Miller INTELLIMATIC S-52M User manual

Millerfi
May1994
Form:
OM-1547H
Effective
With
Serial
No. KE621
826
OWNERS
MANUAL
INTELLIMATICTM S-52M
And
S-54M
u
Read and follow these instructions
and
all
U
Give
this
manual
to
the
operator.

safety
blocks
carefully.
Have
only
trained and
qualified
persons
install,
operate,
or
service this
unit.

U
For
help,
call
your
distributor

Call
your
distributor
if
you
do
not
understand
I~J

or:
MILLER Electric
Mfg.
Co.,
P.O.
Box
1079,
the
directions.
Appleton,
WI 54912
414-734-9821
cover
1194
-
SC-090 864-C
'
1994
MILLER Electnc
Mfg.
Co.
PRINTED
IN
USA

MILLERS TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This limited
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
I!
LIMITED
WARRANTY

Subject
to
the
terms
and
conditions
below,
MILLER Electric
Mtg.
Co.,
Appleton,
Wisconsin,
warrsnts
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date ot
this
limited
warranty
Is
tree
ot de
tects
in
material
and
workmanship
at the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDINO
THE WARRANTIES
OF
MERCHANTABILITY AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to such
detects
in
material
or
workmanship.
MILLER
must
be
notitied
in
writing
within
thirty
(30) days
ot
such
detect
or
taiture,
at
which time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
tollowed.
al
MILLER shall honor
warranty
claims
on
warranted
equipment
listed below
in
the
event
ot
such
s
tailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor.
1.
5YeersPerte-3YeersLabor

Original
main
power
rectitiers
2.
3 Years

Parts
and
Labor

Trenatormer/Rectitier
Power
Sources

Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic Wire
Feeders

Robots
3.
2 Years

Parts
and
Labor

Engine
Driven
Wetding
Generators
(NOTE:
Engines
era
warranted
separately by
the
engine
menutecturer
tore
period
ot
two
years.)

Air
Compreeeors
4. 1
Year

Parts end Labor

Motor Driven
Guns

Process Controllers
*
Water Coolant
Systems

HF
Units

Grids

Spot
Wetdera

Load
Benke
*
SDX
Trenatormera
*
Running
Gear/Trailers

Field
Options
(NOTE:
Field
options
ere
covered under
True
BIueTM
tor
the
remaining
warranty
period
ot
the
product
they
are
installed
in,
or
tore
minimum
ot
one
year

whichever
is
greeter.)
5.
6
Months

Benenea
6. 90
Days

Parts
end
Labor

MIG
Guna/TIG Torches

Plasma
Cutting
Torches
-

Remote Controls

Accessory
Kite

Replacement
Parts
MILLERS
True
BlueTM
Umited
Warranty
shell
not
apply
to:
1.
Iteme tumiahed
by
MILLER,
but
menutectured
by
others,
such
as
engines
or
trade
acceaeoriee.
These
items
are
covered
by
the
menutecturere
warranty,
it
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contectors
end
relays
or
parts
that
teil due
to
normel
wear.
3.
Equipment
that has
been moditied
by
any
perty
other then
MtLLER,
or
equi~i
ment
that has been
improperly
installed,
improperiy opereted
or
misused
based upon
industry
standards,
or
equipment
which has
not
had
reasonable
end
necessary
maintenance,
or
equipment
which has been ueed tor
operation
outside
ot
the
epeciticetions
tor
the
equipment.
MILLER
PRODUCTS ARE
INTENDED FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL USERS
AND
PERSONS
TRAINED AND
EXPERIENCED
IN
THE USE AND MAINTENANCE OF
WELDING
EOUIPMENT.
In
the
event
ot
a
warranty
claim covered
by
this
warranty,
the exclusive remedies
shall
be.
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the reasonable
coat
ot
rerair
or
replace
ment
et
en
euthorized MILLER
service
station;
or
(4)
payment
ot
or
ciodit
tor
the
pur
cheae
price
(lees
raeeonable
depreciation
based
upon
actual
use)
upon
return
ot
the
goode
at
customers risk end
expense.
MILLERS
option
ot
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
eta
MILLER
authorized
eer
vice
tacility
as
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
tor
transportation
coats
ot
any
kind
wilt
be
allowed.
TO THE EXTENT PERMITTED
BY
LAW,
THE
REMEDIES PROVIDED HEREIN
ARE THE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
HO
EVENT
SHALL
MILLER BE
LIABLE
FOR
DIRECT, INDIRECT, SPECIAL,
INCIDENTAL
OR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND ANY
REMEDY FOR
BREACH
OF CONTRACT TORT OR
ANY
0rHER
LEGAL
THEORY
WHICH,
BUT
FOR THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION OF
LAW,
CUSTOM OF
TRADE
OR COURSE OF
DEALING,
IN
CLUDING
ANY IMPLIED WARRANTY OF
MERCHANTABILITY
OR
FITNESS
FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO ANY
AND
ALL EOUIPMENT
FURNISHED
BY
MILLER IS EXCLUDED AND
DISCLAIMED
BY MILLER.
Some
states
In
the
U.S.A.
do
not
allow
imitations
ot
how
long
en
implied
warranty
lasts,
or the
exclusion ot
incidental,
indirect,
special
or
consequential
damages,
so
the
above limitation
or
exclusion
may
not
apply
to
you.
This warranty
provides
ape
citic
legal rights,
end other
rights
may
be
available,
but
may
very
trorn
state to
state.
In
Ceneda,
tegietetion
in
some
provinces provides
br certain additional warranties
or remediee
other
then
as
stated
herein.
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
end exclusions
aet out
above
may
not
apply.
This
Limited
Warranty provides apecitic leget
rights,
end other
rights
may
be
available,
but
may
vary
trom
province
to
province.
I.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier. Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation Department.
When
requesting
information about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit. The information is located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
9/93

EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1

SAFETY
RULES FOR OPERATION
OF ARC WELDING POWER SOURCE
1
1
7
11
12
12
13
14
14
14
16
16
17
17
18
18
21
21
22
22
22
23
23
23
23
23
24
24
24
24
24
24
OM-1
547H
-
5/94
NOTE
~
I
Considerations About
Magnetic
Fields
The
following
is
a
quotation
from
the
General Conclusions Section
Welding
And
The Effects Of Low
Frequency
Electric And
To reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
procedures:
Effects of Power
Frequency
Electric
&
Magnetic
Fields

Background
Paper,
OTA-BP-E-53
(Washington,
DC: U.S.
Government
Printing
Office,
May
1989):
U
there is
now a
very
1.
Keep
cables close
together by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side and
away
from the
operator.
large
volume
of scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables around
the
body.
cellular level and from studies
with
animals and
people
which
clearly
establish
that low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of this
work is
of
very
high quality,
the results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the evidence
in
a
4.
Keep
welding
power
source
and cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the weld
as
possible.
single
coherent
framework. Even
more
frustrating,
it
does
not
yet
About Pacemakers:
allow
us
to
draw definite conclusions about
questions
of
possible
The
above
procedures
are
among
those
also
normally
risk
or
to
offer
clear science-based advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor for
or
avoid
potential
risks.
complete
information.
modlO.1
4/93
1-1.
Introduction
1-2.
General Precautions
1-3. Arc
Welding
1-4.
Standards
Booklet Index
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information And
Safety
2-2.
Safety
Alert Symbol And
Signal
Words
SECTION
3
SPECIFICATIONS
3-1.
Description
SECTION 4INSTALLATION OR
RELOCATION
4-1. Location
4-2.
Hub Installation
4-3.
Wire
Guide
And Drive Roll
Installation
4-4.
Welding
Gun Connections
4-5.
Voltage
Sensing
Connections
4-6.
Shielding
Gas Connection
4-7.
Drive Motor
Vent
Screw
4-8.
Current
Relay (Reed Switch)
4-9.
Internal
Program Options
4-10.
Welding
Power
Source/Wire
Feeder
Connections
4-11.
Welding
Wire Installation
4-12.
Welding
Wire
Threading
SECTION
5
OPERATOR CONTROLS
5-1.
Power
Switch
5-2.
Key-Switch
5-3.
Program
Select Push
Button
5-4.
Purge
Push
Button
5-5.
Sequence
Advance Push
Button
5-6.
Program
Sequence
Indicator
Lights
5-7.
Jog/Hours
Push Button
5-8.
Volts Numeric
Display
5-9.
Volts
Increase
And Decrease
Push
Buttons
5-10.
Wire
Speed
Numeric
Display
5-11.
Wire
Speed
Increase
And Decrease
Push
Buttons
5-12.
Program/Time
Numeric
Display
5-13.
Time Increase
And Decrease
Push
Buttons

