats,
bien
ajustØs
et
ignifugØs.
On
ne
dolt
pas
souder
(ou
couper)
le
ctØ
oppose
des
murs
touchant
les
combustibles.
Les
murs,
plafonds
et
planchers
proches
du
travail doivent Œtre
protØgØs
par
des
couvertures
ou
Øcrans
protecteurs
ignifuges.
Un surveillant dolt
se
tenir a
proximitØ
avec
un
materiel
de lutte
contre
Iincendie
adØquat, pendant
et
quelque
temps
aprŁs
le
soudage
ou
le
coupage
Si:
a.
Des
quantites
apprØciables
de
combustibles
(y
compris
une
construction
on
chantier)
so
trouvent
Ł moms
de
35
pieds.
b.
Des
quantitØs appreciables
do combustibles
sont
a
plus
de
35
pieds
mais
peuvent
Œtre
enflammØes
par
des
Øtincelles.
c.
Des
ouvertures
(cachØes
ou
visibles)
sur
los
planchers
ou
los
murs
a
moms
de
35
plods
peuvent exposer
dos combustibles
aux
Øtincelles.
d.
Les combustibles
adjacents
aux
murs,
plafonds,
toits
ou
cloisons
mØtalliques
peu
vent
Œtre enflammØs
par
une
chafeur
rayon
nante
ou
transmiso.
Avant
de
commencer,
avisez le contremaltre
pour
quil
sassure
que
les
precautions adØquates
solent
prisos.
Une fois
le
travail
terminØ,
vØrifiez
quil
ny
ait
pas
dØtincelles,
de
cendres
ardentes
ou
do
flammes
dans
le
local.
On
ne
doit
jamais
souder ni
couper
sur
un
recipient
ayant
contenu
dos
combustibles,
ou
pouvant
produire
des
vapeurs
inflammables
ou
toxiques
a
Ia
chauffe,
a
moms
que
le
recipient
nait
ete
(aye
au
prealable,
corn-
me
dØcrit
dans Ia
Norme
AWS
A6.O,
figurant
au
paragraphe
3
de l~lndex des
Normes.
Cola
comprend:
un
nettoyage
a
fond a Ia
vapeur
ou au
caustique
(ou
un
lavage
avoc
dissolvant
ou
eau
solon
(a
solubilitØ
du
combustible)
suivi
dune
purge
et
dune
in
OM-267
Page
3

bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using protective
equipment
as
recommended
in
A6.O.
Waterfilling just
below
working
level
may
substitute
for
inerting.
A container with
unknown
contents
should be
cleaned
(see
paragraph
above).
Do
NOT
depend
on sense
of
smell
or
sight
to
determine if it is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and those
detailed in
CGA Standard
P-i,
PRECAUTIONS FOR SAFE
HANDLING OF
COM
PRESSED GASES
IN
CYLINDERS,
listed
6
in
Stan
dards index.
1.
Pressure
Regulators
Regulator
relief
valve is
designed
to
protect
only
the
regulator
from
overpressure;
it is
not
intended
to
pro
tect
any
downstream
equipment.
Provide such
protec
tion with
one or more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than that for which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated repair
center,
where
special techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be handled
carefully
to
prevent
leaks
and
damage
to
their
walls, valves,
or
safety
devices:
Avoid
electrical circuit
contact
with
cylinders including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
toa
serious
ac
cident.
(See 1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when the
cylinder
is
properly
handled.
jection
dazote
ou
de
gaz
carbonique,
en
utilisant
un
Øquipement
de
protection
comme
rocommandØ dans
lA6-O.
LatmosphŁre
inerte
peut
Œtre
remplacØe
par
un
niveau
deau
arrivant
au-dessous du
travail a effectuer.
Vous
dovez layer
un
recipient
dont
Ia
nature
de
contenu
est
inconnue
(voir
paragraphe
ci-dessus).
NE
vous
fiez
PAS
a Iodorat
ou
a
Ia
vue
pour
dire si
lon
peut
le
souder
ou
le
couper
en
toute
sØcuritØ.
Vous
devez
pratiquer
un
event
sur
Ies
piŁces
ou
rØci
pients
creux
avant
de
los
souder
ou
couper:
ils
peuvent
exploser.
Atmospheres
explosives:
Ne
soudez ni
ne
coupez
jamais
dans des
lioux oCi lair
peut
contenir des
poussiŁres,
gaz
ou
vapeurs
liquides
inflammables
(tels
que
lessence).
D.
Gaz
comprimØ
Precautions
gØnØrales:
Suivez
los
precautions
do
ce
manuel,
et
celles dØcrites
a
Ia Norme CGA P-i
(PrØcau
tions
do sØcuritØ
pour
Ia
manipulation
de
gaz
comprimØs
on
bouteilles),
paragraphe
6
do
Ilndex
des
Normes.
1. DØtendeurs
de
pression
La
soupape
do sretØ dun
dØtondour
est
dostinØo
a
pro
tØger
seulement
le dØtendeur
do Ia
surpression.
Ello na
pas pour
but
do
protØger
los
boyaux
et
le chalumoau:
on
protege
ceux-ci
par
des
soupapes
de
retenuo
concues
spØcialomont
pour
cette
fonction.
Ne
montoz
jamais
un
dØtendeur
sur
uno
bouteille
conte
nant
un
gaz
different
do
celui
pour
lequel
le dØtendeur
a
ØtØ
concu.
Enlevez
immØdiatement
un
dØtondeur dØfoctueux
pour
lo faire
rØparer
(dabord,
formez
le
robinet
do
Ia
bouteille).
Los
symptomes
suivants
dØnotont
Ia dØfec
tuositØ
du dØtendeur:
Fuites
-
Si le
gaz
fuit
extØrieurement.
Ascension
excessive
-
si Ia
pression
de
debit
continue
a
montor,
le robinet
du
chalumeau Øtant fermØ.
