Miller ps-100 User manual

June
1988
Millerfi
F~1LE
COPY
RETURN
TO
FOLDER
OWNERS
MANUAL
iMPORTANT
Read and
understand
the
entire
contents
of this
manual.
with
special emphasis
on
the
safety
material
throughout
the
manual.
Miller Electilc
Mfg.
Co.
A~L~C~at~
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
P0. Box 1079
these
instructions
are
for
use
only
by
persons
trained
and
experienced
In
Appleton,
WI
54912 USA
the
safe
operation
of
welding equipment.
Do
not
allow
untrained
persons
Tel.
414-734-9821
to
install,
operate,
or
maintain this
unit. Contact
your
distributor
if
you
do
not
fully
understand these instructions.
FORM:F2544B
Effective
With
Serial
No.
JJ393769
MODEL
ps-100
PRINTED
IN
U.S.A.
ACOITIONAL
COPY
PRCE
70
CENTS

EFFECTIVE:
FEBRUARY
16.
1988
This
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
case
at
Millers breech
of
warranty
or
any
other
duty
dons
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to the
quality
of
any goods,
the exclusive
rwi~diemi
warrants to
its
Distributor/Dealer
that
all
new
and
unused
therefore shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller
is
free from
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
coat
of
repair
or
replacement
at
an authorized
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
(4)
pa~mant
of
or
credit
for
the
purchase
accessories
or
other items manufactured
by
others.
Such
pnce
(lees
reasonable
depreciation
based
upon
actual
use)
upon
engines,
trade
accessories
and other items
are
sold
subject
to
return
of the
goode
at
Customers
risk
and
expense.
MILLERs
the warranties of their
respective manufacturers,
if
any
.
All
option
of
repair
or
replacement
will be
F.O.B.,
Factory,
at
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton, Weconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecurnseh
engines
which
facility,
therefore,
no
compensation
for
transportation
costs
of
have
a
two
year
warranty.
any
kind
will
be
allowed.
Upon receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
insmact
the
claimant
on
the
warranty
Except
as
specified below,
Millers
warranty
does
not
apply
claim
procedures
to
be
followed.
to
components
having
normal
useful life
of
lees
then
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY
EXPRESS WARRANTY
NOT PROViDED
HEREIN
AND
wire
including
nozzles and
nozzle
insulators
where
failure
dose
ANY
IMPUED
WARRANTY.
GUARANTY
OR
REPRESENTA
~
not
result
from
defect
in
workmanship
or
material.
liON AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH OF CONTRACT
WHICH,
BUT FOR ThIS
PROVISION,
~
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE BY
IMPUCA11ON,
OPERATION
OF
LAW,
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG.
INCLUDING
~
within
the
following
periods
from
the
date of
delivery
of
Equip-
ANY
IMPUED WARRANTY
OF MERCHANTABIUTY
OR
OF
merit
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY
AND
AU.
EQUIPMENT
FURNISHED
BY MILLER IS
EX
~.f
1. Arc
weldais,
p~re~irces,
robots,
and
c
,or~nts
.
1
yeer
CLUDED AND
DISCLAIMED BY MILLER.
2. Loadbanks
1
year
j
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
~
4. All
welding
guns,
feeder/gun,
and
torches 90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
r1~
5. All
other
Millermatic
Feeders
1
year
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
~
6.
Replacement
or
repair
parts,
exclusive
of labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS TRAINED
AND
ij(
7.
Batteries
6
months
EXPERIENCED
IN
ThE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
~
provided
that
Miller
i.
notified
in
writing
within
thirty
(30)
days
CONSUMER
USE.
MILLERS WARRANTIES
DO
NOT
EXTEND
!~
of
the
date
of
such
failure.
TO,
AND
NO
RESELLER
IS AUTHORIZED
TO
EXTEND
.~
As
a
matter
of
general
policy only,
Miller
cay
honor
dims
MILLERS WARRANTIES
TO,
ANY
CONSUMER.
by
the
original
user
within
die
foreyoing
periods

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
4
1-4.
Standards
Booklet Index
6
SECTiON
2-INTRODUCTION
2-1.
Vott-Ampere
Curves
8
2-2.
Duty
Cycle
8
2-3.
General
Information
And
Safety
8
2-4.
Receiving-Handling
8
2-5.
Description
9
SECTION
3
INSTALLATION
3-1.
Location
9
3-2. Weld
Output
Connections
9
3-3.
Control
Module
Receptacle
Information
And
Connection
10
3-4.
Electrical
Input
Connections
11
SECTION
4-
OPERATOR CONTROLS
4-1.
PilotLight
13
4-2.
Circuit
Breaker
13
4-3.
Control
Module
Receptacle
13
SECTION
5-
SEQUENCE
OF OPERATiON
5-1.
Operation
13
5-2.
Shutting
Down
13
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
14
6-2.
Fan
Motor
14
6-3.
Overload
Protection
14
6-4.
Troubleshooting
Chart
16

