Miller DIALARC 400 AC/DC User manual

Miller
February
1990 FORM:
OM-317B
Effec five With Serial No.
JK646436
MODEL:
DIALARCfi
400
AC/DC
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.
AMHe~~~Ltd..
Co~any
installing,
operating,
or
maintaining
this
equipment.
This unit and
these
Instructions
are
for
use
only by
persons
trained
and
experienced
in
the safe
1079
Ap~leton,
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.
PRINTED
IN
U.S.A

_J
<,,
I
LIMITED
WARRANTY
EFFECTIVE: MARCH
15,
1989
This
warranty
supersedes
all
previous
MILLER
warranties
and is
exclusivewith
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
nished
by
Miller
is free
from
defect
in
workmanship
andmaterial
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
engiqes
which have
a
two
year
warranty.
Except
as
specified
below,
Millers
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
MATIC
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,
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)repairor
(2)
replacement
or,
where
authorized
in
writing by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at an
author
ized Miller
service
station
or
(4)
payment
of
or
credit for the
pur
chase
price
(less
reasonable
depreciation
based upon
actual
use)
upon
return
of
the
goods
at Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will be
FOB.,
Fac
tory
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
ap
parent
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
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 COMMERCIALi1NDUSTRIAL
USERS
AND
FOR
OPERATION BYPERSONSTRAINEDAND
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.
UI

ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Replace
warranty
with
the
following:
.j
-~..
i.
MILLERS
TRUE
BLUETM
LIMITED WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
warranties
and
is exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
terms
and
conditiona below.
MILLER
Electric

Accessory
Kits
Mfg.
Co.,
Appleton.
Wisconsin,
warrants
tO
its
original
retail
purchaser
that
new *
Replacement
Parts
MILLER
equipment
sold
after the
effective date of this
limited
warranty
is
free
of
de
fects
in
material and
workmanship
at
the
time
it is
shipped
by
MILLER. THIS
WAR-
.
PANTY
IS
EXPRESSLY
IN LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS OR
MILLER S
True
Blue
Limited
Warranty
shall
not
apply
to:
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY AND
FIT-
NESS.
1..
Items furnished
by
MILLER.
but
manufactured
by
othirs.
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
It
Within
the
warranty
periods
listed
below. MILLER
will
repair
or
replace
any
war-
any.
ranted
parts
or
components
that tail due
to such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30) days
of such
defector
failure,
at
2..
Con~umabIe
components;
such
as
contact
lips,
cutting
nozzles.
contactora
which
lime
MILLER
will
provide
instructions
on
the
warranty
ciaim
procedures
lobe
and
relays.
followed.
3..
Equipment
that
has been
modified
by
any
party
other than
MILLER.
or
equip.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
tP,e
ment
that
has
been
improperfy Installed, improperly
operated
or
misused
event
of such
a
failure
within the
warranty
time
periods.
All
warranty
time
periods
based upon
industry
standards, or
equipment
which has
not
had reasonable
start
on
the
date that the
equipment
was
delivered
to
the
original
retail
purchaser,
and
necessary
maintenance,
or
equipment
which has been
used
for
operation
and
are as
follows:
outside oI
the
specifications
for the
equipment.
1..
5
Years
Parts
3
Years
Labor
MILLER
PRODUCTS
ARE INTENDED FOR
PURCHASE
AND
USE BY
COMMER
CIALJINDUSTRIAL
USERS AND PERSONS TRAINED
AND
EXPERIENCED
IN

Original
main
power
rectifiers
THE
USE
AND
MAINTENANCE OP
WELDING
EQUIPMENT.
2..
3
YearsParts
and
Labor
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies

Transformer/Rectifier
Power
Sources
shall
be.
at
MILLERS
optIon: (1)
repaIr;
or
(2) replacement; or.
where
authorized
In

Plasma
Arc
Cuffing
Power Sources
writing by
MILLER
inappropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replace-
*
Semi-Automatic
and
Automatic Wire Feeders
ment at
an authorized
MILLER
service station:
or
(4)
payment
of
or Credit forthe
pur
P
b
ts
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of the
0 0
goods
at
customers
risk and
expense.
MILLERS
option
of
repair
or
replacement
3..
2
Years

Parts
and
Labor
wilt
be
FOB..
Factory
atAppleton.
Wisconsin.
or
FOB.
ate
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse-
Engine
Driven
Welding
Generators
ment
for
transportation
costs
of
any
kind
will be
allowed.
(NOTE: Engines
are
warranted
separately
by
the
engine
manufacturer.)
4
,,,
~
TO
THE
EXTENT PERMITTED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
ear

arts
and
r
ARE THE
SOLE
AND EXCLUSIVE REMEDIES.
IN NO EVENT
SHALL
MILLER BE

Motor
Driven
Guns LIABLE
FOR
DIRECT, INDIRECT. SPECIAL,
INCIDENTAL OR
CONSEQUENTIAL

Process
Controllers
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON CON

Water
coolant
Systems
TRACT,
TORT OR
ANY
OTHER
LEGAL THEORY.