ManomŁtre
dØfectuoux
-
si
laiguille
du manomŁtre
no
sØcarte
pas
de Ia
goupille
do
butØe
lors do Ia
mise
en
prossion,
ou
no
reviont
pas
sur
Ia
goupille
aprŁs
lØchap
pement
de Ia
prossion.
Reparation.
NESSAYEZ
PAS do
reparer
vous-mŒmes.
Envoyoz
los
dØtendeurs
dØfectuoux a
rØparer
aux
ateliers do
reparation
agrees
du
fabricant,
oCi des
techni
ques
ot
des outils
spØciaux
sont
utilisØs
par
un
person
nel
formØ.
2.
Bouteilles
Les
bouteilles
doivent
Œtre
manipulees
avec
soin
pour
prØvonir
les
fuites
ou
dØgts
a leurs
parois,
robinets
ou
systŁmes
de
sOretØ. Evitez
quun
circuit
Ølectriquo
soit
en
contact
avoc
los
bouteilles,
y
compris
los rails do
con
tact,
les fils
Ølectriques
ou
les circuits de
soudage.
Cela
pourrait
crØer des
arcs
courts-circuits
pouvant
ontraIner
des accidents
graves
(Voir
i.3C.).
Chaque
bouteille doit
porter
les
inscriptions
ICC
ou
DOT. Cest
un
gage
de sØcuritØ
pourvu quo
Ia
bouteillo
soit bien
manipulØe.
OM-267
Page
4

Identifying
gas
content.
Use
only cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
lt is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other than its intended
use,
NEVER
as
a
support
or
roller.
Locate
or secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use a secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool with
water
spray
where such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling objects,
and
weather.
Replace
caps
securely
when
moving cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
3. Hose
Prohibited
use.
Never
use
hose
other
than that
designed
for
the
specified
gas.
A
general
hose identification
rule
is: red for fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps designed
for the hose
(not
or
dinary
wire
or
other
substitute)
as a
binding
to
connect
hoses to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
f
it
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose from
damage by
sharp edges,
and
by
sparks, slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose in
water;
bubbles
in
dicate
leaks.
Identification
du
gaz:
Nutilisez
que
los
bouteilles
mdi
quant
Ia
nature
du
gaz;
ne
vous
fiez
pas
a
Ia
couleur
pour
reconnaltre Ia
nature
du
gaz.
Adressez-vous
a
votre
fournisseur
si
cola
nest
pas
indique.
NEFFACEZ
ou
ne
modifiez JAMAIS
los
noms,
numØros
ou
autres
indications
sur
une
bouteille.
Cela
est
illegal
et
dangereux.
Vides:
Maintenez
les robinets
fermØs,
replacez
bien
les
chapeaux;
inscrivez
Vides;
sØparoz-Ies
des Pleines
et
retournez-Ies
rapidement.
Emploi
interdit:
Nutilisez
une
bouteille
ou
son contenu
que
pour
ce
a
quoi
elle
est
destinØe,
mais
JAMAIS
com
me
support
ou
rouleau.
Placez les
bouteilles
pour
quelles
ne
tombent
pas.
Lors
quun
dØtendeur
(et
un
boyau)
est
monte
sur
elles,
placez
les
ou
attachez-les
debout.
Passages
et
lieux
de
travail. Enlevez
les
bouteilles
dun
endroit
oCi lon
pourrait
les
trapper.
Transport
des
bouteilles. Avec
une
grue,
utilisez
un
sup
port
fiable
tel
quune plate-forme
ou un
cadre.
NE
SOULEVEZ
PAS
des
bouteillos
du
sol
par
leur
robinet
ou
chapeau,
ou
avec
des
chaInes,
Ølingues
ou
aimants.
NEXPOSEZ PAS
los
bouteilles a
une
chaleur
excessive,
aux
Øtincelles,
au
laitier
et
aux
flammes,
etc.,
pouvant
causer
leur
rupture.
Le
contenant
no
doit
jamais
dØpasser
55C.
Refroidissez
en
pulverisant
de
Ieau
si
nØcessaire.
ProtØgez
les bouteilles
et
particuliŁrement
los
soupapes
contre
les
chocs,
les
chutes,
les chutes
dobjets
et Ia
temperature.
Remettez bien
les
chapeaux
Iorsque
vous
dØplacez
les bouteilles.
Robinet coincØ.
NUTILISEZ PAS
un marteau
ou une
clØ
mØtallique
pour
ouvrir
un
robinet
de
bouteillo
que
lon
no
peut
pas
ouvrir a
Ia
main. Avisez
votre
four
nisseur.
MØlange
do
gaz.
Nessayez
jamais
do
melangor
des
gaz
dans
une
bouteille.
Ne
rechargez
jamais
une
bouteille. Les ØlØments
do
Ia
bouteille
ne
doivent
jamais
Œtre
modifies
ou
romplacØs.
3.
Boyau
Utilisation
interdite.
Nutilisez
jamais
un
boyau
autre
que
celui
appropriØ
au
gaz
indiquØ.
La
reglo
gØnØrale
didentification
est:
rouge
pour
los
gaz
combustibles,
vert
pour
Ioxygeno,
et
noir
pour
les
gaz
inertes.
Utilisez
des
bagues
ou
colliers
appropriØs
au
boyau
tot
non
du
fil
ordinaire
ou
autre
substitution)
pour
brancher
los
boyaux
a
Iappareillage.
Nutilisez
pas
des raccords
en
cuivre.
Nutilisoz
quo
des
accessoires
standard
en
laiton
pour
raccorder
un
boyau.
Utilisez
une
petite
Ionguour
de
boyau.
Cola
Øvitera los
noeuds
et
lusure
prØmaturØe. Suspondez
le
boyau
au
dessus
du sol
pour
Øviter
quil
no
soit
ØcrasØ,
pietinØ
ou
endommagØ.
Enroulez le
surplus
de
boyau
pour
Øviter les
noeuds
et
emmØlements.
Evitez
quo
le
boyau
ne
soit
endommagØ
par
des
tranchants, Øtincolles,
laitior
et
flamme
nue.
