Miller PORTA-MIG User manual

Millerfi
August
1990
FORM:
OM-1220F
Eff
ective
WI th
Serial
No
.
JK674436
MODEL:
PORTA-MIGfi
OWNERS
MANUAL
IMPORTANT:
Read
and understand the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER
ELECTRIC
Mfg.
Co.
AMIerGr~pLtd..Co~y
Installing, operating,
or
maintaining
this
equipment.
This
unit
and these
Instructions
are
for
use
only by
persons
trained and
experienced
in
the
safe
P0
Box
1079
A~Ieton,
WI
54912
USA
operation
of
welding
equipment.
Do
not
allow untrained
persons
to
install,
Tel.
414-734-9821
operate,
or
maintain
this
unit.
Contact
your
distributor
If
you
do
not
fully
understand these
instructions.
TC-105
522-A
PRINTED
IN
U.S.A.

IF
LIMITED
WARRANTY
EFFECTIVE: AUGUST
6,
1990
-1~
This
warranty
supersedes
all
previous
MILLER
warranties and is exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
~~1
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof.
MILLER
Electric
Mfg.
Co..
Appleton.
Wisconsin
war
rants
to
its
DistributoriDealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
detect
in
workmanship
and
material
as
of
the time and
place
ot
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.
A))
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase.
except
Deutz
engines
which
have
a one
year,
2000 hour
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
omi
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc welders,
power
sources.
robots, and
1
year
components
2. Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns.
feeder/guns
and
torches
.
,
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7. Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of the
date
of
such
failure.
As
a
matter
of
general
policy
only.
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
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) replace
ment
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
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin.
or
FOB.
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 REPRE
SENTATION 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 MERCHAN
TABILITY OR
OF
F!TNESS
FOR
PARTICULAR PURPOSE.
WITH
RESPECT TO
ANY AND ALL
EQUIPMENT
FURNISHED
BY
MILLER 5
EXCLUDED
AND
DISCLAIMED
BY MILLER.
EXCEPT AS
EXPRESSLY PROVIDED
BY
MILLER
IN
WRITING,
MILLER PRODUCTS
ARE
INTENDED FOR
ULTIMATE PURCHASE
BY
COMMERCIALINDUSTRIAL
USERS
AND
FOR
OPERATION BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS OR
CONSUMER USE.
MILLERS WARRANTIES DO NOT
EXTEND TO. AND NO
RESELLER
IS AUTHORIZED TO
EXTEND MtLLERS WARRANTIES
TO,
ANY
CONSUMER.
I

ERRATA
SHEET
**First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE TO
PROVIDE
MODEL
AND
SERIAL NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
After
this
manual
was
printed,
refinements
in
equipment design
occurred.
This sheet lists
exceptions
to
data
appearing
later
in
this
manual.
AMEND
MENT
TO
SECTION
9

PARTS LIST
Amend Parts List
as
follows:
All
Parts
Effective
w/KB029819
--
Dia.
Part
Mkgs.
No.
Replaced
With
Description Quantity
29-25
116 964 143
922
CLAMP,
cable
strain
relief
1
29-26
PLG7
111 122
109 770
141
162
143
922
HOUSING
PLUG &
PINS,
(consisting
of)
TERMINAL,
male
1
pin
18-14 wire
1
29-46
079 633
144
172
FITTING,
brs barbed
M
3/l6tbg
x
.250-20
1
32-
Qi
037 824
144
240
THYRISTOR,
scr
16A
600V
1
14

OM.1220F
-
6/90
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier. mation
is
located
on
the
data
card
or
the
nameplate.
Assistance for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_________________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
______________________
Number.
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.
Arc
Welding
7
1-4. Standards
Booklet Index
11
SECTION
2-
SAFETY PRECAUTIONS-AND
SIGNAL WORDS
2-1.
General Information
And
Safety
12
2-2.
Safety
Alert
Symbol
And
Signal
Words
12
SECTION
3
SPECIFICATIONS
3-1.
Description
13
SECTION
4
INSTALLATION
OR
RELOCATION
4-1.
Location
14
4-2.
Opening
Wire Feeder
Case
14
4-3.