HF
Units
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN AND ANY
IMPLIED
WAR-

Grids
PANTY. GUARANTY OR REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
*
Spot
Welders
REMEDY
FOR
BREACH OF
CONTRACT
TORT OR
ANY
OTHER
LEGAL

Load
Banks
THEORY
WHICH,
BUT
FOR
THIS
PROVISION, MIGHT
ARISE BY
IMPLICATION.

SDX Transformers
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
*
Running
Gear/Trailers
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY AND ALL
EQUIPMENT

Field
Options
FURNISHED BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
(NOTE:
Field
options
are
covered under
True Blue
for
the
remaining
warranty
period
of the
product
they
are
Installed
in.
or
for
a
minimum
ot
Some
states
In the
U.S.A.
do
not
allow
limitations
of
how
long
an
Implied
warranty
one
year

whichever
is
greater.)
lasts,
or
the exclusion
of
Incidental,
Indirect,
special
or
consequential
damages,
so
the above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
ape-
5.. 6 Months

Batteries
cific
legal
rights,
and
other
rights
may
be
available,
but
may vary
from
state to slate.
6..
90
Days

Parts
and
Labor
.
in
Canada,
legislation
In
some
provinces
provides
for certain additional
warranties

I
or
remedies other than
as
stated
herein,
and
to the
extent
that
they
may
not
be
u 0 C
CS
waived,
the
limitations
and
exclusions
set
Out
above
may
not
apply.
This
Limited

Plasma
cutting
Torches
Warranty
provides
specifIc
legal
rights,
and other
rights
may
be
available,
but
may

Remote
Controls
vary
from
province
to
province.
_1
I WI,

AMENDMENT
TO
SECTION
9
PARTS
LIST
Amend
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs.
No. With
Description
Quantity
21-4
....
W
...
009 859
..
137 900
..
KIT,
contactor
(Eff w/KB022071)
1
21-25
081 016~.. Deleted
..
Effw/KB022071
1
~First
digit
represents
page
no

digits
following
dash
represent
item
no.
+Quantity
changes
for
090 716
Assembly
only.
BE
SURE TO PROVIDE MODEL
AND
SERIAL NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-317B
Page
2

OM.3178-2/gO
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam- Use the
following
spaces
to
record
the Model
Designa
age
that
may
have
occurred
duiing
shipment.
File
any
tion and
Senal
or
Style
Number
of
your
unit.
The
infor
claims for
loss
or
damage
with
the
delivering
carTler. mation
is located
on
the data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from the
distnbutor
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
4
1-4.
Standards
Booklet Index
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1
.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Woitis
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.
Remote
Amperage
Control
Receptacle
Information And
Connections
10
4-5.
Electrical
Input
Connections
10
SECTION
5-
OPERATOR CONTROLS
5-1.
Power
Switch
13
5-2.
Range
Switch
13
5-3.
AC/DC
Selector
Switch
13
5-4.
Amperage Adjustment
Control
13
5-5.
Remote
Amperage
Control
Switch
13
5-6.
Control
Circuit Overload
Breaker
13

Section
No.
Page
No.
SECTiON
6
SEQUENCE
OF
OPERATION
6-1.
ShIelded
Metal
Arc
Welding
(SMAW)
6-2.
Shutting
Down
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
Routine Maintenance
Oveiload
Protection
Thermal
Protection
Voltage
Reducer Circuit
Operation
Circuit
Board
Handling
Precautions
Troubleshooting
Chart
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
Diagram
8-2.
Circuit
Diagram
For
Firing
Board
PCi
Diagram
8-3.
Circuit
Diagram
For
Voltage
Reducer Board
PC2
SECTION
9
PARTS
LIST
Figure
9-1.
20
Figure
9-2.
22
Figure
9-3.
24
Figure
9-4.
25
Figure
9-5.
26
Figure
9-6.
28
Figure
9-7.
30
Figure
9-8.
30
Figure
9-9.
31
Figure
9-10.
32
Table
3-1.
7
Chart
3-1.
7
Chart
3-2.
8
Table
4-1.
9
Table
4-2.
11
Table
7-1.
15
Table
7-2.
16
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
14
14
14
15
15
15
15
16
17
17
18
Main
Assembly
Panel,
Front
-
w/Components
Switch,
PIrt
Switch,
Range
Circuit
Card,
MA
Control
PCi
Circuit
Card,
Voltage
Reducer
PC2
Switch,
PB
Rectifier,
Si
Diode
Panel,
Rear
-
w/Components
SCR Contactor
&
Primary
Terminal
LIST
OF
CHART
AND
TABLES
Specifications
Volt-Ampere
Curves
Duty
Cycle
Weld
Cable Size
Input
Conductor
And
Fuse
Size
Maintenance Schedule
Troubleshooting
Chart

