Miller ARC PAK 350 User manual

Miller
September
1989
FORM:
OM-126853A
Effective
With
Serial
No.
JJ401061..
MODEL:
ARC
PAKIM
350
Manufactured
For
Chicago
Bridge
&
Iron
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
MfcI.
Co.
AMrnGfG(O~OLtd.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
.Appleton,
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.
PRINT~D
IN
U.S.A

I
-J
LIMITED
WARRANTY
EFFEC1IVE:
MARCH
15,
1989
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
conditions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nishedby
Miller is
free from defect
in
workmanship
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
ac
cessories
and other
items
are
sold
subject
to
the warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year from
date of
original
purchase,
except
Tecumseh
and
Onan
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,
MILLER-,
5MA11C
parts
that
come
in
contact
with the
welding
wire includ
ing
nozzles
and
nozzle insulators
where
failure
does
not
result
from defect
in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
warranted
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,
MiHer
may
honor
daims
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
excluswe
remedies
therefore
shall
be,
at
Millers
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
depreaation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk and
expense.
MILLERsoption
of
repairorreplacenientwill
be
F.O.B..
Factory
at
Appleton,
Wisconsin,
or
FOB.
ata
MILLER authorized
serv
ice
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
war
ranty
claim
procedures
to be
followed.
ANY EXPRESS WARRANTY
NOT PROVIDED HEREIN
AND ANY IMPLIED
WARRANTV
GUARANTY OR REPRE.
SENTAT1ON
AS TO
PERFORMANCE,
AND ANY REMEDY
FOR BREACH
OF
CONTRACT
WHICH,
BUT
FOR THIS
PRO
VISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPUED WARRANTY
OF MERCHAN
TABILITY
OR OF FITNESS FOR PARTICULAR
PURPOSE,
WiTH
RESPECT
TO
ANY
AND ALL
EQUIPMENT FUR
NISHED
BY MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER
EXCEPT
AS
EXPRESSLY PROVIDED
BY
MILLER
IN
WRITING,
MILLER PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY COMMERCIAL/INDUSTRIAL USERS
AND
FOR OPERATION
BY
PERSONS TRAINED
AND
EXPE
RIENCED
IN
THE USE AND MAINTENANCE OF
WELDING
EQUIPMENT
AND NOT FOR CONSUMERS OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT EXTEND
TO,
AND
NO
RESELLER IS AUTHORIZED TO
EXTEND
MILLERS WARRANTIES
TO.
ANY
CONSUMER.
I

OM-126853A9/89
RECEiVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use the
following
spaces
to
record the
Model
Design
a-
age
that
may
have occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infcr
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
eq~iipment
manufactur-
Model
_______________________________
ers
Transportation Department.
Senal
or
Style
No.
____________________
When
requesting
information
about this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Dateof
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
4
1-4. Standards
Boo
k~et Index
5
SECTION
2SAFETY
PRECAUTIONS
AND
SIGNAL WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3SPECIFICATIONS
3-1.
Volt-Ampere
Curves
8
3-2.
Duty Cycle
8
3-3.
Description
8
SECTION
4-INSTALLATION
OR
RELOCATION
4-1.
Site
Selection
8
4-2.
Transporting
Methods
9
4-3.
Weld
Output
Connections
9
4-4.
Electrical
Input
Connections
10
SECTION
5-OPERATOR
CONTROLS
5-1.
PowerSwitch
12
5-2.
Pilot
Light
12
5-3.
Output
Control
12
5-4.
Arc
Control/Inductance
Control
12
5-5.
Contactor
Switch
13
5-6.
Output
Control
Switch
13
5-7.
CV/CC
Switch
14

Section
No.
Page
No.
SECTION
6
SEQUENCE
OF OPERATION
6-1.
Gas
Metal
Arc
(GMAW)
And
Flux Cored
Arc
Welding
(FCAW)
14
6-2.
Tungsten
Arc
Welding
(GTAW)
14
6-3.
Shielded
Metal Ait
Welding
(SMAW)
15
6-4.
SubmergedArc
Welding
(SAW)
15
6-5.
Air
Carbon Arc
Cutting
And
Gouging
(ACA)
15
6-6.
Shutting
Down
15
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine Maintenance
16
7-2.
Overload
Protection
16
7-3. Thermal
Protection
17
7-4.
Circuit
Board
Indicator
Lights
17
7-5.
Circuit
Board
Handling
Procedures
18
7-6.
Troubleshooting
18
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
21
Diagram
8-2.
Circuit
Diagram
For Control
Circuit
Board
PCI
22
Diagram
8-3.
Circuit
Diagram
For Base Drive
Circuit Boards
PC2
And
PC3
24
Diagram
8-4.
Circuit
Diagram
For
Snubber Circuit
Board
PC4
24
Diagram
8-5.
Circuit
Diagram
For Balance
Circuit
Board
PC5
25
SECTION
9-
PARTS LIST
Figure
9-1.
Main
Assembly
26
Figure
9-2.
Panel,
Front
W/Components
28
Figure
9-3.
Baffle,
Center
W/Components
30
Figure
9-4.
Transistor
Assembly,
Main
32
Figure
9-5.
Module,
Diode
34
LIST
OF CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Chart
3-1.
Volt-Ampere
Curves
7
Chart
3-2.
Duty Cycle
8
Table
4-1.
Weld
Cable Size
9
Table
4-2.
Input
Conductor
And Fuse Size
11
Table
7-1.
Maintenance Schedule
16
Table 7-2.
Troubleshooting
18