Drive Motor
14
4-4.
Interconnecting
Cord
And
Shielding
Gas
Hose
Installation
14
4-5.
Drive
Roll Installation
15
4-6.
Welding
Gun
Installation
On Metal Case Models
16
4-7.
Welding
Gun
Installation
On ABS Case Models
18
4-8.
Wire
Spool
Installation
18
4-9.
Adjustment
Of
Hub
Tension
19
4-10. Weld
Cable
Connections
19
4-11.
Welding
Wire
Threading
19
SECTION
5-OPERATOR CONTROLS
5-1.
General
20
5-2. Power
Switch
20
5-3. Wire
Speed
Control
20
SECTION
6
SEOUENCE
OF
OPERATION
6-1.
Gas
Metal Arc
Welding
(GMAW)
21
6-2.
Shutting
Down
21

Section
No.
Page
No.
SECTION
7- MAINTENANCE
&
TROUBLESHOOTING
7-1.
Opening
Wire
Feeder Case
21
7-2.
Routine
Maintenance
22
7-3.
Aligning
Drive
Rolls
And Wire
Guides
22
7-4.
Brush
Inspection
And
Replacement
23
7-5.
Overload Protection
23
7-6.
Circuit Board Precautions
24
7-7.
Troubleshooting
24
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
26
Diagram
8-2.
Circuit
Diagram
For Motor
Control
Board PCi
26
SECTION
9
PARTS LIST
Figure
9-1.
Main
Assembly
28
Figure
9-2.
Control
Box
30
Figure
9-3.
Circuit Card
32
Figure
9-4.
Wire
Drive And
Gears
33
LIST
OF
CHARTS
AND
TABLES
Table
3-i.
Specifications
13
Table
7-1.
Maintenance
Schedule
22
Table
7-2.
Troubleshooting
25
Table
9-1.
Drive Roll
And
Wire Guide
Kits
34

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
Iappren
tissage
de
Ia
vie,
lapprentissage
de
Ia
sØcuritØ
par
ex
pØrience
personnelle,
comme
Ienfant
qui
touche
un
poŒle
chaud,
est
dangereux,
imprudent
et
inutile.
lnstruisez-vous
donc de
IexpØrience
dautrui.
Des
mØthodes
de
sØcuritØ
issues
de
lexpØrience
du
soudage
et
du
coupage
sont
dØcrites
dans
le
manuel.
La
recherche,
le
progrØs
et
IexpØrience
dans
ce
domaine
ont
dØveloppØ
un
materiel
fiable
et
des
mØthodes
de
sØcuritØ
pour
Iinstallation,
le
fonctionnement
et
Ientre
tien. Des
accidents
se
produisent
lorsque
le materiel
est
inadØquatement
utilisØ
ou entretenu.
La
raison
de
ces
mØthodes de
sØcuritØ
peut
ne
pas
Œtre
toujours
donnØe.
Certaines
sont
fondØes
sur
le
sens
commun,
dautres
demanderont
a Œtre
expliquØes
par
des
livres
techni
ques.
Il
est
plus
sage de
suivre
les
regles.
Lisez
et
comprenez
ces
mØthodes de
sØcuritØ
avant
dessayer
dinstaller,
de
faire fonctionner
ou
de
rØparer
lappareil.
Pour
votre
sØcuritØ
personnelle
et
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 devient
une
habitude,
le
materiel
peut
alors
Œtre
utilisØ
en toute
confiance.
Ces mØthodes
de
sØcuritØ
sont
divisØes
en
deux
sec
tions: 1
-
Precautions
gØnØrales,
communes
au
soudage
et au
coupage
a
larc,
et
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
que
ceux
du
present
manuel. Elles
sont
donnØes
dans
lln
dex des
Normes
de
ces
regles
de sØcuritØ. ANSI
Z49-1
est
Ia
plus
complete.
Les
codes
de
IACNOR,
es
codes
provinciaux
et
municipaux
donnent
aussi les
exigences
pour
une
in
stallation,
une
utilisation
et
un
entretien
srs.
1-2.
PRECAUTIONSGENERALES
Plusieurs
procedØs
du
soudage
a
Iarc,
des
Ølec
trodes
allies,
et
los flux
peuvent
produire
des
vapeurs,
gaz,
et
niveaux
do
rayonnement
diffØrents.