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
safe
practices
may
cause
sen
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.
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 I
-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
avadab~e
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
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
perchioroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be drawn
into the
welding
or
cutting
OM-317
Page
1

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
cdmbustibles.
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
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 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
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
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
l-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.
Prohibited
use.
Never
use
a
cyinder
or
its
contents
for
other than its
intended
use,
NEVER
as
a
support
or
roUer.
OM-317
Page
2

Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
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 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
or worn
hose
by
cutting
area
out
and
splic
ing
(1 -2D3).
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
that the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and smooth
seats
where
necessary.
Tighten.
If
connection
leaks, disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your sup
plier)
between
cylinder
arid
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked
RIGHT
and LEFT
HAND
threads.
Reguiatoroutiet(orhose)
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 fully
to
seal
stem
against possible
leak.
For
fuel
gas,
open
to
less than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(availabe
from
your
supplier)
for
safe
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
afterlest;
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
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
bum.
*Trademark
of Proctor
&
Gamble.
OM-317
Page
3

1-3.
ARC WELDING
Comply
with
precautions
in
1-1, 1-2,
and
this
section.
Arc
Welding,
property
done,
is
a
safe
process,
but
a
careless
operator
invites trouble.
The
equipment
carnes
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.
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.
~ONT
GET
BURNED;
COMPLY
WITH
PRECAUTlOI~IS.
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
burns.
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.
B. Toxic
Fume Prevention
Comply
with
precautions
in
1
-2B.
Generator
engine
exhaust
must
be
vented
to
the outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
ExplosIon
Prevention
Comply
with
precautions
in
1
-2C.
Equipments
rated
capacity.
Do
not
overload
arc
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.
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
Safety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each unit
such
as
welding
power
source,
control,
worktable,
and
water
ci
r
culatorto the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-317
Page
4

electrically
HOT
by
stray
current
may
shock,
possibly
fa
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
conne~cted
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
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
opera
tion.
6.
Electrode
a.
Equipment
with
output
on/oft
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-oft
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.
It,
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.
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,
refertothefollowing
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
Rd, 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 Ameri
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.
OM-317
Page
5

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.
7.
AWS
Standard
A6.O,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES obtainable
from the American
Welding
So
ciety,
550
N.W. LeJeune
Ad, 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,
Qui
ncy,
MA
02269.
9.
NFPA
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
l~s#ationaI
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 Jef
ferson 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
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-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
32.
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 for
the
safe
and
effective
use
of
this
equipment.
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
the front
panel
controls.
The
symbols
also
appear
at
the
appropriate
section
in
the
text.
33.
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
identify
different levels
of
hazard
and
special
instruc
tions.
a
This
safety
alert
symbol
is
used
with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
a
WARNING
statements
identify
procedures
or
practices
which
must
be followed
to
avoid seri
ous
personal
injury
or
loss
of
life.
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
necessaiy
for the
most
efficient
operation
of this
equip
ment.
OM-31
7
Page
6

SECTION
3
SPECIFICATIONS
Table
3-1.
SpecIfications
NEMA
Class
1(60)
Rated
Output
At
60%
Duty_Cycle
WeldinF
Range
n
Amperes
Reduced
Open-
Circuit
voltage
Max.
open-
Circuit
voltage
Amperes
in~ut
At
Rated
Load
utput*