OM-267
P~ee
5

Repair
leaky
or worn
hose
by
cutting
area
out and
splic
ing
(1-203).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to a
cylinder
containing
any
other
gas.
Tighten
connections. When
assembling
threaded
con
nections,
clean
and smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and LEFT HAND
threads.
Regulator
outlet
(or hose)
connections
may
be
iden
tified
by
right
hand threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on nut or
shank)
for fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve in
following
position:
For
oxygen,
and inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe and
efficient,
recommended
pressure
settings
or,
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
*Trademark
of Proctor &
Gamble
OM-267
Page
6
VØrifiez
reguliŁrement
les
fuites,
lusure
et
les
rac
cordements lches.
Plongez
le
boyau
sous
pression
dans
do
leau;
les
bulbs
indiqueront
los
fuites.
Reparation.
Coupez
Ia
partie
percØe
ou
usØe,
et
rac
cordez
(1-2D3).
NUTILISEZ JAMAIS
de
ruban
adhØsif.
4.
Branchements
corrects
Avant
de brancher
be
dØtendeur,
nettoyez
Ia
sortie
du
robinet do
Ia
bouteille
des
impuretØs
qui
peuvent
obstruer
es
orifices
et
endommager
los
sieges.
Sauf
pour
lhydrogene,
ouvrez
momentanØment
le
robinet,
en
Øloignant
Ia
sortie
des
personnes
et
des
sources
in-
flammables.
Essuyez
avec
un
tissu
propre
et
non
graisseux.
Appareillez
le
dØtendeur
a Ia
bouteille.
Avant
de
bran
cher,
vØrifiez
que
Ia
marque
du
dØtendeur
et
Ia
descrip
tion
de
Ia bouteilbe
concordent,
et
que
lorifice
dentrØe
du
dØtendeur
et
lorifice
de
sortie
de Ia
bouteille
aillent
ensemble.
NE
BRANCHEZ
JAMAIS
un
dØtendeur
concu
pour
un
gaz
special
(ou
des
gaz
spØciaux)
a
une
bouteille
contenant
dautres
gaz.
Serrez les branchements.
Lorsque
vous
assembbez
des
branchements
filetØs,
nettoyez
et
polissez
les
sieges
oi~
cest
nØcessaire.
Serrez. Si
les
branchements
perdent,
dØmontez-les,
nettoyez
et
resserez avec une
clef
adØ
quate.
Adaptateurs.
Placez,
si
besoin
est,
un
adaptatour
CGA
(en
vente
chez
votre
fournisseur)
entre
Ia bouteilbe
et
be
dØtendeur.
Avec deux
clefs,
serrez
ladaptateur
filetØ
A
DROITE
et
A
GAUCHE.
On
peut
reconnaltre
los branchements
do sortie du
dØtendeur
(ou
boyau)
a
laide
du
fibetage
a droite
pour
loxygŁne
et
a
gauche
(identifiØ
par
an
Øcroa
cannelØ)
pour
les
gaz
combustibles.
5.
DØmarches
de mise
en
pression
Purgez
be
dØtendeur
de
rØsidu de
gaz
avant
douvrir Ia
bouteille
(ou
le
robinet
de
canalisation)
en
serrant
Ia
vis
de
rØglage
(dans
le
sens
des
aiguilles
dune
montre).
Cette
operation
permet
au
siege
de haute
pression
de
souvrir
a
Ia
mise
en
pression,
supprimant
ainsi
toute
surchauffe
de
compression.
Maintenez
be vis de
reglage
des
dØtendeurs
a
simple
dØtente
lØgerement
engagee.
Avant
douvrir
be
robinet
do Ia
bouteille,
assurez-vous
que
les
boyaux
sont
branches
et
que
les
soupapes
aval
sont
fermØes.
Tenez-vous
latØrabement
au
dØtendeur
en
ouvrant
le
robinet de
Ia bouteille.
Ouvrez-le
lentement
pour
que
Ia
pression
du
dØtendeur
monte
progressivement.
Lorsque
be
manomØtre
est
mis
sous
pression
(indique
be
max
imum)
le
robinet
de Ia
bouteille
de
gaz
inerte
ou
dox
ygene
devra Œtre
ouvert
a
fond pour
assurer
lØtanchØitØ
et
celui
de Ia
bouteible
de
gaz
combustible
ouvert
de
moms dun
tour
pour
pouvoir
be
refermer
rapidement
en
cas
durgence.
RØfØrez-vous
aux
tableaux
de
pression
(distribuØs
par
votre
fournisseur)
pour
un
rØgbage
recommandØ
de
pression
sr
et
efficace
sur
bes
dØtendeurs. VØrifiez les
fuites
a Ia
premiere
mise
en
pression puis
rØguliŁrement,
brossez
avec une
solution
savonneuse
(un
bouchon
dlvory
Liquid*
ou
semblable
par
gallon
deau).
Los
bulles
indiquent
une
fuite. Enlevez leau
savonneuse
apres examen;
be
savon sec
est
inflammable.
*Marque
do
Commerce
do
Proctor
&
Gamble

F.
Leaving Equipment
Unattended
E.
RosponsabilitØs
do
Iusager
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3.
ARC
WELDING
-
Comply
with
precautions
in
1-1,
1-2,
and this
section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents at
significant
voltages.
The
arc
is
very
bright
and hot.
Sparks fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
ed. The wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
are
described
here and in
standards referenced in index.
A.
Burn
Protection
Comply
with
precautions
in 1-2.
The
welding
arc
is intense
and
visibly bright.
Its
radia
tion
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn the skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs
are
more severe
and
painful.
DONT GET
BURNED;
COMPLY WITH PRECAU
TIONS.
1. Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-
resistant
leggings.
Avoid
outergarments
of
untreated
Cotton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and neck
and
button
pockets
to
prevent entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser must
be
used when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Otez
immØdiatement
les
parties
percØes
ou
dØfec
tueuses.