SECTION
6-
PRESETTING SEMIAUTOMATIC
WELDING
PROGRAMS
6-1.
Definition
Of Terms
24
6-2.
Presetting
Semiautomatic
Welding
Programs
25
SECTION
7
SEQUENCE
OF OPERATION
7-1.
Normal
Welding
Without Dual
Scheduling
.
26
7-2.
Dual
Scheduling Using
The
Gun
Trigger
.
27
SECTION
8-
MAINTENANCE
&
TROUBLESHOOTING
8-1.
Routine Maintenance
29
8-2.
Aligning
Drive Rolls
And Wire
Guide(s)
On
Two
Drive
Roll Models
30
8-3.
Aligning
Motor
Gear
And
Drive Gears
On
Four
Drive
Roll Models
30
8-4.
Reinstallation
Of
Hub
Assembly
31
8-5.
Overload Protection
31
8-6.
Brush
Inspection
And
Replacement
32
8-7.
Diagnostic Displays
33
8-8.
Microprocessor
Battery
33
8-9.
Clearing
The Weld
Program Memory
(RAM)
33
8-10. Encoder
Disc
Cleaning
33
8-11.
Circuit
Board
Handling
Precautions
34
8-12.
Troubleshooting
34
SECTION
9
ELECTRICAL
DIAGRAMS
Diagram
9-1.
Circuit
Diagram
For Wire Feeder
38
Diagram
9-2.
Wiring Diagram
40
SECTION
10
PARTS
LIST
Figure
10-1.
Main
Assembly
42
Optional Equipment
44
Figure
10-2.
Wire Drive &
Gears
45
Figure
10-3. Wire Drive &
Gears
46
Figure
10-4.
Control
Box
48
LIST
OF CHARTS AND TABLES
Table
3-1.
Specifications
13
Table
6-1.
Program
Steps
25
Table
8-1.
Maintenance Schedule
29
Table
8-2.
Self-Diagnostic
Checks
35
Table
8-3.
Troubleshooting
36
Table
10-1.
Drive Roll
& Wire
Guide
Kits
(2
Drive
Roll)
51
Table
10-2.
Drive Roll & Wire
Guide Kits
(4
Drive
Roll)
..
52

SECTION
1
-
SAFETY
RULES
FOR OPERATION OF
ARC
WELDING
POWER SOURCE
SECTION
1
- REGLES
DE
SECURITE
POUR
LE
FONCTIONNEMENT
DU
POSTE
DE
SOUDAGE
A
LARC
1-1.
INTRODUCTION
-
We
learn
by
experience.
Learning
safety through personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise.
Let
the
experience
of
others teach
you.
Safe
practices developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
for the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It is
wiser
to
follow the
rules.
Read and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death. When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These safe
practices
are
divided into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also available for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this manual.
ANSI
Z49.1 is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2. GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
different
fumes,
gases,
and
radiation levels. In
addition
to
the
information
in
this
manual,
be
sure
to
consult
flux
and elec
trode manufacturers
for
specific
technical data
and
precautionary
measures
concerning
their
material.
A. Burn Prevention
Wear
protective
clothing
-
gauntlet
gloves
designed
for
4
use
in
welding,
hat,
and
high
safety-toe
shoes. Button
shirt collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear helmet with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
1-1.
INTRODUCTION
-
Contrairement
a
lappren
tissage
de Ia
vie,
lapprentissage
de Ia
sØcuritØ
par
ex
pØrience
personnelle,
comme
lenfant
qul
touche
un
poŒle
chaud,
est
dangereux,
imprudent
et
inutile.
lnstruisez-vous donc
de
lexpØrience
dautrui.
Des
mØthodes de
sØcuritØ
issues
de
lexpØrience
du
soudage
et
du
coupage
sont
dØcrites
dans le
manuel.
La
recherche,
le
progres
et
lexpØrience
dans
ce
domaine
ont
dØveloppØ
un
materiel
fiable
et
des
mØthodes
de
sØcuritØ
pour
installation,
le
fonctionnement
et
lentre
tien.
Des
accidents
se
produisent
lorsque
le materiel
est
inadØquatement
utilisØ
ou
entretenu.
La
raison
de
ces
mØthodes
de
sØcuritØ
peut
ne
pas
Œtre
toujours
donnØe.
Certaines
sont
fondØes
sur
le
sens
commun,
dautres
demanderont
a
Œtre
expliquees
par
des livres
techni
ques.
II
est
plus
sage de
suivre
es
regles.
Lisez
et
comprenez
ces
mØthodes
de sØcuritØ
avant
dessayer
dinstaller,
de
faire
fonctionner
ou
de
rØparer
lappareil.
Pour
votre
sØcuritØ
personnelle
et
celle
dautrui,
conformez-vous
a
ces
rŁgles
et
aux
manuels
dinstructions.
Manquer
dobserver
ces
mØthodes de sØcuritØ
pourrait
entrainer
des blessures
graves
ou
mŁme Ia
mort. Quand
Ia
sØcuritØ
devient
une
habitude,
le materiel
peut
alors
Œtre
utilisØ
en
toute
confiance.
Ces mØthodes
de sØcuritØ
sont
divisØes
en
deux
sec
tions:
1
-
Precautions
genØrales,
communes
au
soudage
et
au
coupage
a
larc,
et
2
-
Soudage
a larc
(et
coupage)
(uniquement).
Normes de
rØfØrence:
Des
publications
des
normes
amØricaines
de
sØcuritØ
sont
aussi
a
votre
disposition
pour
dautres
modes
opØratoires
plus
complets
que
ceux
du
present
manuel. Elles
sont
donnØes
dans lln
dex des
Normes
de
ces
rŁgles
de sØcuritØ.
ANSI Z49-1
est
Ia
plus
complete.
Les
codes
de
IACNOR,
les codes
provinciaux
et
municipaux
donnent aussi les
exigences
pour
une
in
stallation,
une
utilisation
et
un
entretien
sOrs.
1-2.
PRECAUTIONSGENERALES
Plusieurs
procØdØs
du
soudage
a
Iarc,
des
Iec
trodes
allis,
at les
flux
peuvent
produire
des
vapeurs,
gaz,
at
niveaux
de
rayonnement
diffØrants.
Pour
tout
ronseignement
supplØmen
taire
a
ce
manuel,
consultez
aussi les
fabricants
dos
electrodes
et des flux
afin
dobtenir
las
rensaignaments techniques
spØcifiquos
et
los
mosures
de
precaution
concernant leurs
matØriaux.
A.
Prevention des
brOlures
Portez
des
vŒtements
de
protection
-
des
gants
a
crispin
spØcialement
dØsignes
pour
le
soudage,
un
casque
et
des chaussures
de sØcuritØ.
Boutonnez
le
col de
votre
chemise
et
les
pattes
de
vos
poches,
et
portez
des
pan-
talons
sans
revers
pour
Øviter
que
des
Øtincelles
et
du
laitier
ne
sy
introduisent.
Portez
un
masque
avec
lunettes
de
sØcuritØ
ou
avec
Øcrans latØ-raux de
protection,
des
lunettes
filtrantes
ou
des
couvre-lentilles
(protØgØs
par
un
verre
clair).
Pour le
soudage
ou
le
coupage
(et
le
burinage),
il
est
OM-1547
Page
1

from radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See 1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode stubs and
workpieces
should
never
be handled without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid facilities
and
a
qualified
first aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
im
mediate
treatment
of
flash
burns
of the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A hard hat should be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic Fume Prevention
Severe
discomfort,
illness
or
death
can
result from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI Stan
dard Z49.1 listed
1
in
Standards index. NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when welded
(or
cut)
may
produce
harmful
concentrations
of toxic fumes.
Ade
quate
local exhaust ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated
with
or
containing
materials that emit
toxic
fumes should
not
be
heated unless
coating
is
removed
from the work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in the
space
if
downstream valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that the
space
is safe
before
re-entering
it.
Vapors
from chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of the
arc
can
also
decompose
trichloroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
OBLIGATOIRE
de
protØger
ses
yeux
contre
lØnergie
de
rayonnement
et
les
Øclats
de
metal.
Remplacez
le
verre
protecteur
lorsquiI
est
brisØ,
piquØ
ou
quil
a
reu
des
projections.
Voir
1.3A.2.
Evitez
de
porter
des
habits
imprØgnØs
dhuile
ou
de
graisse.
Une
Øtincelle
pourrait
les
enflammer.
Ne
manipulez jamais
sans
gants
un
metal chaud tel
que
des
chutes
dØlectrde
et
des
piŁces
a
souder.
Premiers
soins
et
traitement
des
yeux:
Tout
atelier
devrait
avoir
a
sa
disposition
un
poste
de
premiers
soins
ainsi
quune
personne
compØtente,
a moms
quur,
ser
vice
medical
ne
soit
a
proximite
pour
soigner
immediate
ment
les brt~lures des
yeux
et
de Ia
peau.
Portez
des bouche-oreilles
lorsque
vous
travaillez
au
plafond
ou
dans
un
espace
restreint.
Portez
un
casque
lorsque
dautres
personnes
travaillent
au
plafond.
Les
personnes
devant souder
ou
couper
ne
doivent
pas
employer
des
preparations
inflammables
pour
leurs
cheveux.
B.
Prevention
des
gax
toxiques
Les
gaz,
les
vapeurs,
Ia
chaleur,
un
enrichissement
ou
un
manque
doxygene
peuvent
entrainer
un
malaise,
une
maladie
ou
mØme Ia
mort.
RemØdiez-y
par
Ia
ven
tilation dØcrite
dans
Ia
Norme
ANSI
Z49.1
paragraphe
1
de
Ilndex
des
Normes.
NE
ventilez
JAMAIS
a
r~~
ygene.
En soudant
ou
en
coupant,
les
plomb,
cadmium, zinc,
mercure
et
beryllium
ou
autres
matØriaux semblables
peuvent
crØer
des
concentrations
nocives
de
gaz
toxi
ques.
On dolt avoir
recours
a
une
ventilation
aspirante
adequate
du
local,
ou
alors
toute
personne
sur
les
lieux,
de
mŒme
que
le
soudeur,
doit
porter
un
masque
a
ad
duction dair. On
doit
employer
les deux
pour
le
beryllium.
Les mØtaux
enrobØs
ou
composes
de
matØriaux
Ømet
tant
des
gaz
toxiques
ne
doivent
pas
Œtre
chauffØs a
moms
que
lenrobage
ne
soit
tØ
de
Ia
surface a
travailler,
que
le
local
ne
soit
bien
ventilØ,
ou
que
le
soudeur
ne
porte
un
masque
a
adduction
dair.
Ne travaillez dans
un
espace
restreint
que
sil
est
bien
ventilØ
et,
si
nØcessaire,
portez
un
masque
a
adduction
dair.
On doit Øviter
les
fuites
de
gaz
dans
un
espace
restreint.
Les fuites
de
gaz
en
grande
quantitØ
peuvent
transformer
dangereusement
Ia
concentration
dox
ygene.
Namenez
pas
de
bouteilles de
gaz
dans
un
espace
restreint.
En
quittant
un
espace
restreint,
FERMEZ
le
robinet
dalimentation
de
gaz
de
Ia
bouteille. Ainsi
on
pourra
rentrer en
toute
sØcuritØ
dans Ia
piŁce,
mŒme
si les
robinets
aval
ont
etØ
ouverts
par
accident,
ou
si
Ofl
les
a
laissØs
ouverts.
Les
vapeurs
de
dissolvants
chlorØs
peuvent
Œtre
dØcom
posØes
par
Ia chaleur de
Iarc
(ou
de
Ia
flamme)
et
former
du
PHOSGENE,
gaz
trŁs
toxique,
et
dautres
produits
irritant
les
poumons
et
les
yeux.
LØnergie
ultra-violette
de
Iarc
peut
aussi
dØcomposer
les
vapeurs
de
trichloroØthylene
et
de
perchloroØthylene
pour
former
du
phosgene.
NE
SOUDEZ. PAS
ou ne
coupez
pas
dans
des
endroits
o
les
vapeurs
de
dissolvants
peu
vent
Œtre
attirØes
dans
IatmosphŁre
de
soudage
ou
de
4
OM-1547
Page
2

energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
per
chloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
yen
tilators.
If
the work
cannot
be
moved,
move
com
bustibles at
least 35 feet
away
out
of reach
of
sparks
and
heat;
or
protect against
ignition
with suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(or cut).
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment during
and
for
some
time
after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within 35
feet
b.
appreciable
combustibles
are
further
than 35
feet but
can
be
ignited
by sparks
c.
openings
(concealed
or
visible)
in floors
or
walls
within
35
feet
may
expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot work
permit
should be
obtained
before
operation
to
ensure
supervisors approval
that
adequate
precautions
have
been taken.
After work
is
done,
check
that
area
is free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container has
first
been
cleaned
as
described
in
AWS Standard
A6.O,
listed
7
in
Standards
index.
This
includes:
a
thorough
steam or
caustic
cleaning
(or
a
solvent or
water
washing,
depending
on
the
corn-
coupage
et
o
lenergie
de
rayonnement
peut
pØnØtrer
dans
des
atmospheres
contenant
des
quantites
mŒme
minuscules
de
trichloroØthylŁne
ou
de
per
chloroethylene.
C.
Prevention
des
incendies
et
des
explosions
Les
causes
dincendie
et
dexplosion
sont
les
com
bustibles atteints
par
larc,
Ia
flamme,
les
Øtincelles,
le
laitier
chaud
ou
les matØriaux
chauffØs,
le mauvais
emploi
des
gaz
comprimØs
et
des
bouteilles ainsi
que
es
courts-circuits.
Sachez
que
les
Øclats
dØtincelles
ou
Ia
chute
du
laitier
peuvent
sinfiltrer
dans les
fissures,
le
long
des
tuyauteries,
par
les
fenØtres
et
les
portes
et
par
les
couvertures
des
murs ou
du
sol,
sans
que
le soudeur
portant
des lunettes
ne
les
voie.
Les Øtincelles
et
les
scones
peuvent
voler
jusqu
35
pieds.
Pour
prØvenir
les incendies
et
les
explosions:
Veillez
a
ce
que
votre
appareil
soit
propre
et
en
Øtat de
marche,
dØnuØ
dhuile
et
de
graisse,
et
de
particules
de metal
sur
les
piŁces electriques
qui
pourraient
entralner
des
courts-circuits.
Si
des
combustibles
se
trouvent a
proximitØ,
ne
soudez
pas,
ne
coupez pas.
Si
possible,
dØplacez
votre
travail
loin des combustibles. Evitez
es
ateliers
de
peinture
au
pistolet,
les
cuves
dimmersion,
les
entrepts,
les
yen
tilateurs.
Si
cela nest
pas
possible,
placez
les
com
bustibles a
au
moms 35
pieds
des
Øtincelles
et
de Ia
chaleur
et
protØgez-Ies
des
Øtincelles
avec
des
couver
tures ou
des
Øcrans
protecteurs
adequats,
bien
ajustØs
et
ignifugØs.
On
ne
doit
pas
souder
(ou
couper)
le ctØ
oppose
des
murs
touchant
les
combustibles.
Les
murs,
plafonds
et
planchers proches
du travail
doivent
Œtre
proteges
par
des
couvertures ou
Øcrans
protecteurs
ignifugØs.
Un surveillant
doit
se
tenir
a
proximitØ
avec
un
materiel
de
lutte
contre
lincendie
adequat,
pendant
et
quelque
temps
aprŁs
le
soudage
ou
le
coupage
si:
a.
Des
quantites apprØciables
dØ
combustibles
(y compris
une
construction
en
chantier)
se
trouvent
a moms de
35
pieds.
b.
Des
quantites
apprØciables
de combustibles
sont
a
plus
de 35
pieds
mais
peuvent
Œtre
enflammØes
par
des
Øtincelles.
c.
Des
ouvertures
(cachØes
ou
visibles)
sur es
planchers
ou
les
murs
a moms de 35
pieds
peuvent
exposer
des
combustibles
aux
Øtincelles.
d. Les
combustibles
adjacents
aux
murs,
plafonds,
toits
ou
cloisons
mØtalliques
peu
vent
Œtre enflammØs
par
une
chaleur
rayon
nante
ou
transmise.
Avant de
commencer,
avisez
le
contremaitre
pour
quiI
sassure
que
les
precautions
adequates
soient
prises.
Une
fois le
travail
terminØ,
vØrifiez
quiI ny
ait
pas
dØtincelles,
de cendres
ardentes
ou
de
flammes
dans le
local.
On
ne
doit
jamais
souder ni
couper
sur
un
recipient
ayant
contenu
des
combustibles,
ou
pouvant
produire
des
vapeurs
inflammables
ou
toxiques
a Ia
chauffe,
a
moms
que
le
recipient
nait ØtØ
lavØ
au
prealable,
com
me
dØcrit dans
Ia
Norme
AWS
A6.O,
figurant
au
paragraphe
7
de llndex des
Normes.
Cela
comprend:
un
nettoyage
a
fond a Ia
vapeur
ou au
caustique
(ou
un
lavage
avec
dissolvant
ou eau
selon Ia
solubilitØ
du
combustible)
suivi
dune
purge
et
dune
in-
OM-1547
Page
3

bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A container
with
unknown
contents
should
be
cleaned
(see
paragraph
above).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine if it is safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be vented
before
welding
or
cuthng.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
SAFE
HANDLING
OF COMPRESSED GASES
IN
CYLINDERS,
listed 11
in
Standards
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only.
the
regulator
from
overpressure;
it
is
not
intended
to
pro
tect
any
downstream
equipment.
Provide
such
protec
tion
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that for which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel.
2. Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical circuit
contact
with
cylinders including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short circuit
arcs
that
may
lead
to
a
serious
ac
cident.
(See 1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
jection
dazote
ou
de
gaz
carbonique,
en
utilisant
un
Øquipement
de
protection
comme
recommandØ dans
lA6-O.
LatmosphŁre
inerte
peut
Œtre
remplacØe
par
un
niveau deau arrivant au-dessous du travail
a
effectuer
Vous
devez
layer
un
recipient
dont
Ia
nature
de
conten
est
inconnue
(voir
paragraphe
ci-dessus).
NE
vous
fiez
PAS
a
lodorat
ou
a Ia
vue
pour
dire si
lon
peut
le
souder
ou
le
couper
en toute
sØcuritØ.
Vous devez
pratiquer
un
event
sur
les
piŁces
ou
red
pients
creux avant
de les souder
ou
couper:
ils
peuvent
exploser.
Atmospheres
explosives:
Ne
soudez ni
ne
coupez
jamais
dans des lieux oCi
Iair
peut
contenir
des
poussiŁres,
gaz
ou
vapeurs
liquides
inflammables
(tels
que
Iessence).
D.
Gaz
comprimØ
Precautions
gØnØrales:
Suivez
les
precautions
de
ce
manuel,
et
celles
dØcrites
a Ia
Norme CGA
P-i
(PrØcau
tions
de
sØcuritØ
pour
Ia
manipulation
de
gaz
comprimØs
en
bouteilles),
paragraphe
ii
de Ilndex des
Normes.
i.
DØtendeurs
de
pression
La
soupape
de
sOretØ dun dØtendeur
est
destinØe
a
pro
tØger
seulement
le
dØtendeur de
Ia
surpression.
Elle na
pas
pour
but
de
protØger
les
boyaux
et
le
chalumeau:
on
protege
ceux-ci
par
des
soupapes
de
retenue
conues
spØcialement
pour
cette
fonction.
Ne
montez
jamais
un
dØtendeur
sur une
bouteille
conte
nant
un
gaz
different de celui
pour
lequel
le
dØtendeur
a
ØtØ
concu.
Enlevez immØdiatement
un
dØtendeur
dØfectueux
pour
le
faire
rØparer
(dabord,
fermez
le
robinet
de
Ia
bouteille).
Les
symptmes
suivants dØnotent
Ia
dØfec
tuositØ
du
dØtendeur:
Fuites
-
Si le
gaz
fuit
extØrieurement.
Ascension
excessive
-
si
Ia
pression
de debit
continue
a
monter,
le
robinet du
chalumeau
Øtant fermØ.
ManomŁtre
dØfectueux
-
Si
laiguille
du
manomŁtre
ne
sØcarte
pas
de
Ia
goupille
de
butØe
lors
de
Ia
mise
en
pression,
ou ne
revient
pas
sur
Ia
goupille
aprŁs
lØchap
pement
de Ia
pression.
Reparation.
NESSAYEZ
PAS
de
rØparer
vous-mŒmes.
Envoyez
les
dØtendeurs
dØfectueux
a
reparer
aux
ateliers
de
reparation
agrees
du
fabricant,
o
des
techni
ques
et
des
outils
spØciaux
sont
utilisØs
par
un
person
nel formØ.
2.
Bouteilles
Les
bouteilles doivent
Œtre
manipulØes
avec
soin
pour
prØvenir
les
fuites
ou
dØgts
a
leurs
parois,
robinets
ou
systŁmes
de
sOretØ.
Evitez
quun
circuit
Ølectrique
soit
en
contact
avec
les
bouteilles,
y
compris
les rails
de
con
tact,
les
fils
electriques
ou
les
circuits
de
soudage.
Cela
pourrait
crØer
desarcs
courts-circuits
pouvant
entraIner
des
accidents
graves
(Voir
i.3C.).
Chaque
bouteille
doit
porter
les
inscriptions
ICC
ou
DOT. Cest
un
gage
de
sØcuritØ
pourvu
que
Ia
bouteille
soit
bien
manipulØe.
OM-1547
Page
4

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
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
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
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
exchang
ed.
3.
Hose
Prohibited
use.
Never
use
hose other than
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
or
dinary
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.
Identification du
gaz:
Nutilisez
que
les
bouteilles
mdi
quant
Ia
nature
du
gaz;
ne vous
fiez
pas
a Ia
couleur
pour
reconnaItre Ia
nature
du
gaz.
Adressez-vous
a
votre
fournisseur si cela nest
pas
indiquØ.
NEFFACEZ
ou ne
modifiez
JAMAIS
les
noms,
numØros
ou autres
indications
sur une
bouteille.
Cela
est
illegal
et
dangereux.
Vides: Maintenez lŁs robinets
fermØs,
replacez
bien
les
chapeaux;
inscrivez
Vides;
sØparez-les
des
Pleines
et
retournez-les
rapidement.
Emploi
interdit:
Nutilisez
une
bouteille
ou
son
contenu
que
pour
ce
a
quoi
elle
est
destinØe,
mais JAMAIS
com
me
support
ou
rouleau.
Placez les
bouteilles
pour
quelles
ne
tombent
pas.
Lors
quun
dØtendeur
(et
un
boyau)
est
monte
sur
elles,
placez
les
ou
attachez-les
debout.
Passages
et lieux
de travail. Enlevez
les
bouteilles
dun
endroit o
lon
pourrait
les
frapper.
Transport
des
bouteilles. Avec
une
grue,
utilisez
un
sup
port
fiable
tel
quune
plate-forme
ou
un
cadre.
NE
SOULEVEZ PAS
des bouteilles du sol
par
leur
robinet
ou
chapeau,
ou avec
des
chalnes,
Ølingues
ou
aimants.
NEXPOSEZ PAS
les
bouteilles
a
une
chaleur
excessive,
aux
Øtincelles,
au
laitier
et
aux
flammes,
etc.,
pouvant
causer
leur
rupture.
Le
contenant
ne
doit
jamais
dØpasser
55C. Refroidissez
en
pulvØrisant
de
leau
si
nØcessaire.
ProtØgez
les
bouteilles
et
particuliŁrement
les
soupapes
contre
es
chocs,
les
chutes,
les
chutes
dobjets
et
Ia
temperature.
Remettez bien les
chapeaux lorsque
vous
dØplacez
les
bouteilles.
Robinet
coincØ.
NUTILISEZ
PAS
un
marteau
ou
une
clØ
mØtallique
pour
ouvrir
un
robinet
de
bouteille
que
lon
ne
peut
pas
ouvrir a Ia main. Avisez
votre
four
nisseur.
MØlange
de
gaz.
Nessayez jamais
de
mØlanger
des
gaz
dans
une
bouteille.
Ne
rechargez
jamais
une
bouteille. Les
ØlØments
de Ia
bouteille
ne
doivent
jamais
Œtre modifies
ou
remplaces.
3.
Boyau
Utilisation
interdite. Nutilisez
jamais
un
boyau
autre
que
celui
appropriØ
au
gaz
indiquØ.
La
regle
gØnØrale
didentification
est:
rouge
pour
les
gaz
combustibles,
vert
pour
loxygene,
et
noir
pour
les
gaz
inertes.
Utilisez
des
bagues
ou
colliers
appropriØs
au
boyau
(et
non
du
fil
ordinaire
ou autre
substitution)
pour
brancher
les
boyaux
a
lappareillage.
Nutilisez
pas
des raccords
en
cuivre. Nutilisez
que
des
accessoires
standard
en
laiton
pour
raccorder
un
boyau.
Utilisez
une
petite longueur
de
boyau.
Cela
Øvitera
les
noeuds
et
lusure
prØmaturØe. Suspendez
le
boyau
au
dessus du sol
pour
Øviter
quil
ne
soit
ØcrasØ,
piØtinØ
ou
endommagØ.
Enroulez
le
surplus
de
boyau
pour
Øviter les
noeuds
et
emmŒlements.
Evitez
que
le
boyau
ne
soit
endommage
par
des
tranchants,
Øtincelles,
laitier
et
flamme
nue.
OM-1
547
Page
5