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
oth
ers
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
safe
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
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.
12.
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
manu
facturers
Material
Safety
Data
Sheets
(MSDSs)
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
cuff
less
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 immediate
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
Standard
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
orcontaining
materials
that
emit
toxic
fumes
should
not
be
heated unless
coating
is
removed
from
the
work
surface,
the
area
is well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
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
if
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
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
OM-126
853
Page
1

to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloroethylene~
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,
throughwindows
ordoors,
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,
venti
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
thatadequate
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:
athorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
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
11
in
Standards
Index.
1.
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
regulatorfrom
service
immediately
for
re
pair
(first
close
cylinder valve).
The
following
symptoms
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
pointerdoes
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do NOT
attempt
to
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
cittuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short circuit
arcs
that
may
lead
to
a
serious
acci
dent.
(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.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
OM-126
853
Page
2

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
mag~nets.
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
orwrench
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.
Cylinderfittings
should
never
be modified
orexchanged.
3. Hose
Prohibited
use.
Never
use
hose
otherthan
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
ordi
nary
wire
or
other
substitute)
as a
binding
to
connect
hoses to
fittings.
No
copper
tubing splices.
Use
only
standard brass
fit
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
orwom
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
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
area,
and
thatthe
regulator
inlet
and
cylinderoutlet
match.
N
EVER
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.
usetwowrenchestotighten
adaptermarked
RIGHTand
LEFT
HAND
threads.
Regulatoroutlet
(or
hose)
connections
may
be identified
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
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
rully
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
on
regulators.
Check
for
leaks
on
first
pressurization
and
regullarly
there-after.
Brush
with
soap
solution
(capfull
of
Ivory
Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
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
Staglng.Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope may
burn.
*Trademark
of
Proctor
&
Gamble.
OM-1
26
853
Page
3

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
in
frared
energy
radiates,
weldments
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 andin
stan
dards referenced
in
index.
A.
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
burns 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
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
bums.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted1
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
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
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.
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
arcwelding
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.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other bare
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:
Wear
dry
insulating
gloves
and
body
protection.
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
moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces
the
electrical
resistance,
and could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between
the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
conduct
ing
objects
include,
but
are
not
limited
to,
buildings,
elec
trical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
1.
Grounding
the
Equipment
Arc
welding equipment
must
be
grounded
according
to
the
National Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
usafety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
worktable,
and
water
cir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-126
853
Page
4

electrically
HOT
by
stray
current
may
shock,
possibly
I
a-
tally.
Do
NOT
GROUND
to
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
or
flammable
liquid
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
of 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
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
USQ
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be used
to
join
welding
cable
lengths.
4. Cables
Frequently
inspect
cables
forwear,
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
operation.
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
electri
cally
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
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.
F.
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 their doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
referto
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
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standad
Z41.1,
STANDARD FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American National
Standards
Institute,
1430 Broad
way,
New
York,
NY
10018.
6.
ANSI Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE OF
CUTTING
AND
WELDING
PROCESSES
OM-
126 853
Page
5

obtainable from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS Standard
A6.0,
WELDING
AND~
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from
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.
NF?A
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
ii. CGA
Pamphlet
P-i,
SAFE HANDLING OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
1235
Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
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
M9W1R3.
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
Rd,
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
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2.1.
GENERAL INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should
be
read, understood,
and
followed forthe safe and effective
use
of
this
equipment.
The
nameplate
of this unit
uses
international
symbols
for
labeling
the front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
B
.
Safety
The
installation,
operation,
maintenance,
and trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only by qualified
per
Sons
in
accordance with this
manual
and
all
applicable
codes
Such
as,
but
not
limited
to,
those listed
at
the
end
of
Section
1

Safety
Rules For
Operation
Of
Arc
Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout this
manual
to
call
attention
to
and iden
tify
different levels of hazard
and
special
instructions.
a
a
This
safety
alert
symbolis
used with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
OM-126
853
Pages