Voir
les
ResponsabilitØs
do
lUsager
du manuel
de
Iappareil.
F.
Appareil
laissØ
sans
surveillance
Fermez
lalimentation
do
gaz
a
Ia
source
et
purgez.
G.
Liens
at
supports
temporairos
Pour
vos
travaux
do
soudage
ou
do
coupaga,
nutilisez
pas
do
Ia
corde
comma
soutien, ella
est
inflammable.
1-3.
SOUDAGE
A
LARC
-
Conformaz-vous
aux
precautions
des
paragraphes
1.1
at
1.2
de
cette
section.
Le
soudage
a larc
bien exØcutØ
est
sOr,
mais
un
soudeur
negligent
est
un
danger.
La
poste
do
soudago
transporte
des
courants
ØlavØs
sous
de fortes
tensions.
Larc
ost
trØs vif
et
chaud.
Los Otincelles
volent,
las
vapeurs
montont,
lØnorgie
ultra-violette
et
infrarouga
rayonnent,
les
soudures
sont
chaudes,
at
des
gaz
corn
primes
peuvent
Œtre
utilisØs.
Le
soudeur
prudent
Øvite
los
risques
inutiles,
se
protege
at
protege
autrui
contra
(es accidents. Las
precautions
sont
dØcrites
id
et
dane
les
normes
donnØes
dans
(Index.
A. Protection contra
los
brOlures
Conformez-vous
aux
precautions
du
paragraphe
1.2.
Larc
de
soudage
est
intense
et
visiblement
vif.
Son
rayonnement peut
blosser
las
yeux,
traverser
los
habits
lØgers,
se
rØflØchir
sur
los surfaces
claires,
at
bri~Ier
Ia
peau
et
las
yeux.
Los
brOlures
do
Ia
peau
ressemblent
a
un
gros coup
do
soleil.
Celles
darcs
sous
gaz
protocteur
sont
plus
graves
at
plus
douloureuses. NE
VOUS
BRULEZ
PAS
-
SUIVEZ LES
PRECAUTIONS.
1.
VØtements
do
protection
Portez
des
vŒtements
a
manchos
longues
(surtout
pour
(arc
en
atmosphere
inerte)
avoc
gants,
masque
at
chaussures
(1.2A.).
Si nØcessaire
portez
en
plus
une
voste ou
des
manches
en
cuir,
un
tablier
at
des
guetres
ignifugØs.
Do
prØfØrence
no
portez
pas
de
vŒtements
en
coton
non
traitØ.
Protection
do
(a
poau.
Portez des
vŒtements
Øpais
foncØs. Boutonnez
le
col
pour
protØger
Ia
poitrine
at
le
cou,
et
boutonnoz
las
poches
pour
prØvenir
(infiltration
dØtincellos.
2. Protection
des
yeux
et
de
Ia tŒte
Evitez
quo
vos
yeux
soient
exposØs
a larc.
NE
regardez
JAMAIS
un
arc
Ølectrique
sans
protection.
Lorsque
vous
soudez,
portoz
un
Øcran
ou
masque
avec
verre
filtrant teintØ
N
12
ou
plus
foncØ.
Mettez-le
sur
le
visage
avant
damorcer
(arc.
Protegez
le
verre
filtrant
dun
couvro-verre
clair. NE
PORTEZ
PAS
un
masque
fendu
ou
brisØ;
le
rayonne
ment
pout
sinfiltrer
at
causer
des
brUluros.
Les
vorres
filtrants
fendus,
brisØs
ou
(echos
doivent
Œtre
remplacØs
IMMEDIATEMENT.
Remplacez
un
couvre
verre brisØ,
piquØ
ou
tachØ
par
des
projections.
OM-267
Page
7

Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the helmet
not
be lowered
over
the
face before
an arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high intensity
gas-shielded
arc)
can
cause
a
retinal burn that
may
leave
a
permanent
dark
area
in
the
field of vision.
3. Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the weld.
Provide
face shields
for
all
persons
who will be
looking
directly
at
the weld.
Others
working
in
area.
See that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic Fume Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in 1-2C.
Equipments
rated
capacity.
Do
not overload
arc
welding
equipment.
It
may
overheat cables
and
cause a
fire.
Loose
cable connections
may
overheat
or
flash
and
cause
a
fire.
Never strike
an arc on a
cylinder
or
other
pressure
vessel.
It
creates
a
brittle
area
that
can cause
a
violent
rupture
or
lead
to
such
a
rupture
later under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in 1-20.
E.
Shock Prevention
Exposed
hot conductors
or
other
bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person.
whose
body
becomes
a
conductor.
DO
NOT
STAND, SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface when
welding,
without
suitable
protection.
Vous
devez
portez
des
lunettes
a
Øcrans latØraux
sous
le
masque pour
protØger
les
yeux
dans.le
cas
o
le
masque
ne
serait
pas
abaissØ
sur
le
visage
avant
lamorcage
de
larc.
Regarder
momentanØment
un
arc sans
protection
(principalement
un
arc
en
atmosphere
inerte
a
haute in
tensitØ)
peut
brler Ia rØtine
et
laisser
un
point
sombre
permanent
dans le
champ
de
vision.
3.
Protection du
personnel
a
proximitØ
Local
de
soudage
fermØ. Pour
le
soudage
de
produc
tion,
il
vaut
mieux
utiliser
une
salle
sØparØe
ou
une
baie
fermØe.
Dans los locaux
ouverts,
entourez
les
travaux
dØcrans
ou
panneaux
peu
rØflØchissants
et
ininflam
mables.
Laissez Iair
circuler
librement,
particuliŁrement
au
niveau
du sol.
Donnez des
masques
aux
personnes
qui regarderont
directement
Ia soudure.
Autres
personnes
travaillant
sur
los
lieux.
Veillez
a
ce
quo
toutes
les
personnes
portent
les lunettes de
protec
tion.
Avant
dattaquer
Ia
soudure,
assurez-vous
que
les
rebords dØcran
ou
les
portes
soient fermØs.
B.