Repair leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(t-2D3).
Do
NOT
use
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
agree,
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
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be iden
tified
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
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
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
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For fuel
gas,
open
to
less than
one
turn to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E. User
Responsibilities
Remove
leaky
or
defective
equipment
from service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
*Trademark
of
Proctor
&
Gamble
VØrifiez
reguliŁrement
les
fuites,
lusure
et les
rac
cordements lches.
Plongez
le
boyau
sous
pression
dans
de
leau;
les
bulles
indiqueront
les
fuites.
Reparation. Coupez
Ia
partie percØe
ou
usØe,
et
rac
cordez
(1-2D3).
NUTILISEZ
JAMAIS
de
ruban
adhØsif
4.
Branchements
corrects
Avant de
brancher
le
dØtendeur,
nettoyez
Ia
sortie
du
robinet
de Ia
bouteille
des
impuretØs
qui
peuvent
obstruer les
orifices
et
endommager
les
sieges.
Sauf
pour
lhydrogŁne,
ouvrez
momentanØment
le
robinet,
en
eloignant
Ia
sortie des
personnes
et
des
sources
in
flammables.
Essuyez
avec
un
tissu
propre
et
non
graisseux.
Appareillez
le
dØtendeur
a
Ia
bouteille. Avant
de
bran
cher,
vØrifiez
que
Ia
marque
du
dØtendeur
et
Ia
descrip
tion de Ia
bouteille
concordent,
et
que
lorifice
dentrØe
du dØtendeur et
Iorifice
de
sortie
de Ia
bouteille
aillent
ensemble.
NE
BRANCHEZ
JAMAIS
un
dØtendeur
concu pour
un
gaz
special
(ou
des
gaz
spØciaux)
a
une
bouteille
contenant
dautres
gaz.
Serrez
les
branchements.
Lorsque
vous
assemblez
des
branchements
filetØs,
nettoyez
et
polissez
les
sieges
o
cest
nØcessaire. Serrez.
Si
les
branchements
perdent,
dØmontez-les,
nettoyez
et
resserez
avec
une
clef
adØ
quate.
Adaptateurs.
Placez,
si
besoin
est,
un
adaptateur
CGA
(en
vente
chez
votre
fournisseur)
entre
Ia
bouteille
et
le
dØtendeur.
Avec
deux
clefs,
serrez
ladaptateur
filetØ
A
DROITE
et
A
GAUCHE.
On
peut
reconnaitre
les
branchements
de
sortie
du
dØtendeur
(ou
boyau)
a
laide du
filetage
a
droite
pour
loxygŁne
et
a
gauche
(identifiØ
par
un
Øcrou
cannelØ)
pour
les
gaz
combustibles.
5.
DØmarches de
mise
en
pression
Purgez
le dØtendeur
de rØsidu
de
gaz
avant
douvrir
Ia
bouteille
(ou
le
robinet
de
canalisation)
en
serrant
Ia
vis
de
rØglage
(dans
le
sens
des
aiguilles
dune
montre).
Cette
operation
permet
au
siege
de
haute
pression
de
souvrir
a
Ia
mise
en
pression,
supprimant
ainsi
toute
surchauffe
de
compression.
Maintenez Ia
vis
de
reglage
des
dØtendeurs a
simple
dØtente
lØgerement
engagee.
Avant
douvrir le
robinet
de
Ia
bouteille,
assurez-vous
que
les
boyaux
sont
branches
et
que
les
soupapes
aval
sont
fermØes.
Tenez-vous
latØralement
au
dØtendeur
en
ouvrant
le
robinet
de Ia
bouteille.
Ouvrez-Ie
lentement
pour
que
Ia
pression
du dØtendeur
monte
progressivement.
Lorsque
le
manomŁtre
est
mis
sous
pression
(indique
le
max
imum)
le robinet de
Ia
bouteille
de
gaz
inerte
ou
dox
ygŁne
devra Œtre
ouvert
a
fond
pour
assurer lØtanchØitØ
et
celui
de
Ia
bouteille
de
gaz
combustible
ouvert
de
moms
dun
tour
pour
pouvoir
le refermer
rapidement
en
cas
durgence.
RØfØrez-vous
aux
tableaux
de
pression
(distribuØs
par
votre
fournisseur)
pour
un
rØglage
recommandØ
de
pression
sUr
et
efficace
sur
les
dØtendeurs.
VØrifiez
Ies
fuites
a Ia
premiere
mise
en
pression puis
rØguliŁrement,
brossez
avec
une
solution
savonneuse
(un
bouchon
dlvory Liquid*
ou
semblable
par
gallon
deau).
Les
bulles
indiquent
une
fuite.
Enlevez
leau
savonneuse
aprŁs
examen;
le
savon sec
est
inflammable.
Marque
de
Commerce
de Proctor
& Gamble
OM-1
547
Page
6

F.
Leaving Equipment
Unattended
E.
ResponsabilitØs
de
lusager
Close
gas
supply
at
source
and
drain
gas.
C.
Rope
Staging-Support
Rope
staging-support
should
not
be used
for
welding
or
cutting
operation;
rope may
burn.
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 infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks and
pro
tects
himself
and
others
from accidents.
Precautions
are
described here and
in
standards
referenced
in index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its
radia
tion
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
PRECAU
TIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and f ire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and button
pockets
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
hemet
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
broken,
pitted,
or
spattered.
Otez
immØdiatement
les
parties
percØes
ou
dØfec
tueuses.
Voir
les
ResponsabilitØs
de
lUsager
du
manuel
de
lappareil.
F.
Appareil
laissØ
sans
surveillance
Fermez lalimentation de
gaz
a Ia
source
et
purgez.
G.
Liens
et
supports
temporaires
Pour
vos
travaux
de
soudage
ou
de
coupage,
nutilisez
pas
de
Ia corde
comme
soutien,
elle
est
inflammable.
1-3.
SOUDAGE
A
LARC
-
Conformez-vous
aux
precautions
des
paragraphes
1.1
et
1.2
de
cette section.
Le
soudage
a
larc bien exØcutØ
est
sr,
mais
un
soudeur
negligent
est
un
danger.
Le
poste
de
soudage
transporte
des
courants
ØlevØs
sous
de
fortes
tensions.
Larc
est
trŁs vif
et
chaud. Les
Øtincelles
volent,
les
vapeurs
montent,
lØnergie
ultra-violette
et
infrarouge
rayonnent,
les
soudures
sont
chaudes,
et des gaz
corn
primes
peuvent
Œtre
utilisØs.
Le soudeur
prudent
Øvite
les
risques
inutiles,
se
protege
et
protege
autrul
contre
les accidents.
Les
precautions
sont
dØcrites ici
et
dans
les
normes
donnØes
dans
lIndex.
A.
Protection
contre
las
brOlures
Conformez-vous
aux
precautions
du
paragraphe
1
.2.
Larc
de
soudage
est
intense
et
visiblement
vif.
Son
rayonnement
peut
blesser
les
yeux,
traverser
les habits
lØgers,
se
rØflØchir
sur
les
surfaces
claires,
et
brler
Ia
peau
et
les
yeux.
Les brlures de
Ia
peau
ressemblent
a
un
gros
coup
de
soleil.
Celles
darcs
sous
gaz
protecteur
sont
plus
graves
et
plus
douloureuses.
NE
VOUS
BRULEZ PAS
-
SUIVEZ LES
PRECAUTIONS.
1.
VŒtements
de
protection
Portez
des
vŒtements
a manches
longues
(surtout
pour
larc
en
atmosphere
inerte)
avec
gants,
masque
et
chaussures
(1.2A.).
Si
nØcessaire
portez
en
plus
une
veste
ou
des
manches
en
cuir,
un
tablier
et
des
guŒtres
ignifugØs.
De
preference
ne
portez
pas
de
vŒtements
en coton
non
traitØ.
Protection
de Ia
peau.
Portez
des
vŒtements
epais
foncØs.
Boutonnez
le
col
pour
protØger
Ia
poitrine
et
le
cou,
et
boutonnez
les
poches
pour
prØvenir
linfiltration
dØtincelles.
2.
Protection
des
yeux
et
de Ia
tŒte
Evitez
que
vos
yeux
soient
exposØs
a
larc.
NE
regardez
JAMAIS
un
arc
Ølectrique
sans
protection.
Lorsque
vous
soudez,
portez
un
Øcran
ou
masque
avec
verre
filtrant
teintØ N
12
ou
plus
foncØ.
Mettez-le
sur
le
visage
avant
damorcer
Iarc.
Protegez
le
verre
filtrant
dun
couvre-verre
clair.
NE
PORTEZ
PAS
un
masque
fendu
ou
brisØ;
le
rayonne
ment
peut
sinfiltrer
et
causer
des
brOlures.
Les
verres
filtrants
fendus,
brisØs
ou
laches doivent
Œtre
remplacØs
IMMEDIATEMENT.
Remplacez
un
couvre
verre
brisØ,
piquØ
ou
tachØ
par
des
projections.
OM-1547
Page
7