Pour
tout
renseignement
supplØmen
taire
a
ce
manuel,
consultez
aussi lea
fabricants
des electrodes et des flux afin
dobtenir
lee
ronsoignements
techniques
spØcifiques
et
lee
mesures
do
precaution
concernant
leurs
matØriaux.
A.
Prevention
des
brOlures
Portez
des
vŒtements
de
protection
-
des
gants
a
crispin
spØcialement
designØs
pour
le
soudage,
un
casque
et
des
chaussures
de
sØcuritØ.
Boutonnez
le
col
de
votre
chemise
et
les
pattes
de
vos
poches,
et
portez
des
pan-
talons
sans revers
pour
Øviter
que
des
Øtincelles
et
du
laitier
ne
sy
introduisent.
Portez
un
masque
avec
lunettes
de
sØcuritØ
ou
avec
Øcrans
latØ-raux de
protection,
des
lunettes
filtrantes
ou
des
couvre-Ientilles
(proteges
par
un
verre
clair).
Pour
le
soudage
ou
le
coupage
(et
le
burinage),
il
est
OM-1220
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
de
protØger
ses
yeux
contre
lØnergie
de
rayonnement
et
les Øclats
de
metal.
Remplacez
le
verre
protecteur
lorsquil
est
brisØ,
piquØ
ou
quil
a
recu
des
projections.
Voir
1
.3A.2.
Evitez
de
porter
des habits
imprØgnØs
dhuile
ou
de
graisse.
Une
Øtincelle
pourrait
les
enflammer.
Ne
manipulez
jamais
sans
gants
un
metal chaud tel
que
des
chutes
dØlectrdde
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
competente,
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
inflammables
pour
leurs
cheveux.
B. Prevention
des
gax
toxiques
Les
gaz,
les
vapeurs,
Ia
chaleur,
un
enrichissement
ou
un
manque
doxygene
peuvent
entrainer
un
malaise,
une
maladie
ou
mŒme Ia
mort.
Remediez-y
par
Ia
ven
tilation
dØcrite
dans
Ia
Norme
ANSI
Z49.1
paragraphe
1
de
llnclex
des
Normes.
NE ventilez
JAMAIS
a
ox
ygene.
En soudant
ou en
coupant,
les
p10mb,
cadmium, zinc,
mercure
et
beryllium
ou
autres
matØriaux
semblables
peuvent
crØer
des
concentrations nocives
de
gaz
toxi
ques.
On
doit
avoir
recours
a
une
ventilation
aspirante
adequate
du
local,
ou
alors
toute
personne
sur
les
lieux,
de mŒme
que
le
soudeur,
doit
porter
un
masque
a ad
duction
dair.
On
doit
employer
les deux
pour
le
beryllium.
Les mØtaux
enrobØs
ou
composes
de matØriaux Ømet
tant
des
gaz
toxiques
ne
doivent
pas
etre
chauffØs
a
moms
que
lenrobage
ne
soit tØ
de Ia surface a
travailler,
que
le local
ne
soit bien
ventilØ,
ou
que
le
soudeur
ne
porte
un
masque
a
adduction dair.
Ne travaillez
dans
un
espace
restreint
que
sil
est
bien
ventilØ
et,
si
nØcessaire,
portez
un
masque
a
adduction
dair.
On doit
Øviter les
fuites
de
gaz
dans
un
espace
restreint.
Les fuites
de
gaz
en
grande
quantitØ
peuvent
transformer
dangereusement
Ia concentration
dox
ygene.
Namenez
pas
de
bouteilles
de
gaz
dans
un
espace
restreint.
En
quittant
un
espace
restreint,
FERMEZ
le
robinet
dalimentation
de
gaz
de Ia
bouteille. Ainsi
on
pourra
rentrer
en
toute
sØcuritØ
dans Ia
piŁce,
mŒme
si
les
robinets
aval
ont
ete
ouverts
par
accident,
OU
si
on
les
a
laissØs
ouverts.