60 Hz
Single-Phase
200V
230V 460V
575V kva
kw
Weight
Net
Ship
400
Amperes
At 32
Volts
AC/DC
50-500
AC
36
AC
80
AC
150
130 65 52
29.9 22.8
650
I
bs.
(295
kg)
670
lbs.
(304
kg)
45-400
DC
32
DC
72
DC
IMPORTANT:
The
power
factor
correcting
capacitors supplied
in
this
product
contain
no
PCB
s.
The
dielectric
ma
terial
is
an
OSHA
class
Ill B
fluid
having
a
f4~sh
point
of
44~?
F
(227~ C).
Each
individual
capacitor
is
protected
by
an
internal
UL
recognized
pressure
sensitive disconnect
and
an
internal
fuse.
inches
Millimeters
A
2.1/2
64
B
26
660
C
7/16
11
D
19
483
E
16-3/4
425
F
1-1/8
29
G
35-3/4
908
H
32-3/4
862
I
1-1/2
38
TC-087
183
Figure
3-1.
Overall
Dimension
And
Base
Mounting
Hole
Layout
90
60
70
60
cn
I-.
50
>
~
40
30
20
l0
Chart
3-1.
Volt-Ampere
Curves
100
200
300 400 500
600
700
000
DC
AMPERES
8.085
715
300
400
AC
AMPERES
600 700
8-085
692
OM-31
7
Page
7

Chart
3-2.
Duty
Cycle
3-2. DUTY
CYCLE
(Chart
3-2)
600
~
500
4
400
z
0
300
3-1.
VOLT-AMPERE
CURVES
(Chart 3-1)
(34.
RATED
OUTPUT
The
volt-ampere
curves
show
the
voltage
and
amper
age
output
capabilities
of
the
welding
power
source.
Voltage
and
amperage
adjustment
is
provided
by
the
AMPERAGE
ADJUSTMENT
Control. Curves
of other
settings
fall
between
the
curves
shown.
With the
use
of
the
volt-ampere
curves,
it
is
possible
to
determine
the
weld
amperage
at
any
particular
load volt
age.
The
duty cycle
is the
percentage
of
a
ten
minute
period
that
a
welding
power
source can
be
operated
at
a
given
output
without
overheating
and
damaging
the
unit. This
welding
power
source
is rated
at
60%
duty
cycle
when
operated
at
400
amperes.
The unit
can
be
operated
at
400
amperes
for six
consecutive
minutes,
but
it
must
op
erate
at
no
load
for
the
remaining
four
minutes
to
allow
proper
cooling.
If
the
welding
amperes
decrease,
the
duty cycle
increases.
Refer
to
the
Duty
Cycle
chart
(Chart
3-2)
to
determine
the
output
of the
welding
power
source
at
various
duty
cycles.
3-3.
DESCRIPTION
This unit
produces
constant current
ac/dc weld
output
for the
Shielded
Metal Arc
Welding
(SMAW)
process.
This unit
requires
single-phase
input
power
of
the volt
age
specified
on
the
nameplate.
Rated
output
is 400
amperes,
36
volts
ac/dc
at
60%
duty
cycle.
This
unit is
equipped
with
a
voltage
reducer which
maintains terminal
open-circuit voltage
at
32
volts
DC
or
36
volts
Ac when the unit
is
energize
but
not
actually
welding.
SECTION
4-
INSTALLATION OR
RELOCATION
4-1.
SITE
SELECTION
Select
an
installation site
which
provides
the
following:
1. Correct
input
power supply
(see
unit
nameplate)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No flammables
6.
A
clean and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around unit
9.
Adequate
space
for
removing
top
cover
and
outer
panels
for
installation,
maintenance,
and
repair
functions.
OM-317
Page
8
Base
mounting
holes
provide
the
capability
to
install
and
secure
the
unit
on a
running
gearorin
a
permanent
loca
tion.
Figure
3-1
gives
overall dimensions
and
base
mounting
hole
layout.
a
WARNING:
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on or
over
combustible
surfaces;
RESTRICTED AIRFLOW
can
cause
overheating
and
possible
damage
to
Internal
parts.

Do
not
locate
unit
overcombustible surfaces.

Maintain
at
least
18
inches
(457
mm)
of
unrestricted
space
on
all sides of
unit,
and
keep
underside free
of
obstructions.

Do
not
place
any filtering
device
over
the
in
take
air
passages
that
pro
vide
airflow for
cooling
this unit.
Warranty
is
void
if
any
type
of
filtering
device
is
used
at
intake
air
passages.
800
700
MODEL
GOLD
STAR
600Ss
200
20 25
40055
30055
30 35
40
50
60 70 80 90
100
%
DUTY CYCLE
B-000865.C
a
CAUTION:
EXCEEDING
DUTY
CYCLE
RATINGS
will
damage
the
welding
power
source.

Do
not
exceed
indicated
duty
cycles.