Prevention des
gaz
toxiques
Suivez
los
precautions
du
paragraphe
1.2B.
LØchappe
ment
du
moteur de Ia
gØnØratrice
doit Œtre
ventilØ
a
lair
extØrieur.
Loxyde
de carbone
peut
tuer.
C.
Prevention des
incendies
et
des
explosions
Suivez
les
precautions
1.2C.
Puissance nominale
de
Iappareil.
Ne
surchargez
pas
le
poste
de
soudage
a
larc. Cela
peut
surchauffer
les cØbles
et
causer un
in
cendie.
Les
branchements
lØches do
cable
peuvent
surchauffer
ou
faire
des
Øtincelles
et
causer
un
incendie.
Namorcez
jamais
un
arc sur
une
bouteille
ou
autre
rØci
pient
sous
pression.
Cola
crØerait
un
point
do
rupture
entramnant
a
plus
ou
moms
longue
ØchØance
lexplosion
du
reservoir.
D.
Gaz
comprimØ
Suivez
les
precautions
1 .2D.
E. Prevention des
dØcharges
Ølectriquee
Des conducteurs
charges
ou
metal
flu
incorporØs
au
cir
cuit
de
soudage
ou
a
un
appareil
chargØ
sans
mise a Ia
terre
peuvent
donfler
une
dØcharge
fatale
a Ia
personne
dont
le
corps
devient
conducteur.
NE
SOUDEZ PAS
DEBOUT, ASSIS,
COUCHE,
PENCHE
sur.une
surface
humide
ni
en
contact
avec une
telle
surface
sans
protec
tion
appropriØe.
OM-267
Page
8

To
protect
against
shock:
Keep body
and
clothing
dry.
Never work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
damp
ness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling dangerous
and
possibly
lethal
currents to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding equipment
is
grounded
according
to
the
National Electrical
Code,
and the work
is
grounded
according
to
ANSI Z49.1
Safety
In
Welding
And Cut
ting,
a
voltage
may
exist
between
the
electrode and
any
conducting
object.
Examples
of
conducting
objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces.
etc.
Never
touch the electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
When
installing,
connect
the frames
of each
unit such
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe carrying
ANY
gas
or a
flammable
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
9f
the
3-phase
line. Do
NOT
connect
the
equip
ment
ground
lead
to
the third
(live)
wire,
or
the
equip
ment
will become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal
of
equipment
frames
at
connections.
If
a
line cord
with
a
ground
lead is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead to
the
grounded
switchbox.
If
a
three-
prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead must
be
connected
to
the
ground
prong
only.
If the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2. Electrode
Holders
Fully
insulated
electrode
holders
should
be used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
Pour
vous
protØger
contre
les
dØcharges
Ølectriques,
maintenez votre
corps
et
vŒtements
secs.
Ne
travaillez
jamais
dans
un
endroit
humide
sans
isolation
adequate
contre
les
dØcharges
Ølectriques. Lorsque
vous
no
pouvez
Øviter
thumiditØ
ou
Ia
sueur,
placez-vous
sur un
caillebotis
sec
ou un
tapis
en
caoutchouc.
La
sueur,
leau
de
mer,
ou
lhumiditØ
entre
le
corps
et
une
piŁce
CHARGEE,
ou une
piŁce
de
metal a Ia
masse,
rØduisent
Ia
rØsistance
Ølectrique
de
Ia
surface
du
corps,
permet
tant
lentrØe
de
courants
dangereux,
voire
mortels.
1.
Mise
a
Ia
terre
de
lappareil
Lorsque
lappareil
de
soudage
a
larc est
mise a Ia
terre
suivant
Ia
norme
National
Electrical
Code,
et
Ia
masse
est
mise
a
Ia
terre
suivant
Ia
norme
ANSI Z49.1
Safety
in
Welding
and
Cutting,
une
tension
peut
exister
entre
lØlectrode
et
un
objet
conducteur.
Certaines
de
ces
ob
jets
sont
par
exemple
(mais
pas
seulement),
des
btiments,
des
outils
Ølectriques,
des
Øtablis,
des
chØssis
de
postes
de
soudure,
des
piŁces
douvrage,
etc.
Ne
jamais
touchez
IØlectrode
ou
des
objets
en
metal
avant
davoir
mis le
poste
de
soudure
a
larrŁt.
A
linstallation,
branchez
les
chassis
de
chaque
ØlØment
(source
de
courant,
commande,
Øtabli
et
circuit
deau)
a
Ia terre.
Les
conducteurs
doivent
pouvoir
conduire
es
courants
telluriques
en
toute
sØcuritØ.
Lappareil chargØ
par
les
courants
vagabonds
peut
donner
une
decharge
risquant
dŒtre
mortelle.
NE
BRANCHEZ
PAS VOTRE
PRISE
DE TERRE a
une
conduite
Ølectrique,
ou
a
un
tuyau
de
gaz
ou
de
liquide
inflammable
tel
que
lhuile
ou
un
combustible.
Connexion
triphasØe.
Avant
linstallation vØrifiez
Ia
phase
nØcessaire a
lappareil.
Si seul
to
triphasØ
est
disponible,
ne
branchez
Iappareil
monophasØ
qu
deux
des fils
de Ia
ligne triphasØe.
NE
BRANCHEZ
PAS
le
conducteur
do
terre
de
lappareil
au
troisiŁme
fit
(sous
tension),
autrement
Iappareil
serait
chargØ:
condition
dangereuse
pouvant
donner
une
dØcharge
fatale.
Avant
le
soudage,
vØrifiez
si
Ia
prise
de
terre
est
uniforme.
En
branchant,
assurez-vous
que
los
con
ducteurs
touchent
le metal
nu
du
chassis
de
lappareil.
Lorsquun
appareil
doit Œtre alimentØ
a
partir
dun
cof
f
ret
dalimentation,
le
conducteur de
terre
doit Œtre
reliØ
a
celui-ci.