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
separate
room or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air circula
tion,
particularly
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
welding
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
vessel.
It
creates
a
brittle
area
that
can
cause
a
violent
rupture
or
lead
to
such
a
rupture
later
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
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
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.
Vous devez
portez
des
lunettes a
Øcrans latØraux
sous
le
masque
pour
protØger
les
yeux
dans
le
cas
o
le
masque
ne
serait
pas
abaissØ
sur
le
visage
avant
lamorcage
de
larc.
Regarder
momentanØment
un
arc sans
protection
(principalement
un
arc
en
atmosphere
inerte
a
haute
in
tensitØ)
peut
brOler
Ia rØtine
et
laisser
un
point
sombre
permanent
dans le
champ
de
vision.
3.
Protection
du
personnel
a
proximitØ
Local
de
soudage
fermØ.
Pour le
soudage
de
produc
tion,
il
vaut
mieux utiliser
une
salle
sØparØe
ou une
baie
fermØe. Dans les locaux
ouverts,
entourez
les
travaux
dØcrans
ou
panneaux
peu
rØflØchissants
et
ininflam
mables.
Laissez
lair circuler
librement,
particuliŁrement
au
niveau du sol.
Donnez des
masques
aux
personnes
qui
regarderont
directement
Ia soudure.
Autres
personnes
travaillant
sur
les
lieux.
Veillez
a
ce
que
toutes
les
personnes
portent
les
lunettes
de
protec
tion.
Avant
dattaquer
Ia
soudure,
assurez-vous
que
les
rebords
dØcran
ou
les
portes
soient fermØs.
B. Prevention des
gaz
toxiques
Suivez
les
precautions
du
paragraphe
1.2B.
LØchappe
ment
du
moteur
de Ia
genØratrice
dolt Œtre ventilØ
a
lair
extØrieur.
Loxyde
de carbone
peut
tuer.
C. Prevention des incendies
et
des
explosions
Suivez
les
precautions
1.2C. Puissance nominale
de
Iappareil.
Ne
surchargez
pas
le
poste
de
soudage
a
Iarc.
Cela
peut
surchauffer les cables
et
causer
un
in
cendie.
Les
branchements
lches
de cable
peuvent
surchauffer
ou
faire
des
Øtincelles
et
causer
un
incendie.
Namorcez
jamais
un arc sur une
bouteille
ou
autre
rØci
pient
sous
pression.
Cela
crØerait
un
point
de
rupture
entrainant a
plus
ou
moms
longue
ØchØance
lexplosion
du
reservoir.
D.
Gaz
comprimØ
Suivez
les
precautions
1
.2D.
E.
Prevention
des
dØcharges
Ølectriques
Des
conducteurs
charges
ou
metal
nu
incorporØs
au
cir
cuit de
soudage
ou
a
un
appareil
chargØ
sans
mise a Ia
terre
peuvent
donner
une
dØcharge
fatale a Ia
personne
dont
le
corps
devient conducteur. NE
SOUDEZ
PAS
DEBOUT,
ASSIS, COUCHE,
PENCHE
sur
une
surface
humide
ni
en
contact avec
une
telle surface
sans
protec
tion
appropriØe.
OM-1547
Page
8

To
protect
against
shock:
Keep
body
and
clothing
dry.
Never work
in
damp
area
without
adequate
insulation
against
electrical shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
damp
ness
or
sweat
can
not
be avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding
equipment
is
grounded
according
to
the
National Electrical
Code,
and
the work
is
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cut
ting,
a
voltage
may
exist
between
the electrode and
any
conducting
object.
Examples of
conducting
objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
When
installing,
connect
the frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
water
circulator to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or to
a
pipe carrying
ANY
gas
or
a
flammable
li
quid
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
receptacle,
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
recep
tacle.
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.
Pour
vous
protØger
contre
les
dØcharges
Ølectriques,
maintenez
votre
corps
et
vŒtements
secs.
Ne travaillez
jamais
dans
un
endroit
humide
sans
isolation
adequate
contre
les
decharges
Ølectriques.
Lorsque
vous
ne
pouvez
Øviter
lhumiditØ
ou
Ia
sueur,
placez-vous
sur
un
caillebotis
sec ou
un
tapis
en
caoutchouc.
La
sueur,
leau de
mer,
ou
IhumiditØ
entre
le
corps
et
une
piŁce
CHARGEE,
ou
une
piŁce
de
metal
a
Ia
masse,
rØduisent
Ia rØsistance
Ølectrique
de Ia surface du
corps,
permet
tant
lentrØe
de
courants
dangereux,
voire mortels.
1. Mise
a
Ia
terre
de
lappareil
Lorsque
lappareil
de
soudage
a
larc
est
mise
a Ia
terre
suivant
Ia
norme
National
Electrical
Code,
et
Ia
masse
est
mise
a
Ia terre
suivant
Ia
norme
ANSI Z49.1
Safety
in
Welding
and
Cutting,
une
tension
peut
exister
entre
IØlectrode
et
un
objet
conducteur.
Certaines
de
ces
ob
jets
sont
par
exemple
(mais
pas
seulement),
des
btiments,
des
outils
Ølectriques,
des
Øtablis,
des
chassis
de
postes
de
soudure,
des
piŁces
douvrage,
etc.
Ne
jamais
touchez
IØlectrode
ou
des
objets
en
metal
avant
davoir
mis le
poste
de
soudure
a larrŒt.
A
linstallation,
branchez
les
chassis
de
chaque
ØlØment
(source
de
cou
rant,
commande,
Øtabli
et
Circuit
deau)
a
Ia
terre.
Les
conducteurs
doivent
pouvoir
conduire
les
courants
telluriques
en
toute
sØcuritØ.
Lappareil
chargØ
par
les
courants
vagabonds
peut
donner
une
dØcharge
risquant
dŒtre
mortelle.
NE
BRANCHEZ PAS
VOTRE
PRISE
DE
TERRE
a
une
conduite
Ølectrique,
ou
a
un
tuyau
de
gaz
ou
de
liquide
inflammable tel
que
lhuile
ou
un
combustible.
Connexion
triphasØe.
Avant
linstallation
vØrifiez Ia
phase
nØcessaire
a
Iappareil.
Si
seul le
triphasØ
est
disponible,
ne
branchez
lappareil
monophasØ
qua
deux
des
fils
de
Ia
ligne triphasØe.
NE
BRANCHEZ PAS
Ic
conducteur de
terre
de
lappareil
au
troisiŁme fil
(sous
tension),
autrement
lappareil
serait
chargØ:
condition
dangereuse
pouvant
donner
une
dØcharge
fatale.
Avant Ic
soudage,
vØrifiez
si
Ia
prise
de
terre est
uniforme. En
branchant,
assurez-vous
que
les
con
ducteurs
touchent
le metal
flu
du
chassis
de
lappareil.
Lorsquun appareil
doit Œtre
alimentØ
a
partir
dun cof
f
ret
dalimentation,
le conducteur
de
terre
doit
Œtre
reliØ
a
celui-ci.
Si
vous avez
en
plus
une
fiche
a
trois
broches
pour
Ia
terre,
ne
branchez
le conducteur
de
terre
qua
Ia
broche
de
terre.
Si
le cordon
dalimentation
a une
fiche
a
trois
broches,
reliez-le
a
une
prise
femelle
tripolaire
reliØe a Ia
terre.
Nenlevez
jamais
Ia
broche
de
terre
dune
fiche
ou
nutilisez
jamais
une
fiche
dont
Ia broche de
terre
serait
brisØe.
2. Pince-Ølectrodes
Utilisez
des
pince-Ølectrodes
bien
isolØes.
NUTILISEZ
PAS
des
pince-Ølectrodes
avec
vis
saillantes.
3. Connecteurs
Utilisez
des
connecteurs
a
verrouillage
bien
isolØs
pour
assembler de
longs
cables.
OM-1547
Page
9