4-2.
TRANSPORTING
METHODS
This
welding
power
source
is
equipped
with
a
lifting
eye
for
moving
the
unit
during
installation.
Weight
capacity
of
the
lifting
eye
only
allows
for
supporting
the
welding
power
source.
a
WARNING:
ELECTRIC
SHOCK can
kill.

Do
not
touch
live
electrical
parts.

Disconnect
input
power
conductors
from
deenerg
ized
supply
line
BEFORE
moving
weld
ing
power
source.
FALLING
EQUIPMENT
can cause
serious
personal
Injury
and
equipment
damage.

Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
heavy
accessories
or
devices.

Use
equipment
of
adequate
capacity
to
lift
the unit.
I

If
lifting
or
moving
this
unit
with
lift forks under
the
base,
be
sure
that
lift
forks
are
long
enough
to extend
beyond
opposite
side of the
base.
Using
lift
forks too
short
can
damage
internal
parts
if
tips
of the
lift
forks
penetrate
the unit
base,
or
may
cause
personal
injury
and/or
equipment
damage
if
unit
falls
off the
lift
forks.
4-3.
WELD
OUTPUT
CONNECTIONS
(FIgure
4-1)
RATED
OUTPUT
To
obtain full rated
output
from this
unit,
it
is
necessary
to
select,
prepare,
and install
proper
weld
cables.
Fail-
ure
to
comply
in
any
of
these
areas
may
result
in
unsatis
factory
welding
performance.
A. Weld
Cable
Selection
Use
the
following guidelines
to
select
weld
cables:
1.
Use the shortest
possible
cables,
and
place
cables
close
together.
Excessive
cable
lengths
may
re
duce
output
or
cause
unit
overload due
to
added
re
sistance.
2.
Use
weld cable
with
an
insulation
voltage rating
equal
to
or
greater
than
the maximum
open-circuit
voltage
(ocv)
of the
welding
power
source
(see
Table
3-1
for
unit
maximum
ocv
rating).
3.
Select
welding
cable size
according
to
maximum
weld
output
and total
length
of
connecting
cables
in
weld
circuit.
For
example,
if
a
25
foot
(7.5
m)
elec
trode
holder cable
is
used
with
a
25
foot
(7.5
m)
work
cable,
select the
cable
size
recommended
in
Table
4-1
for
50 feet
(15
m).
4.
Do
not
use
damage
or
frayed
cables.
Weld
Cable
Preparation
Install
terminal
lugs
of
adequate
amperage
capacity
and
correct
stud
size
onto
cables that
connect
to
the
work
clamp,
electrode
holder,
and
weld
output
ter
minals.
2.
When
installing
an
electrode
holder,
follow
manu
facturers
installation instructions.
Always
use
an
in
sulated
electrode holder
to
ensure
operator
safety.
3.
Install
work
clamp
onto
cable.
Table
4-1.
Weld Cable
Size
Total Cable
(Copper)
Length
In
Weld Circuit
Not
Exceeding*

100 ft.
Or
Less
150 It. 200
ft.
250
ft.
300
ft.
350 ft. 400
ft.
(30
m)
(45 m)
(60
m)
(70
m)
(90
m)
(105
m)
(120
m)
10 To
60%
60
Thru
100%
10
Thru
100%
Duty Cycle
Duty Cycle Duty
Cycle
4
3
3
2
1
1/0
1/0
2/0
3/0
4
3
2
1
1/0
2/0
2/0
3/0
4/0
4
2
1
1/0
2/0
3/0
3/0
4/0
2-2/0
3
1
1/0
2/0
3/0
4/0
4/0
2-210
2-3/0
2
1/0
210
3/0
4/0
2-2/0
2-2/0
2-3/0
2-4/0
1
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
*weld
cable size
(AWG)
is based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
more
than
300 circular
mils
per ampere.
S0007/8-88
B.
1.
OM-317
Page
9

WARNING:
ELECTRIC SHOCK can
kill.

Do
not
touch
IWe
electrical
parts.