Les
vapeurs
de
dissolvants
chlorØs
peuvent
Œtre
dØcom
posØes
par
Ia chaleur
de
larc
(ou
de
Ia
flamme) et
former
du
PHOSGENE,
gaz
trŁs
toxique,
et
dautres
produits
irritant
les
poumons
et
les
yeux.
Lenergie
ultra-violette
de
larc
peut
aussi
dØcomposer
les
vapeurs
de
trichloroethylene
et
de
perchloroethylene
pour
former
du
phosgŁne.
NE
SOUDEZ
PAS
ou
ne
coupez
pas
dans
des
endroits
o
les
vapeurs
de
dissolvants
peu
vent
Œtre attirØes
dans
latmosphŁre
de
soudage
ou
de
OM-1220
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,
flying
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
7
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energie
de
rayonnement peut
pØnØtrer
dans
des
atmospheres
contenant
des
quantitØs
mŁme
minuscules
de
trichloroethylene
ou
de
per
chloroØthylŁne.
C.
Prevention
des
incendies
et
des
explosions
Les
causes
dincendie
et
dexplosion
sont
les
com
bustibles atteints
par
larc,
Ia
flamme,
les
Øtincelles,
le
laitier
chaud
ou
les
matØriaux
chauffØs,
le mauvais
emploi
des gaz
comprirnØs
et
des
bouteilles ainsi
que
les
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
es
portes
et
par
les
couvertures
des
murs
ou
du
sol,
sans
que
le
soudeur
portant
des
lunettes
ne
les
vole.
Les Øtincelles
et
(es
scones
peuvent
voler
jusqu
35
pieds.
Pour
prØvenir
les
incendies
et les
explosions:
Veillez
a
ce
que
votre
appareil
soit
propre
et
en
Øtat de
marche,
dØnuØ
dhuile
et
de
graisse,
et
de
particules
de metal
sur
es
piŁces electriques
qul
pourraient
entrairier
des
courts-circuits.
Si
des combustibles
se
trouvent
a
proximitØ,
ne
soudez
pas,
ne
coupez
pas.
Sipossible,
dØplacez
votre
travail
loin des combustibles.
Evitez
les ateliers de
peinture
au
pistolet,
es
cuves
dimmersion,
les
entrepts,
les
yen
tilateurs.
Si
cela nest
pas
possible,
placez
les
com
bustibles
a
au
moms 35
pieds
des
ØtinceUes
et
de
Ia
chaleur
et
protegez-les
des
Øtincelles
avec
des
couver
tures
ou
des
Øcrans
protecteurs
adequats,
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
proteges
par
des
couvertures
ou
Øcrans
protecteurs
ignifugØs.
Un surveillant
doit
se
tenir a
proximitØ
avec
un
materiel
de
lutte
contre
lincendie
adequat,
pendant
et
quelque
temps
aprŁs
le
soudage
ou
le
coupage
si:
a.
Des
quantites
apprØciables
dØ
combustibles
(y
compris
une
construction
en
chantier)
se
trouvent
a moms
de
35
pieds.
b.
Des
quantites
apprØciables
de
combustibles
sont
a
plus
de
35
pieds
mais
peuverit
Œtre
enflammØes
par
des
Øtincelles.
c.
Des
ouvertures
(cachØes
ou
visibles)
sur es
planchers
ou
es
murs
a
moms de
35
pieds
peuvent
exposer
des
combustibles
aux
Øtincelles.
d.
Les
combustibles
adjacents
aux
murs,
plafonds,
toits
ou
cloisons
metalliques
peu
vent
Łtre
enflammØs
par
une
chaleur
rayon
nante
ou
transmise.
Avant
de
commencer,
avisez le contremaitre
pour
quil
sassure
que
les
precautions
adequates
soment
prises.
Une
fois le
travail
terminØ,
vØrifiez
quil
ny
alt
pas
dØtincelles,
de cendres
ardentes
ou
de
flammes
dans
le
local.
On
ne
dolt
jamais
souder
ni
couper
sur
un
recipient
avant
contenu
des
combustibles,
ou
pouvant
produire
des
vapeurs
inflammables
ou
toxiques
a
a
chauffe,
a
moms
que
le
recipient
nait
ete
aye
au
prØalable,
corn-
me
dØcrit
dans Ia Norme
AWS
A6.O,
figurant
au
paragraphe
7
de
lIndex des Normes.