Si
vous avez en
plus
une
fiche a
trois
broches
pour
Ia
terre,
ne
branchez
le conducteur
de
terre
quŁ
Ia broche
de
terre.
Si
le
cordon
dalimentation
a une
fiche
a
trois
broches,
reliez-Ie
a
une
prise
femelle
tripolaire
reliØe a Ia
terre.
Nenlevez
jamais
Ia broche
de
terre
dune
fiche
ou
nutilisez
jamais
une
fiche dont Ia
broche
de
terre
serait
brisØe.
2.
Pince-Ølectrodes
Utilisez
des
pince-Ølectrodes
bien
isolØes.
NUTILISEZ
PAS des
pince-Ølectrodes
avec
vis
saillantes.
3. Connecteurs
Utilisez
des
connecteurs
a
verrouillage
bien isolØs
pour
assembler
de
longs
cables.
OM-287
Page
9

4.
Cables
4.
Cables
Frequently inspect
cables for
wear,
cracks and
damage.
IMMEDIATELY
REPLACE
those with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free of oil
arid
grease,
and
protected
from hot
metal
and
sparks.
5.
Terminals And Other
Exposed
Parts.
Terminals
and other
exposed
parts
of electrical units
should have
insulating
covers
secured before
operation.
6.
Electrode
a.
Equipment
with
output
on/off
control
(con
tactor)
Welding
power
sources
for
use
with the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and similar
processes
normally
are
equipped
with
devices
that
per
mit on-off control
of
the
welding
power
out
put.
When
so
equipped
the electrode wire
becomes
electrically
HOT
when
the
power
source
switch is ON
and the
welding
gun
switch is closed. Never
touch
the
electrode
wire
or
any
conducting
object
in
contact
with
the electrode
circuit unless
the
welding
power
source
is off.
b.
Equipment
without
output
on/off
control
(no contactor)
Welding
power
sources
used
with
shielded
metal
arc
welding
(SMAW)
and
similar
pro
cesses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equipment
the electrode
is
electrically
HOT
when the
power
switch
is
turned
ON.
Never touch
the
electrode
unless
the
welding
power
source
is
oft.
7.
Safety
Devices
Safety
devices
such
as
interlocks and circuit
breakers
should
not
be disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches) to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash from
switch
arcing.
Leaving
equipment
unattended.
Always
shut OFF
and
disconnect all
power
to
equipment.
Power
disconnect switch
must
be
available
near
the
welding
power
source.
OM-267
Page
10
VØrifiez
frØquemment
lusure,
las fissures
et
laltØration
des
cables.
REMPLACEZ
IMMEDIATEMENT
ceux
dont
lisolation
serait
trop
usØe
ou
altØrØe
pour
prØvenir
los
dØcharges
mortelles
provoquØes
par
un
cable dØnudØ.
Vous pouvez
enrouler
les
parties
endommagØes
de
ruban
adhØsif
en
Øpaisseur
suffisante
pour
donner
une
rØsistance
de
cØble
neuf.
Maintenez
los
cables
secs,
dØpourvus
dhuile
et
de
graisse
et
mettez-les a labri
du
metal
chaud
et
des
Øtincelles.
5.
TŒtes
de
cables
et autres
parties
dØnudØes
Avant
Ia mise
en
marche,
les
tŒtes
de
cables
et
autres
parties
dØnudØes
dun
appareil
Ølectrique
doivent
Œtre
munies
de leurs
couvrefils
isolants.
6.
Electrode
a
. Appareil ØquipØ
dune commando
mar
che/arrŒt
(contacteur)
En
gØnØral,
les
postes
de soudure
utilisØs
pour
le
soudage
a Iarc
sous
protection
gazeuse
avec
electrode
fusible
(GMAW),
ou
avec
electrode
tungstŁne
(GTAW)
et
des
procŁs
semblables
sont
ØquipØs
dune
corn
mande
marche/arrØt
de Ia
puissance
de
sor
tie.
Lorsque
linterrupteur
est
en
position
MARCHE
et
linterrupteur
du
pistolet
est
fermØ,
le
fil dØlectrode
devient
chargØ.
Ne
touchez
jamais
le fil
electrode
ou
tout
autre
objet
conducteur
faisant contact
avec
le cir
cuit dØlectrode
sans
couper
le
courant
au
poste
de soudure.
b
.
Appareil non-equipØ
dune commande
mar
che/arrØt
(sans
contacteur)
Les
postes
de soudure
utilisØs
pour
le
soudage
a larc
avec
electrode
enrobØe
(SMAW)
et
des
procŁs
semblabes
peuvent
Œtre
non-Øquipes
dune
commande
mar
che/arrŒt
de
Ia
puissance
de sortie.
Lorsque
linterrupteur
est en
position
MARCHE
lØlectrode
devient
chargØ.
Ne
touchez
jamais
lØlectrode
sans
couper
Ia
courant
au
poste
de soudure.
7.
Dispositif
de sØcuritØ
Le
dispositif
de
sØcurite-verrouillage
et
coupe-circuit
ne
doit
pas
Œtre
dØbranchØ
ou
dØshuntØ.
Avant
linstallation,
linspection
ou
Ia
reparation
de
lap
pareil,
mettez
lalimentation
sur
ARRET
et
enlevez les
fusibles
generaux
(ou
verrouillez les
interrupteurs)
pour
Øviter
une
remise
en
MARCHE accidentelle.
DØbran
chez
tous
les cables do Ia
source
de
courant
ainsi
que
los
prises
des cordons
dalimentation
en
115
volts.
Lors
du
soudage,
nouvrez
pas
le
circuit dalimentation
at
no
changez
pas
Ia
polarite.
Sil
est
dØbranchØ
au
cours
dune
urgence,
faites
attention
aux
brlures
de
decharge
ou aux
jaillissements
dØtincelles.
Appareil
laissØ
sans
surveillance. Mettez
toujours
sur
ARRET
at
dØbranchez
lappareil.

F.