Shut
down
welding
power
source,
and
dis
connect
input
power
employing lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tag9ing
circuit breaker
or
other discon
necting
device.
Socket
E:
Amperage
control
connection
(wiper
con
tact).
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
3-0005
Figure
4-2. Front View
Of
5-Socket
Amphenol
Re
ceptacle
With Socket
Locations
1.
Open
lower
front
access
doorto
gain access
to
weld
output
terminals.
2.
Connect electrode
holder
cable
to
ELECTRODE
output
terminal.
3.
Connect
one
end
of
work cable
to
WORK
output
ter
minal.
I
I
Work
Electrode
Output
Output
Terminal Terminal
R~. TA-087
338
Figure
4-1.
Lower Front Panel
View With
Access
Door
Open
4-4.
REMOTE
AMPERAGE CONTROL RECEPTA
CLE
INFORMATION
AND
CONNECTIONS
(Figure
4-2 And
Figure
5-1)
REMOTE
A
AMPERAGE
The
five-socket
Amphenol
REMOTE AMPERAGE
con
trol
receptacle
RC1
is
usedto
connect
a
Remote
Amper
age
Control
to
the
control
circuitry
of
the
welding
power
source.
To
connect
the Remote
Amperage
Control
to
the
REMOTE
AMPERAGE
control
receptacle, align
keyway,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
Receptacle
Rd
socket connections
to
the
welding
power
source
control
circuitry
are
as
follows:
Socket
C:
Amperage
control connection
(maximum
Socket
D:
Amperage
control
connection
(minimum
side).
4-5.
ELECTRICAL
INPUT
CONNECTIONS
INPUT
AA
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
welding
power
source,
and
dis
connect
input
power
employing lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist of
padlocking
line
disconnect switch
in
open
posi
tion,
removing
fuses
from fuse
box,
or
shutting
ott
and
red-tagging
circuit breaker
or
other.dis
connecting
device.
A.
Electrical
Input Requirements
Operate
the
welding
power
source
from
a
single-phase,
60
Hertz,
ac
power
supply.
The
input
voltage
must
match
one
of
the
electrical
input
voltages
shown
on
the
input
data label
on
the
unit
nameplate.
Contact
the local
electric
utility
for
information about
the
type
of electrical
service
available,
how
proper
connections should be
made
and
inspection required.
B.
Jumper
Link
Installation
(Figure
4-3)
a
WARNING:
Read
precautionary
InformatIon
at
beginning
of
entire
Section
4-5
before
pro
ceeding.
Jumper
links
are
used
to
allow the
equipment
to
operate
from different line
voltages.
The
jumper
links
may
be
in
a
bag
attached
to
the
input
terminal
board
or
installed
on
the
input
terminal board
for
the
highest voltage
shown
on
the
input voltage
label.
1.
Remove
right
side
panel.
2.
Compare
position
of
jumper
links
on
the
inputtermi
nal
board
to
the
voltage
link
arrangement
shown
on
input voltage
label.
C.
Weld
Cable
Connections
(Figure
4-1)
W RK
ELECTRODE
0
I
O~O O~O
side).
OM-317
Page
10

4A
CAUTION:
INCORRECT
INPUT
VOLTAGE
JUMPER
LINK
PLACEMENT
can
damage
unit.

Position
jumper
links
as
shown on
the
input
voltage
label
(see
Figure
4-3).

Store unused
jumper
links
across
linked
ter
minals.
3.
Install
jumper
links
onto
the
input
terminal board to
match
the
available
input
line
voltage.
C.
Welding
Power
Source
Input
Power
Connec
tions
(FIgure
4-3)
a
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not touch
live
electrical
parts.

Install
a
fusible
line
disconnect
switch
in
the
input
circuit
to
the
welding
power
source.

Connect
input
conductors
to
the
welding
powersource
before
connect
ing
to
single-phase
input
power.

Read and
follow
safety
in
formation
at
begin
fling
of
entire
Section
4-4
before
proceeding.
The
line
disconnect
switch
provides
a
sate
and
convenient
means
to
completely
remove
all
electrical
power
from the
welding
power
source
whenever
it is
necessary
to
inspect
or
service
the unit.
Input
Voltage
220
230
460
575
Input
Conductor
Size
(AWG)
1/0
1
6
6
Ground
Conductor
Size_(AWG)
6
6 88
Fuse
Size
In
Amperes
225 200
150 80
*Conductor
size
is based
on
the
1987
Edition
of
the
National
Electrical Code
(NEC) specifications
for
allowable
am
pacities
of
insulated
copper
conductors,
having
a
tempera
ture
rating
of 167F
(75C),
with
not
more
than
three
single
current-carrying
conductors
in
a
raceway
(Article
310
of
NEC). (The
ground
conductor is not counted
as a
current-
carrying conductor.)
¶use
size
is
based
on
not
more
than 200
percent
of
the
rated
input
amperage
of
the
welding
power
source
(Article
630
of
NEC).
S.~2/4.8a
1.
Use
Table
4-2
as a
guide
to
select
input
conductors
for
the
installation. The
input
conductors
should
be
covered
with
an
insulating
material
that
complies
with
national,
state,
and local codes.
2. Install
terminal
lugs
of
adequate
amperage
capacity
and
correct
stud
size
onto
the
input
and
ground
con
ductors.
Table 4-2.
input
Conductor
And
Fuse
Slze*
Ground
IGreen)
Conductor
Input
Terminal
Board With
Jumper
Rear
Panel
Access
Hole
-
1-3/4
in.
(44
mm) Dia.
Input Voltage
Terminal Board
Terminal
Figure
4-3.
LocatIon Of
Electrical
Input
Conductor
Connections
And
Components
Ret: TB-ill
134
OM-317
Page
11

a
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not
connect
an
input
conductor to
the
ground
terminal
in
the
unit.