4.
Cables
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of oil arfd
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
(con
tactor)
Welding
power
sources
for
use
with the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
normally
are
equipped
with
devices
that
per
mit on-off
control
of the
welding
power
out
put.
When
so
equipped
the electrode wire
becomes
electrically
HOT
when
the
power
source
switch
is ON
and the
welding
gun
switch is
closed.
Never
touch
the
electrode
wire
or
any
conducting
object
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
pro
cesses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equipment
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
equip
ment,
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
welding.
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.
VØrifiez
frequemment
lusure,
les
fissures
et
laltØration
des
cØbles. REMPLACEZ
IMMEDIATEMENT
ceux
don
lisolation
serait
trop
usØe
ou
altØrØe
pour
prØvenir
le
decharges
mortelles
provoquees
par
un
cable
dØnudØ.
Vous
pouvez
enrouler
les
parties
endommagees
de
ruban
adhØsif
en
Øpaisseur
suffisante
pour
donner
une
rØsistance de
cable
neuf.
Maintenez
los
cØbles
secs,
dØpourvus
dhuile
et
de
graisse
et mettez-les
a labri
du
metal chaud
et
des
Øtincelles.
5.
TŒtes
de cables
et
autres
parties
dØnudØes
Avant Ia
mise
en
marche,
les tŒtes
de
cables
et
autres
parties
dØnudØes dun
appareil
Ølectrique
doivent
Œtre
munies
de leurs
couvrefils
isolants.
6.
Electrode
a
.
Appareil Øquipe
dune
commande
mar
che/arrŒt
(contacteur)
En
gØnØral,
los
postes
de soudure
utilisØs
pour
le
soudage
a larc
sous
protection
gazeuse
avec
electrode fusible
(GMAW),
ou
avec
electrode
tungstene
(GTAW) et
des
procŁs
semblables
sont
equipØs
dune
corn
mande
marche/arrŒt
de Ia
puissance
de
sor
tie.
Lorsque
tinterrupteur
est
en
position
MARCHE
et
linterrupteur
du
pistolet
est
fermØ,
le
fit
dØlectrode
devient
chargØ.
Ne
touchez
jamais
le f
ii electrode
ou
tout autre
objet
conducteur faisant
contact
avec
le cir
cuit dØlectrode
sans
couper
le
courant
au
poste
de
soudure.
b
.
Appareil
non-equipe
dune commande
mar
che/arrŒt
(sans
contacteur)
Les
postes
de soudure utilisØs
pour
le
soudage
a larc
avec
electrode enrobØe
(SMAW) et
des
procŁs
semblabes
peuvent
Œtre
non-equipes
dune commande
mar
che/arrØt
de Ia
puissance
de sortie.
Lorsque
linterrupteur
est en
position
MARCHE
lØlectrode devient
chargØ.
Ne
touchez
jamais
lØlectrode
sans
couper
le
courant
au
poste
de soudure.
7.
Dispositif
de
sØcuritØ
Le
dispositif
de
sØcuritØ-verrouillage
et
coupe-circuit
ne
doit
pas
Œtre
dØbranchØ
ou
dØshuntØ.
Avant
linstallation,
linspection
ou
Ia
reparation
do
lap
pareil,
mettez
lalimentation
sur
ARRET
et
enlevez
los
fusibles
gØneraux
(ou
verrouillez
les
interrupteurs)
pour
Øviter
une
remise
en
MARCHE
accidentelle.
DØbran
chez
tous
los cables de Ia
source
de
courant
ainsi
que
les
prises
des cordons
dalimentation
en
115 volts.
Lors
du
soudage,
nouvrez
pas
le circuit
dalimentation
et
ne
changez
pas
Ia
polarite.
Sil
est
dØbranchØ
au
cours
dune
urgence,
faites
attention
aux
brOlures
d
dØcharge
ou aux
jaillissements
dØtincelles.
Appareil
laissØ
sans
surveillance.
Mettez
toujours
sur
ARRET
et
dØbranchez
lappareil.
OM-1
547
Page
10

F.
Protection
For Wearers
Of
Electronic
Life
Support
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
in
formation,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from the
American
Welding
Society,
550
Le Jeune
Rd,
P.O.
Box
351040, Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from the
U.S. Govern
ment
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 Standard
Z41.1,
STANDARD
FOR MENS
SAFETY
-TOE
FOOTWEAR
obtainable
from
the
American
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018
6. ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE USE OF
CUTTING
AND
WELDING
PRO
CESSES obtainable
from the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL CODE
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10.
NFPA
Standard
51
B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from the
National
Fire
Protection
Association,
470 Atlantic
Avenue,
Boston,
MA
02210.
Linterrupteur
darrŒt
doit
toujours
se
trouver
a
prox
imitØ
de Ia
source
de
courant.
F.
Protection
pour
toute
personne
portant
des
appareils
electroniques
de
sauvetage
(ap
pareil
pour
le
rŁglement
do
battemont
do
coeur)
lnducteurs
de
courant
ØlevØ
peuvent
nuire
le
fonction
nement
dun
appareil
pour
le
reglement
de
battement
de coeur.
Toute
personne
portant
un
appareil
Ølec
tronique
de
sauvetage
(appareil
pour
le
rŁglement
de
battement
de
coeur),
devrait consulter
un
docteur
avant
dapprocher
toute
operation
de
soudage
a
larc,
a
Ia
gouge
ou
a
point.
1-4.
INDEX
DES
NORMES
-
Pour
plus
de
renseignements,
rØfØrez-vous
aux
normes
de
IACNOR
ou
aux
normes
amØricaines
suivantes:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
distribuØ
par
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040
Miami,
FL
33135
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS WELDING AND CUTTING
distribuØ
par
le
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington
D.C.
20402
3.
OSHA,
SAFETY AND HEALTH
STANDARDS,
29CFR
1910,
distribuØ
par
U.S.
Department
of
Labor,
Washington
D.C.
20210
4.
ANSI
Standard
Z87.1,
SAFE PRACTICES FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE PROTECTION distribuØ
par
IAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018
5.
ANSI Standard
Z41.1,
STANDARD FOR
MENS
SAFETY
-
TOE FOOTWEAR
distribuØ
par
Iad
dresse
donnee
en
4.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
distribuØ
par
Iaddresse
donnee
en
4.
7.
AWS Standard
A6.O,
WELDING
AND
CUT
TING CONTAINERS WHICH
HAVE
COM
BUSTIBLES
distribuØ
par
Iaddresse donnee
en
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR WELDING
AND
CUTTING
distribuØ
par
Ia
National
Fire
Protection
Associa
tion,
470
Atlantic
Avenue,
Boston,
MA
02210
9.
NFPA Standard
70-1978,
NATIONAL ELEC
TRICAL CODE distribuØ
par
Iaddresse
donnØe
en
8
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
distribuØ
par
laddresse donnØe
en
8
OM-1547
Page
11

11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from the
Canadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale, Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
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
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING OF COM
PRESSED
GASES
IN
CYLINDERS
distribuØ
par
Ia
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY 10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR SAFETY
IN
WELDING
AND CUTTING
distribuØ
par
Ia
Cana
dian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
distribuØ
par
Ia
National
Welding
Supply
Association,
1900 Arch
Street
Philadelphia,
PA
19103.
14.
American
Welding
Societe
Standard AWSF4.i
Recommended
Safe Practices
for the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
distribuØ
par
IAmerican
Welding
Societe,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135
15.
ANSI Standard
Z88.2
Practice
For
Respiratory
Protection
distribuØ
par
lAmerican
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
for
the
safe
and
effective
use
of this
equipment.
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.
~
This
safety
alert
symbol
is
used
with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
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
identh).
special
instructions
necessary
for
the
most
efficient
operation
of this
equip
ment.
OM-1547
Page
12

SECTION
3
SPECIFICATIONS
Table
3-1.
Specifications

Wire
Standard
Capacity Speed Range*
.
.
Control
Circuit
Voltage
At
Gun
Weight,
Net
Ship
in.
50-800
ipm
mm)
(1.3-20.3 mpm)
15
Volts
DC
48 lbs.
57
lbs.
(22
kg)
(26
kg)
*Optional
low
speed
motor
range:
13
to
205
ipm
(0.33
-
5.21
mpm);
optional
high speed
range:
89
to
1429
1pm (2.26
-
36.3
mpm)
Add
2
lbs.
(1
kg)
for
4-drive roll model.
3-1.
DESCRIPTION
This
unit is
a
semiautomatic,
constant
speed,
digital
wire
feeder
with
a
programmable,
microprocessor-based
control
and
a
permanent magnet
wire
feed
motor.
The
wire feeder is
capable
of
storing
in
memory
and
exe
cuting
eight
complete
and different
wire feed
welding
programs.
Each
program
consist of
PREFLOW,
RUN
IN,
WELD,
CRATER,
BURNBACK,
and
POSTFLOW.
Any
sequence
in
a
program
can
be
timed. The
wire
feeder
is also
capable
of dual
scheduling
(two
weld
se
quences
in
one
program)
of
the weld
parameters
for Gas
Metal Arc
Welding
(GMAW).
The
preset
welding voltage
and wire
speed
parameters
are
maintained
regardless
of
arc
or
load
variations
and
–10%
line
variation.
The
S-52M
models
use a
two-drive
roll
system,
and the
S-54M models
use a
four-drive roll
system.
Dimensions
Without
Wire
Reei
Height:
19-3/8 in.
(493
mm)
Width:
14 In.
(356
mm)
Length:
24 In.
(610 mm)
Figure
3-1.
Wire Feeder
Dimensions
SCO9O
864-C
OM-1 547
Page
13