Protection
For Wearers
Of Electronic
Life
Support
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic life
support
equipment (pacemaker)
should
consult
with
their
doctor
before
going
near ~rc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
-
For
more
in
formation,
refer
to
the
following
standards
or
their latest
revisions
and
comply
as
applicable:
1.
ANSI Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from the
American
Welding
Society,
550
Le
Jeune
Ad,
P.O.
Box
351040,
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S. Govern
ment
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5. ANSI Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY
-TOE FOOTWEAR obtainable from the
American
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018
6. ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS WHICH HAVE
HELD
COM
BUSTIBLES
obtainable from the
American
Welding
Society,
550
Le Jeune
Rd.,
P.O.
Box
351040,
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
frOm
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10.
NFPA
Standard
51
B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
Linterrupteur
darrŒt
doit
toujours
se
trouver
a
prox
imitØ
de
Ia
source
de
courant.
F. Protection
pour
toute
personne
portent
des
appareils
Ølectroniques
de
sauvetage
(ap
pareil
pour
le
rØglement
de battement de
coeur)
Inducteurs
de
courant
ØlevØ
peuvent
nuire le
fonction
nement
dun
appareil
pour
le
rŁglement
de battement
de
coeur.
Toute
personne
portant
un
appareil
Ølec
tronique
de
sauvetage
(appareil
pour
le
rØglement
do
battement
do
coeur),
devrait consulter
un
docteur avant
dapprocher
toute
operation
do
soudage
a
Iarc,
a Ia
gouge
ou
a
point.
1-4.
INDEX
DES
NORMES
-
Pour
plus
do
renseignements,
rØfØrez-vous
aux
normes
do
IACNOR
ou aux
normes
amØricaines
suivantes:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
distribuØ
par
lAmerican
Welding
Society,
550 Le Jeune
Rd.,
P.O. Box
351040
Miami,
FL
33135
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
distribuØ
par
le
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington
D.C. 20402
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
distribuØ
par
U.S.
Department
of
Labor,
Washington
D.C.
20210
4.
ANSI Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
distribuØ
par
IAmerican
Natk,nal
Standards
Institute,
1430
Broadway,
New
York,
NY
10018
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY
-
TOE
FOOTWEAR
distribuØ
par
Iad
dresse
donnee
en
4.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
distribuØ
par
laddresse
donnee
en
4.
7.
AWS
Standard
A6.O,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
COM
BUSTIBLES
distribuØ
par
laddrosse
donnee
en
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
distribuØ
par
Ia
National
Fire Protection
Associa
tion,
470
Atlantic
Avenue,
Boston,
MA
02210
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
distribuØ
par
laddresse
donnØe
en
8
10.
NFPA
Standard
518,
CUTTING
AND
WELDING
PROCESSES
distribuO
par
Iaddresse donnØe
en
8
OM-267
Page
11

11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
distribuØ
par
Ia
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12. CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
distribuØ
par
Ia
Cana
dian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
distribuØ
par
Ia
National
Welding
Supply
Association,
1900
Arch
Street
Philadelphia,
PA
19103.
14.
American
Welding
Societe
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
distribuØ
par
lAmerican
Welding
Societe,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135
15.
ANSI
Standard
Z88.2
Practice
For
Respiratory
Protection
distribuØ
par
IAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-267
Page
12

SECTION
2
-
INTRODUCTION
Model
Rated
Welding
Current
Amperes
100%
Duty
Cycle
Max.
Open-
Circuit
Voltage
Input
At
Rated
Load
Output
60
Hz.
Three-Phase
-
Amperes
At
230V
460V 575V
kva
kw
Dimensions
Weight
Net
Ship
1000
1000
@76
Volts
85 224
112
90 89 85
Height
-
41-1/8
in.
(1045 mm)
Width
-
27-1/4
in.
(692
mm)
Depth
-
46
in.
(1168 mm)
898
lbs.
(406
kg)
986 lbs.
(447
kg)
1500
1500
@76
Volts
85 330
165
132
131
123
Height
-
41-1/8
in.
(1045
mm)
Width
-
27-1/4
in.
(692
mm)
Depth
-46
in.
(1168
mm)
1068
lbs.
(484
kg)
1158 lbs.
(525
kg)
Figure
2-1.
Specifications
2-1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
and
on
various
labels,
tags,
and
plates
on
the
unit
should
be
given
careful consideration
to
assure
optimum
performance
of
this
equipment.
2-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the carrier. A
copy
of
the
bill
of
lading
will be
furnished
by
the manufacturer
on
re
quest
if
occasion to
file claim
arises.
When
requesting
information
concerning
this
equip
ment,
it is
essential
that
Model
Description
and/or
Stock
Number and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
2-3.
DESCRIPTION
-
This
welding
power
source
in
corporates
a
three
phase
Delta
connected,
constant
potential
(CP)
type
main
power
transformer
to
provide
the
constant
voltage
output
required
to
operate
the
resistance
grid
welding
stations
connected
to
the
unit.
2-4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the front of
this
manual
should be read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
im
proper
welding applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT,
and
NOTE
blocks
found
throughout
this
manual:
Is1~tUblIs1~
Under
this
heading, installation,
operating,
and
maintenance
procedures
or
practices
will
be found that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
IMPORTANT:
_______
Under this
heading,
installation,
operating,
and
maintenance
procedures
or
practices will
be found
that
if
not
carefully
followed
may
result in
damage
to
equipment.
I~Is1il~
Under
this
heading,
explanator,
statements
will
be found
that need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
3
-
INSTALLATION
3-1.
LOCATION
(Figure
3-1)
-
A
proper
installation
site
should
be
selected
for
the
welding
power
source
if
the
unit
is
to
provide
dependable
service,
and
remain
relatively
maintenance
free.
A
proper
installation
site
permits
freedom
of
air
move
ment
into
and out
of
the
welding
power
source,
and
also
least
subjects
the unit to
dust,
dirt,
moisture,
and
corrosive
vapors.
A
minimum
of 18
inches
(457
mm)
of
unrestricted
space
must
be
maintained
between
the
welding
power
source
front
and
rear
panels
and
the
nearest
obstruction.