Do
not
connect
the
ground
conductor
to
an
in
put
line
terminal.
Incorrect
input
connections
can
result
in
an
elec
trically
energized
welding
power
source
chas
sis.
The
ground
terminal
is
connected
to
the
welding
power
source
chassis
and is for
ground
ing
purposes
only.
Install
and
connect
input
and
ground
conductors
as
fol
lows:
3.
Obtain and
install
a
standard conduit
strain
relief
connector
into the
rear
panel
access
hole.
4.
Insert
conductors
through
strain
relief installed
in
Step
3,
and
route
conductors
to
input
terminal
board.
5.
Connect
input
conductors
to
the line
terminals
on
the
input
terminal board
(see
Figure
4-3).
6.
Connect
ground
conductor
to
ground
terminal
(see
Figure
4-3).
7.
Connect
remaining
end
of
ground
conductor
to
a
suitable
ground.
Use
a
grounding
method
that
com
plies
with
all
applicable
electrical
codes.
8.
Connect
remaining
ends
of
input
conductors
to
a
deenergized
line
disconnect
switch.
9.
Secure
input
cable
in
strain
relief.
10. Reinstall
right
side
panel.
11.
Use
Table
4-2
as
a
guide
to
select
line
fuses
for
the
disconnect
switch.
Obtain
and
install
proper
fuses.
SECTION
5-
OPERATOR
CONTROLS
Figure
5-1. Front
Panel
Controls
TA-087
338
AC/DC
Selector
Switch
Range~
Switch
Output
Terminal
Switch
OFF
Push
Button
Remote
Amperage
Receptacle
Amperage
Adjustment
Control
OM-317
Page
12

REMOTE
AMPERAGE
ON
OFF
10
5-1.
POWER
SWITCH
(Figure
5-1)
5-4.
AMPERAGE ADJUSTMENT
CONTROL
POWER
ON
~j
0
OFF
(FIgure
5-1)
A
AMPERAGE
ADJUSTMENT
Pressing
the
Power
switch
ON
push
button
energizes
the
welding
Power
source.
The
fan
motor
starts
indicat-
ing
that
the
unit
is
receiving
input
power.
The
AMPERAGE ADJUSTMENT
control
provides
fine
amperage
adjustment
within
the
range
selected
on
the
RANGE
switch. Rotatethe
control
clockwise
to
increase
Pressing
the
Power
switch
OFF
push
button
shuts down
amperage
output.
The scaie
surrounding
the
control
is
the
welding
power
source
and
fan.
calibrated
in
ac/dc
amperes
for the
Shielded
Metal Arc
IMPORTANT:
After
any
interruption
of
input
power,
the
Welding
(SMAW)
process.
Power
switch
ON
push
button
must
be
pressed
to
IMPORTANT:
The
AMPERAGE
ADJUSTMENT
con
reenergize
the
welding
power
source.
trol
may
be
adjusted
while
welding.
5-2.
RANGE
SWITCH
(Figure
5-1)

4~
CAUTION:
ARCING
can
damageswitch
con-
tacts.

Do
not
change
position
of
Range
switch
while
5-5.
REMOTE
AMPERAGE
CONTROL
SWITCH
(Figure
5-1)
welding
or
under
load.
The
Range
switch
provides
a
means
of
selecting
one
of
three
coarse
amperage
ranges.
The
amperage ranges
are
displayed
on
the
nameplate.
If
the desired
amper
age
is
in
the
overlapping
area
of
two
ranges,
use
the
lower
range
for
better
fine
amperage
control.
5-3.
AC/DC
SELECTOR
SWITCH
(Figure
5-1)
STRAIGHT
REVERSE
POLARITY
AC
POLARITY
a
WARNING:
ELECTRIC
SHOCK
can
kill.