SECTION
4-
INSTALLATION
OR
RELOCATION
Figure
4-1.
Hub
Installation
4-1.
LOCATION
(Figure 3-1)
Hex
Nut
Hub
Support
SA-126
870-A
The
service
life
and
efficiency
of this unit
and
associated
components
are
reduced
when
they
are
subjected
to
high
levels
of
dust, dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
A
proper
installation
site
should be
selected
for
the wire
feeder
if
the unit
is
to
provide
dependable
service.
Lead
lengths
must
be considered when
installing
the unit.
A
slot is
provided
in
the base
of
the
unit
to
fit
over
the
lifting
eye
on
welding
power
sources so
equipped.
Suitable
space
should
be
maintained around the unit
for
making
necessary
connections
and for maintenance functions.
4-2.
HUB
INSTALLATION
(Figure
4-1)
The hub
assembly
is
supplied
with
the wire feeder.
Re
move
the
hub
assembly
from the
feeder
carton,
and
in
stall it
as
follows:
1.
Remove
hex
nut
from
end of
hub
support
shaft.
2.
Align
keyway
and insert hub
support
shaft
through
selected
hole
in
hub
support.
Wire
spool
size
determines hole
selection.
3.
Reinstall
hex
nut onto
support
shaft.
Tighten
hex
nut
with
a
wrench until
a
slight drag
is
felt
while
turning
hub.
4-3.
WIRE GUIDE AND
DRIVE
ROLL
INSTALLA
TION
(Figures
4-2
and
4-3)
Upon
initial
installation,
or as a
result
of
changes
in
wire
size
and
type,
it
is
necessary
to
install
the
required
drive
rolls
and wire
guides.
Select
drive rolls
according
to
Table
10-1
or
Table
10-2.
After
obtaining
the
appropriate
drive
rolls and
wire
guides,
proceed
as
follows:
A. Wire
Guide Installation
1.
Loosen
the wire
guide
securing
screw(s).
IMPORTANT:
Wire
guides
should
be
installed
so
that
the
tip(s)
of the
guide
is
as
close
to
the drive roll
as
possi
ble
without
touching.
2.
Install
wire
guides
as
illustrated
in
Figure
4-2
and
Figure
4-3.
Adjust
after
installing
drive
rolls,
and
secure
by
tightening
securing
screws.
B.
Drive
Roll Installation
(Figures
4-2
And
4-3)
1.
Loosen
pressure
adjustment
knob(s),
and
pivot
free of the
cover.
2.
Pivot
gear
cover
away
to
expose
pressure
gear.
3. Loosen and
remove
the
three
securing
screws
on
each
gear.
4.
Slide
a
drive
roll
onto
the drive
gear
and
pressure
gear
with holes
aligned
and
secure
with
screws.
To
ensure
proper
gripping
of
U-Cogged
drive
rolls,
install
all rolls either
showing
the
side
with
slots
or
showing
the
side without slots. Line
up
the
blunted teeth
on
the
pressure
gear
rolls
directly
over
the
spaces
between the
teeth
on
the drive
gear
roll.
IMPORTANT:
When the
grooves
become
worn,
reverse
the
rolls
to
locate
the
unused
grooves
in
position
to
feed
the wire.
IMPORTANT: The
alignment
of the
wire
drive
assembly
is
factory
set.
If
the wire
guide(s)
is
not centered to feed
wire
straight
between
pressure
and
drive
rolls and
in
the
drive
roll
groove,
refer
to
Sections
8-2
and
8-3
for
align
ment
instructions.
Brake Washer
Hub
Assembly
Fiber
OM-1547
Page
14

Cover
Drive Roll
Gear
Securing
Bolt
Drive Roll
Securing
Screw
Intermediate
Motor
Wire
Guide
Gear
Figure
4-3. Drive
Roil And
Wire
Guide
installation
On Four Drive
Roil
Units
Gun/Feeder
Connector
Opening
Securing
Knob
Weld Cable
Terminal
Figure
4-2.
Drive
Roll
And
Wire Guide Installation
On
Two
Drive
Roll Units
SB-047 931-J
Drive
Gear
Cover
Motor
Pressure
Gear
One-Piece
Drive
Roil
Gear
Securing
Bolt
Wire Guide
Securing
Screw
Drive Roll
Securing
Screw
Gun Feeder
Connector
Opening
SB-070
887-E
Securing
Weld Cable
Knob
Mounting
Terminal
Bolt
OM-1
547
Page
15

4-4.
WELDING
GUN
CONNECTIONS
E.
Weld Cable
(If
Applicable)
A.
Gun
Connector
To
Drive
Assembly
(Provides
Weld Power
And
Shielding
Gas)
(Figures
4-2
And
4-3)
IMPORTANT:
The outlet
guide
is
provided
as
part
of the
gun
or
gun
adapter assembly.
1.
Loosen the
gun/feeder
connector
securing
knob.
IMPORTANT:
The outlet
guide
should
be
installed
so
that
tip
of
guide
is
as
close
to
the drive
rolls
as
possible
without
touching.
2.
Insert
the
gun/feeder
connector,
or
gun/feeder
adapter
if
required,
which
includes
installed
outlet
guide,
into
drive
assembly opposite
inlet
guide.
3.
Tighten
gun/feeder
connector
securing
knob.
B.
Gun
Trigger
(Figure
4-5)
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not touch live
electrical
parts.

Do
not
touch
electrode wire
when
gun
trigger
is
pressed.
The
welding
wire
and all metal
parts
in
contact
with it
carry
weld
output
when
the
welding
power
source
contactor
is
energized.
The
TRIGGER
receptacle
is
provided
on
front
of
control
box
for
making
gun
trigger
control
connections.
To
make
connections,
align
keyways,
insert
plug
from
gun
into
TRIGGER
receptacle,
and
rotate
threaded
collar
fully
clockwise.
C.
Shielding
Gas
(If
Applicable)
An
integral
gas
input
fitting
is
provided
on
the
wire
drive
assembly
for
guns
utilizing
this
type
of
connection.
If
the
gun
requires
a
separate
shielding
gas
connection,
dis
connect
the
hose
from the
gas
fitting
on
drive
assembly,
install
proper
fittings
or
connectors,
and
connect to
gas
hose
from
gun.
D.
Water
(If
Applicabe)
a
CAUTION: OVERHEATING
of
Gas
Metal
Arc
Welding (GMAW)
gun
can
damage
gun.

If
using
a
water-cooled
gun
and
recirculating
coolant
system,
do
not
make
connections
from
the coolant
system
to
water
valve. In
stead,
make
connections
directly
from
the
coolant
system
to
gun
hoses.
Connect
the
gun
water
input
hose
to
the
water
output
fit
ting
on
the
front
of the control
box.
Connect
the
water
re
turn
hose
from
the
gun
to
the
adapter
at
the weld terminal
on
the drive
assembly.
Reducing bushings
are
provided
to
accept
5/8-18
left-
hand
fittings.
If
the
reducing
bushings
are
removed,
7/8-14
left-hand
fittings
are
present.
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
wire
feeder
and
welding
powe
source,
and
disconnect
input
power
employ
ing
lockout/tagging
procedures
before
mak
ing
weld
cable
connections.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removin9
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
ARCING
can
damage
weld
cable terminal.

Clean
weld
cable terminal before
connecting
weld
cable
if
necessary.

Tighten
terminal
nut
securely.
Loose
or
dirty
connections
can cause
erratic
weld
output.
WELD
OUTPUT
present
on
grounded
wire
feeder
parts
can
cause
equipment
damage.

Do
not
allow
welding
cable
to touch
grounded
feeder
parts.
If
the
welding
cable
lug
or
exposed
welding
cable
is
in
contact
with
any
grounded
feeder
compo
nents
during
operation,
the
interconnecting
cord
and
plugs
may
be
damaged.
Connect
the
weld
cable
from
the
gun,
if
applicable,
to
the
weld cable
terminal
on
the drive
assembly.
(Use
front
weld cable
terminal
on
four
drive
roll
models.)
4-5.
VOLTAGE
SENSING
CONNECTIONS
(Fig
ures
4-4
And
4-5)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not touch
live
electrical
parts.

Shut
down wire
feeder and
welding
power
source,
and disconnect
input
power
employ
ing
lockout/tagging
procedures
before
mak
ing
voltage sensing
connections.
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
disconnect
ing
device.
EXCESSIVELY
HIGH
WELDING
CURRENT
can
cause
the
electrode wire
to
vaporize.

Be
sure
the
voltage
sensing
leads
are con
nected
properly.
To
make
voltage
sensing
connections,
proceed
as
fol
lows:
1.
Connect
the
plug
on
the
voltage
sensing
cord
to
the
VOLT
SENSE
receptacle
on
the
wire
feeder
(see Figure 4-5).
Align
keyway,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
2.
Connect
the
voltage sensing
lead
with the
ring
terminal attached to
the weld
cable
terminal
on
the
wire
drive
housing
as
shown
on
Figure
4-4.
OM-1
547
Page
16