Also,
the underside
of
the
welding
power
source
must
be
kept
completely
free
of
obstruc
tions.
The installation
site
should
also
permit
easy
removal
of
the
welding
power
source
outer
enclosure
for maintenance
functions.
IMPORTANT:
Do
not
place
any
filtering
device
over
the
intake air
passages
of
the
we/ding
power
source
as
this
would restrict the
volume
of intake
air
and
thereby
subject
the
welding
power
source
internal
components
to
an
overheating
condition
and
subsequent
failure.
Warranty
is void
if
any
type
of
filtering
device is
used.
Holes
are
provided
in
the
welding
power
source
base for
mounting
purposes.
Figure
3-1
gives
overall
dimensions
and
the base
mounting
hole
layout.
OM-267
Page
13

44 j,~*
(1117.6
mm)
21/32
in.
(16.7
mm)
Dia.
4
Holes
-~
25-3/8
in.
(644.5 mm)
27-1/4
in.
(692.1
mm)
.~
46 in.
15/16
in.
~_(1168.4
mm)
(23.8
mm)
~
Including
2-7/8
in.
(73
mm)
Lifting
Eye
Figure
3-1. Overall
Dimensions And Base
Mounting
Hole
Layout
On
most
welding
power
sources a
lifting
device is
pro
vided
for
moving
the unit.
However,
if
a
fork
lift
vehicle
is
used
for
lifting
the
unit,
be
sure
that
the
lift
forks
are
long
enough
to
extend
completely
under
the
base.
IMPORTANT
______________
The
use
of lift forks too
short
to
ex
tend
out
of the
opposite
side
of
the base
will
expose
in
ternal
components
to
damage
should
the
tips
of the
lift
forks
penetrate
the bottom
of the
unit.
3-2.
ELECTRICAL
INPUT
CONNECTIONS
A.
Electrical
Input
Requirements
This
welding
power
source
is
designed
to
be
operated
from
a
three-phase,
60
Hertz,
ac
power
supply
which
has
a
line
voltage rating
that
corresponds
with
one
of
the electrical
input
voltages
shown
on
the
nameplate.
Consult the
local electric
utility
if there is
any
question
about the
type
of
electrical
system
available
at
the in
stallation
site
or
how
proper
connections
to
the
welding
power
source are
to
be made.
B.
Input
Conductor Connections
I~I.1t~
It is recommended
that
a
line disconnect
switch be installed in the
input
circuit
to
the
welding
power
source.
This would
provide
a
safe and
conve
nient
means
to
completely
remove
all
electrical
power
from the
welding
power
source
whenever it is
necessary
to
perform
any
internal function
on
the unit.
CAUTION
___________
Before
making
electrical
input
connec
tions
to
the
welding
power
source,
machinery
lockout
procedures
should be
employed.
If the connection
is
to
be
made from
a
line disconnect
switch,
the
switch
should be
padlocked
in
the
open
position.
If
the
connec
tion is
made from
a
fuse
box,
remove
the fuses
from
the
box and
padlock
the
cover
in
the
closed
position.
If the
unit
is
connected
to
a
circuit
breake,,
or
other discon
necting
device
without
locking
facilities,
attach
a
red
tag
to
the
device
to
warn
others
that
the circuit
is
being
worked
on.
Insert
the
three
input
conductors
plus
one
ground
con
ductor
through
the
access
hole
on
the
rear
panel.
This
hole
will
accept
standard conduit
fittings.
See
Figure
3-2
for
hole location and size.
Connect
the
three
input
conductors
to
the line terminals
on
the
contactor.
Connect
the
ground
conductor
to
the
terminal labeled GROUND
on
the frame
near
the
con
tactor.
The
remaining
end
of
the
ground
conductor
should be connected
to
a
proper
ground.
Use
a
groun
ding
method that is
acceptable
to
the local
electrical
in
spection
authority.
CAUTION
The
ground
terminal
is connected
to
the
welding
power
source
chassis and is for
grounding
pur
poses
only.
Do
not connect
a
conductor from the
ground
terminal
to
any
one
of
the line terminals
as
this
will result
in
an
electrically
energized
welding
power
source
chassis.
1000 Model
Illustrated
2-5/8
in.
(66.7 mm)
Die.
Access
Hole
TB-079
825-A
C.
Matching
The
Welding
Power
Source
To
The
Available
Input
Voltage
1.
For
1000
And
1500
Models
This
unit
is
equipped
with
input
voltage
jumper
links
on
the
primary
terminal board
which
allow
operation
from
different line
voltages.
This
unit is
shipped
with the
CAUTION:
Connect the
input
conductors
to
the
welding
power
source
before
making
connections
to
the
three-phase
power
supply.
The
input
conductors
should
be
covered with
an
in
sulating
material which
conforms
to
local electrical
stan
dards.
Table 3-1
is
provided
only
as a
guide
for
selecting
the
proper
size
input
conductors
and fuses.
Table
3-1.
Input
Conductor
And
Fuse
Sizes
1-7/8
In.
~N~47~6
mm)
42-1/4
in.
-~
(1073.1
mm)
~
Input
Conductor
Size
-
AWG Fuse
Size
In
Amperes
Model
230V 460V 575V 230V 460V
575v
1000
Amperes
4/0
13)
2
(6)
2
(6)
350 175
125
1500
Amperes
400 MCM
12)
2/0
(4)
1/0
(4)
500
250 225
Input
conductor
sizes
are
based
on
National
Electrical
Code
specifications
T8-079
823
for
allowable
ampacities
of insulated
copper
conductors,
having
a
temperature
rating
of
75C,
with
not
more
than
three conductors
in
a
raceway
or
cable. Numbers
in
( I are
equipment ground
conductor
sizes.
Line
Terminals
Ground
Terminal
Input
Voltage
Jumper
Links
Line
Disconnect
Switch
Figure
3-2.
Input
Conductor
Connections
OM-267
Page
14