In
wet
or
confined
areas,
use
only
DC
output
or
remote
output
controL

Read
Safety
Rules
at
beginning
of
this
man
ual.
The
AC/DC
Selector switch
allows the
operatorto
select
AC,
ELECTRODE
POSITIVE,
or
ELECTRODE NEGA
TIVE
output
without
changing
weld
output
cable
con
nections.
To
ensure
that weld
output
matches the
dc
p0-
larity
positions,
make
weld
output
connections
as
in
structed
in
Section
4-3.
a
CAUTION: ARCING
can
damage
switch
con
tacts.

Do
not
change
the
position
of
the
AC/DC Se
lector
switch
while
welding
or
under load.
Arcing
causes
the
contacts to
become
pitted
and
eventually
inoperative.
If
remote
amperage
control is
desired,
make
connec
tions
to
the
REMOTE AMPERAGE control
receptacle
as
instructed
in
Section
4-4.
Place the
REMOTE
AM
PERAGE
switch
in
the
ON
position.
When
remote
amperage
control
is
used,
the
Remote
Amperage
control
has
complete
control
of
the
output
re
gardless
of
the
position
of
the
AMPERAGE ADJUST
MENT
control
on
the
welding
power
source.
If
remote
amperage
control is
not
desired,
place
the
RE
MOTE
AMPERAGE
control
switch
in
the OFF
position.
Only
the
AMPERAGE
ADJUSTMENT
control
on
the
front
panel
then
regulates
the
output.
5-6.
CONTROL
CIRCUIT
OVERLOAD
BREAKER
(Figure
5-1)
CONTROL CIRCUIT
~L
CLOSED
OVERLOAD
BREAKER
£1
OPEN
The
control
circuit
is
protected
by
a
manual
reset
CON
TROL CIRCUIT
OVERLOAD BREAKER.
If
this
circuitry
is
overloaded,
the
overload breaker
opens
shutting
down
the
welding
power
source.
See Section
7-2
for
re
setting
procedures.
OM-317
Page
13

SECTION
6

SEQUENCE
OF OPERATION
4A
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can cause
serious
Injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
Internal
parts.

Do
not
touch
live electrical
parts.

Keep
all
covers
and
panels
in
place
while
op
erating.
Warranty
is
void
if
the
welding
power
source
is
operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.

Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.

Keep
your
head
out
of
the
fumes.

Ventilate
to
keep
from
breathing
fumes and
gases.

If
ventilation
is
made
quate,
use
approved
breathing
device.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire and burns.

Watch for fire.

Keep
a
fire
extinguisher
nearby,
and know
how
to
use
it.

Do
not
use near
flammable
material.

Allow
work and
equipment
to
cool before han
dung.
MAGNETIC FIELDS
FROM HIGH CURRENTS
can
affect
pacemaker
operation.

Wearers should consult their
doctor
before
going
near
arc
welding, gouging,
or
spot
welding
operations.
See Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power Source for basic
welding
safety
information.
6-1.
SHIELDED
METAL
ARC
WELDING
(SMAW)
1.
install and
connect
unit
according
to
Section 4.
2.
Place
the
Range
switch
in
desired
position
(see
Section
4-2).
a
WARNING:
ELECTRIC SHOCK
can
kill.

In
wet
or
confined
areas,
use
only
DC
output
or
remote
output
control.

Read
Safety
Rules
at
beginning
of this
man
ual.
3.
Place
the
AC/DC
Selector
switch
in
desired
position
(see
Figure
5-1).
4.
If
remote
amperage
control
is
not
used,
place
the
REMOTE AMPERAGE
switch
in
the
OFF
position.
If
remote
amperage
control
is
to
be
used,
place
the
REMOTE
AMPERAGE switch
in
the
ON
position
(see
Section
5-5).
5.
Rotate
the
AMPERAGE
ADJUSTMENT
control
or
the
Remote
Amperage
Control,
if
applicable,
to
the
desired
position
(see
Figure
5-1).
6.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet with
proper
filter
lens
according
to
ANSI
Z49.1.
7.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and obtain
proper
electrode,
and
insert
into
electrode
holder.
8.
Depress
the
POWER
switch
ON
push
button
(see
Section
5-1).
9.
Begin welding.
6-2.
SHUTTING DOWN
1.
Stopwelding.
2.
Depress
the
POWER
switch
OFF
button.
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
welding
power
source,
and
dis
connect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect switch
in
open
position,
removing
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
discon
necting
device.
7-1.
ROUTINE
MAINTENANCE
(Table
7-1)
IMPORTANT:
Every
six months
inspect
the
labels
on
this unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
precautionary
labels.
OM-317
Page
14