SECTION
1

SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We learn
by
experience.
Learning
safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
unwise.
Let
the
experience
of
others teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Re
search,
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
rea
son
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
sale
practices
may
cause
seri
ous
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
cut
ting;
and 2-Arc
Welding
(and
Cutting)
(only).
Reference
standards: Published
Standards
on
safety
are
also
ava~able
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
electrode
manufacturers
Material
Safety
Data
Sheets
(MSDSs)
for
specIfic
technical
data
and
precautIon
ary
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
and
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
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
in
Standards
Index.
NEVER
ventilate
with
oxygen.
Lead
-,cadmium-,
zinc
-,
mercury-,
and
beryllium-bear
ing
and
similar
materials,
when
welded
(or
cut)
may
pro
duce harmful
concentrations
of
toxic fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-sup
plied respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
or
containing
materials
that
emit
toxic fumes should
not
be
heated
unless
coating
is
re
moved from
the work
surface,
the
area
is
well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Work
in
a
confined
space
only
while it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
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
it
downstream valves have been
accidentally
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
prod
ucts. The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
perchloroethylene
F2544
Page
1

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
energy
can
penetrate
to
atmospheres
containing,
even
minute
amounts
of
trichioroethylene
or
perchioroethylene.
C.
Fire
and
Explosion
Prevention
Causes of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
rial;
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,
verdi
lators.
if
the work
cannot
be
moved,
move
combustibles
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 extin
guishing
equipment
during
and for
some
time afterweld
ing
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
orvisible)
In
floors orwalls
within
35 feet
may
expose
combustibles 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
corrtustibles,
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
orwaterwashing, depending
on
the
combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective
equip
ment
as
recommended
in
A6.O.
Waterfilling
just
below.
working
level
may
substitute for
inerting.
A
container
with
unknown
contents
should be
cleaned
(see preceding
paragraph).
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
CYLIN
DERS,
listed
ii
in
Standards
Index.
i.
Pressure
Regulators
Regulator
relief valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
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
pres
sure
release.
Repair.
Do
NOT
attempt
to
repair.
Send
faulty
regula
tors
for
repair
to
manufacturers
designated
repair
cen
ter,
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
han
dled.
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.
It
is
illegal
and hazardous.
F2544
Pace
2

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,
stings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not al
low 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
ex
changed.
3. Hose
Prohibited
use.
Never
use
hose
other than that
de
signed
for
the
specified
gas.
A
general
hose
identifica
tion rule is: red for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
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.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-203).
Do NOT
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
soui~es
of
ignition.
Wiper
with
a
clean
lintiess
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
area,
and
that
the
regulator
inlet and
cylinder
outlet match.
NEVER CONNECT
a
regulatordesigned
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
identified
by
right
hand
threads
for
oxygen
and left hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fue
gas.
5.
Pressurizing
Steps:
Drain
regulator
of residual
gas
through
suitable
vent
be
fore
opening
cylinder
(or
manifold
valve)
by turning
ad
justing
screw
in
(clockwise).
Draining prevents
exces
sive
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 fol
lowing
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
sale and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush with
soap
solution
(capfull
of
Ivory
Liquid
or
equivalent
per
gallon
of
water).
Bubbles
indi
cate
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.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and drain
gas.
G.
Rope
Stag lng~Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope
may
burn.
Trademark
of Proctor &
Gamble:
F2544
Page
3

1-3.
ARC
WELDING
Comply
with
precautions
in
1-1,
1-2,
and
this section.
Arc
Welding,
properly
done,
is
a
sale
process,
but
a
careless
operator
invites
trouble. The
equipment
cames
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
in
frared
energy
radiates,
weidments
are
hot,
and
com
pressed
gases
may
be
used.
The wise
operator
avoids
unnecessary
risks
and
protects
himself and others
from
accidents.
Precautions
are
described here
and
in
stan
dards
referenced
in
index.
H.
Burn
Protection
Comply
with
precautions
in 1-2.
The
welding
arc
is intense and
visibly bright.
its
radiation
can
damage
eyes,
penetrate
lightweight clothing,
reflect
from
light-colored
surfaces,
and burn the skin and
eyes.
Skin
bums resemble
acute
sunburn,
those
from
gas-
shielded
arcs
are
more severe
and
painful.
DONT GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1
-2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and fire-re
sistant
leggings.
Avoid
outer
garments
of
untreated
cot
ton.
Bare
skin
protection.
Wear
dark,
substantIal
clothing.
Button collar
to
protect
chest
and neck
and
button
pock
ets 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
am.
Protect filter
plate
with
a
clear
cover
plate.
Cracked
or
broken helmet
or
shield
should NOT
be
worn;
radiation
can
pass
through
to
cause
bums.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when bro
ken,
pitted,
or
spattered.-
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 bum that
may
leave
a
permanent
dark
area
in
the
field of vision.
3.
Protection of
Nearby
Personnel
Enclosed
welding
area.
For
production welding,
a
sepa
rate
room or
enclosed
bay
is
best.
In
open
areas,
sur
round the
operation
with
low-reflective,
non-combusti
ble
screens or
panels.
Allow for free air
circulation,
par
ticularly
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.
I.
Toxic
Fume Prevention
Comply
with
precautions
in
1
-2B.
Generator
engine
exhaust
must
be vented
to
the
outside
air.
Carbon monoxide
can
kilt.
J. Fire and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
weld
ing 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
ves
sel. It
creates
a
brittle
area
that
can
cause a
violent
rup
ture
or
lead
to
such
a
rupture
under
rough
handling.
K.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
L
Shock
Prevention
Exposed
hot conductors
or
other bar
metal
in
the
weld
ing
circuit,
or
in
ungrounded, electrically-HOT
equip
ment
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.
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
dampness
or
sweat
can
not
be
avoided.
Sweat, sea
water,
or
mois
ture
between
body
and
an
electrically
HOT
part-or
grounded
metal-reduces the
body
surface
electrical
re
sistance,
enabling
dangerous
and
possible
lethal
cur
rents
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
usafety
In
Welding
And
Cut
ting,
a
voltage
may
exist
between the
electrode
and
any
conducting object.
Examples
of
conducting
objects
in
clude,
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 oft.
When
installing,
connect
the frames of each
unit such
as
welding
power
source,
control,
work
table,
and
water
cir
culatorto the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by stray
current
may
shock,
possibly
f
a-
tally.
Do
NOT GROUND to
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
ortlammable
liquid
such
as
oil
or
fuel.
F2544 Pace
4

