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