Cela
comprend:
un
nettoyage
a
fond a Ia
vapeur
ou
au
caustique
lou
un
lavage
avec
dissolvant
ou
eau
selon
a
solubilitØ
du
combustible)
suivi
dune
purge
et dune
in-
OM-1220
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,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLINDERS,
listed
ii
in
Standards
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
oft
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
to
a
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
recommandØ dans
lA6-O.
LatmosphŁre
inerte
peut
Œtre
remplacØe
par
un
niveau
deau arrivant au-dessous
du travail a
effectuer.
Vous
devez
(aver
un
recipient
dont (a
nature
de
contenu
est
inconnue
(voir
paragraphe
ci-dessus).
NE
vous
fiez
PAS
a l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
les
piŁces
ou
rØci
pients
creux
avant
de
les souder
ou
couper:
ils
peuvent
exploser.
Atmospheres
explosives:
Ne
soudez
ni
ne
coupez
jamais
dans
des
lieux
o~i
lair
peut
contenir
des
poussiŁres,
gaz
ou
vapeurs
liquides
inflammables
(tels
que
Iessence).
D.
Gaz
comprimØ
Precautions
gØnØrales:
Suivez
les
precautions
de
ce
manuel,
et
celles
dØcrites
a
a
Norme
CGA
P-i
(PrØcau
tions
de
sØcuritØ
pour
Ia
manipulation
de
gaz
comprimØs
en
bouteilles),
paragraphe
11
de Index des Normes.
1.
DØtendeurs
de
pression
La
soupape
de
sQretØ
dun
dØtendeur
est
destinØe
a
pro
teger
seulement
le
dØtendeur
de
Ia
surpression.
Elle
na
pas
pour
but
de
proteger
les
boyaux
et
le
chalumeau:
on
protege
ceux-ci
par
des
soupapes
de
retenue
concues
spØcialement
pour
cette
fonction.
Ne
montez
jamais
un
dØtendeur
sur
une
bouteille
conte
nant
un
gaz
different
de celui
pour
lequel
Ie
dØtendeur
a
ØtØ
concu.
Enlevez
immØdiatement
un
dØtendeur
dØfectueux
pour
le
faire
rØparer (dabord,
fermez
le
robinet
de
Ia
bouteille).
Les
symptmes
suivants
dØnotent
Ia
dØfec
tuositØ du
dØtendeur:
Fuites
-
Si le
gaz
fuit
extØrieurement.
Ascension
excessive
-
si Ia
pression
de
debit
continue
a
monter,
le robinet
du chalumeau
Øtant
fermØ.
ManomŁtre
dØfectueux
-
Si
laiguille
du
manomŁtre
ne
sØcarte
pas
de
(a
goupille
de butØe
lors de Ia
mise
en
pression,
ou
ne
revient
pas
sur
Ia
goupille
aprŁs
lØchap
pement
de Ia
pression.
Reparation.
NESSAYEZ
PAS
de
rØparer
vous-mŁmes.
Envoyez
(es dØtendeurs
defectueux
a
rØparer
aux
ateliers
de
reparation
agrees
du
fabricant,
o des
techni
ques
et
des
outils
spØciaux
sont
utilisØs
par
un
person
nel
formØ.
2.
Bouteilles
Les
bouteilles
doivent
Œtre
manipulØes
avec
soin
pour
prØvenir
les
fuites
ou
dØgats
a leurs
parois,
robinets
ou
systŁmes
de sQretØ.
Evitez
quun
circuit
electrique
soit
en contact
avec
les
bouteilles,
y
compris
Ies rails
de
Con
tact,
les fils
Ølectriques
ou
les
circuits
de
soudage.
Cela
pourrait
crØer des
arcs
courts-circuits
pouvant
entraIner
des
accidents
graves
(Voir
1.3C.).
Chaque
bouteille
doit
porter
les
inscriptions
ICC
ou
DOT.
Cest
un
gage
de
sØcuritØ
pourvu
que
Ia
bouteille
soit
bien
manipulØe.
OM-1220
Page
4