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
of
the
3-phase
line. Do
NOT
connect
the
equip
ment
ground
lead
to
the
third
(live)
wire,
or
the
equipment
will
become
electrically
HOT-a
dangerous
condition
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
re
ceptacle,
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
receptacle.
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.
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 and
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
opera
tion.
6.
Electrode
a.
Equipment
with
output
on/off
control
(contactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
nor
mally
are
equipped
with
devices
that
permit
on-
off control
of
the
welding
power
output.
When
so
equipped
the
electrode wire becomes
elec
trically
HOT
when
the
power
source
switch is
ON
and the
welding
gun
switch
is
closed.
Never
touch
the electrode
wire
or
any
conducting
ob
ject
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
proc
esses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equip
ment
the
electrode
is
electrically
HOT
when
the
power
switch is
turned
ON.
Never
touch
the
electrode
unless
the
welding
power
source
is.
off.
7.
Safety
Devices
Safety
devices
such
as
Interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted out.
Before
installation,
inspection,
or
service,
of
equipment,
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
weld
ing.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
bums,
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.
M.
Protection
For
Wearers of Electronic
LIfe
Sup
port
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic life
support
equipment (pacemaker)
should
consult
with
theirdoctor
before
going
near arc
welding,
gouging,
or
spot welding
operations.
1-4.
STANDARDS BOOKLET
INDEX
For
more
information,
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
N.W.
LeJeune
Ad,
Miami,
FL
33126.
2.
NIOSH,
SAFETY AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Gov
ernment
Printing
Office,
Washington,
D.C. 20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
Amen
can
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
PROCESSES
obtainable
from the
American National Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
F2544
Page
5

7.
AWS
Standard
A6.0,
WELDING
AND
CUTTiNG
CONTAINERS
WHICH
HAVE HELD
COMBUS
TIBLES obtainable
horn
the
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd.
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE obtainable
from
the
National
Fire Protection
Association,
Batterymamh
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from the
National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA 02269.
11. CGA
Pamphlet
P-i,
SAFE
HANDLING OF COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from the
Compressed
Gas
Association,
1235 Jet-
ferson
Davis
Highway,
Suite
501,
Atlington,
VA
22202.
12.
CSA
Standard
W117.2,
CODE
FOR SAFETY
IN
WELDING
AND
CUTTING
obtainable from
the
Ca
nadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING SAFETY BIBLIOGRA
PHY
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
PREPARATION FOR WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Ad, Miami,
FL
33126.
15.
ANSI
Standard
Z88.2,
PRACTICE
FOR
RESPIRA
TORY
PROTECTION,
obtainable
from the Ameri
can
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTiON
2-
INTRODUCTION
Rated
Welding
Amperes
100%
Duty Cycle
Range
Max.
Open-
Circuit
Voltage
Amperes Input
At
Rated Load
Output
KW

Dimensions
Weight
60
Hz
Three-Phase

200V 230V
460V 575V


~ss
~o 160
128
KVA
Net
Ship
1200A@
80V
20-1500
Amperes
.
ioov~c 128
104
Height:37in.
(940mm)
Width:271n.
(686 mm)
Length:
27in
(686mm)
1155
lbs.
(524
kg)
1370 lbs.
(621
kg)
8
B-i
16
834
FIgure
21.
SpecificatIons
X ~PS
Figure
2-2.
Volt-Ampere
Curves
F2544
Pape
6