Miller Maxtron 450 User manual

Millerfi
July
L__Effe
1996
ctive
With
Form:
Serial
No.
OM-167302C
KG181431
OWNERS
MANUAL
MaxtronTM
450
-
CE
CCICV
DC
Welding
Power Source For
GMAW,
GTAW, SMAW,
FCAW,
CAC-A, GMAW-P,
GTAW-P,
And SAW
Welding
Rated
Welding
Output
Voltage
Range
In
CV
Mode
Amperage
Range
In
CC
Mode
Maximum
Open-
Circuit
Voltage
DC
i~
Rating
Amperes
Input
at
Rated Load
Output
50
Hz,
Three-Phase
380
V
I
415
V
38 35
(08)
I
(0.7)
I
KVA
I
KW
400 A
'
34
Volts
DC,
100%
Duty
Cycle
1238 V
5565
A
80
VDC
21
25 25
(0.5)*
(0.2)
*While
idling
cover_om
4/95

ST-BOO
763-A
'
1996
MILLER EIe~tric
Mfg.
Co.
PRINTED
IN
USA

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I
LIMITED
WARRANTY

Subject
to
the
terms
snd
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
original
retail
purchaser
thst
new
MILLER
equipment
sold
sher
the effective
date
ot
this limited
wsrrenty
is tree ot
de
tects in
material
snd
workmanship
st
the
time
it
is
shipped
by
MILLER.
THtS WAR
RANTY
IS
EXPRESSLY
tN LIEU OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLtED,
INCLUDtNG
THE
WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
Within
the
wsrranty
periods
listed
below,
MILLER
will
repait
or
reptsce
sny
war-
rented
parts
or
components
thst tell
due
to
such
detects
in
material
or
workmanship.
MILLER
tnust
be
notified in
writing
within
thirty
(30)
days
of
such
detect
or
failure,
et
which time
MtLLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
tollowed.
MILLER shell
honor
warranty
claims
on
werrented
equipment
listed below in
the
event
ot such
e
failure within
the
warranty
time
periods.
All
warranty
time
periods
stert
on
the
dete
thet
the
equipment
wee
delivered
to
the
original
retell
purcheser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent to
an
International
distributor.
1. 5
Years Parts 3 Years Labor
*
Original
main
power
rectifiers
*
tnverters
(input
and
output
rectifiers
only)
2.
3 Years

Parts and
Labor

Transformer/Rectitier
Power
Sources
*
Plasma
Arc
Cuning
Power
Sources

Semi-Automatic
and Automatic Wire
Feeders
*
tnverter
Power
Supplies

tntellitig

Robots
3. 2
Years
Parts
and Labor

Engine
Driven
Welding
Generators
(NOTE: Engines
are
warranted
separately by
the
engine manutacturer.)
*
Air
Compressors
4. 1
Year

Parts
and Labor
Motor
Driven
Guns
*
Process
Controllers

IHPS
Power Sources
*
Water
Coolant
Systems
*
HF
Units
*
Grids

Spot
Welders
*
Load
Banks
*
SDX
Transformers

Running
Gear/Trailers

Plasma
Cuffing
Torches
(escept
APT,
ZIPCUT
&
PLAZCUT
Models)

Tecumseh
Engines
*
Deutz
Engines (outside
North
America)

Field
Options
(NOTE:
Field
options
are
covered under
True Bluefi
for
the
remaining
warranty
period
of the
product they
are
installed
in,
or
for
a
minimum of
one
year

whichever is
greater.)
 I
~Wt
5. 6
Months

Bafteriea
6.
go
Days

Parts
and Labor
*
MtG
Guns/TIG Torches
APT,
ZIPCUT
&
PLAZCUT
Model Plasma
Curling
Torches

Remote
Controls
*
Accessory
Kits
Replacement
Parts
MILLERS
True
Bluefi Limited
Warranty
shall
not
apply
to:
1. Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips, cusing
nozzles,
contaclors
and
relays
or
parts
that tail due
to
normal
wear.
3.
Equipment
that
has
been modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has been
used
for
operation
outside
of
the
specifications
for the
equipment.
MILLER
PRODUCTSARE
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
of
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
inappropriate
cases,
(3)
the reasonable
coat
of
repair
or
replace
ment at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit for the
pur
chase
price (leas
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
espenae.
MILLERS
option
of
repair
or
replacement
will be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER authorized
ser
vice
facility
as
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be allowed.
TO THE EXTENT
PERMITTED BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE THE
SOLE
AND EXCLUSIVE
REMEDIES.
IN
NO EVEHT
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 OTHER LEGAL
THEORY
WHICH,
BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM OF
TRADE OR
COURSE
OF
DEALING,
IN
CLUDING
ANY IMPUED 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
limitations of
how
tong
an
implied
warranty
lasts,
or
the
esclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal rights,
and other
rights
may
be
available,
but
may vary
from
state to
state.
In
Canada,
legislation
in
some
provinces provides
for
certain
additional
warranties
or
remedies other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and exclusions
set out
above
may
not
apply.
This
Limited
Warranty provides
specific
legal rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO DO
I
CONTACT?
For
help,

contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(SerVice
And
Parts)
Engine
Manuals
Circuit
And
Wiring Diagrams
Process
Handbooks
To
file
a
claim for
loss
or
damage
during
shipment,
.
contact
the
deliVering
carrier
For
assistance in
filing
or
settling
claims,
.
contact
your
distributor and/or
equipment
manufacturers
Transportation
Department
~j~3jjj5~
1211]
Miller
Electric
Mfg.
Co.

CALL:
414-735-4505

FAX:
800-637-2348
(in USA),
or
414-735-4136
(outside
USA)
Users Guides
Distr(butor Directories

contact
your
distributor
oi
.
WRITE:
Miller Electric
Mfg.
Co.
P.O.
BOX 1079
Appleton,
WI
54912
USA
Always provide
Model
Name and
Serial
or
Style
Number
MILLERS
TRUE
BLUEfi LIMITED WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
i-u
miller...wsrl
6/g5

Declaration of
Conformity
For
EurOpean
Community
(CE)
Products
Manufacturers Name:
Miller Electric
Mfg.
Co.
Manufacturers Address:
1635 W.
Spencer
Street
Appleton,
WI
54914
USA
Declares that
the
product:
M
axtro
flTM
450
conforms
to
the
following
Directives
and
Standards:
Directives
Electromagnetic compatibility
Directives:
89/336/EEC,
92/31/EEC
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Standards
Electromagnetic compatibility
(EMC)
Product standard for
arc
welding equipment:
EN50199:
August
1995
Safety Requirements
for
Arc
Welding Equipment
part
1:
EN
60974-1: 1989
Degrees
of
Protection
provided by
Enclosures
(lP code):
IEC
529: 1989
Insulation coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles, requirements
and
tests:
lEG
664-1:
1992
European
Contact: Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via Privata
lseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
10/95

SECTION
1
-
SAFETY
PRECAIJTIONS
FOR ARC
WELDING
0M167
302C

7/96
safety_somi
4/95
1-1.
Symbol
Usage
Means
Warning!
Watch
Out! There
are
possible
hazards
with this
A
Marks
a
special
safety
message.
~
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
,
This
group
of
symbols
means
Warning!
Watch
Out
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT PARTS
hazards. Consult
symbols
and
related instructions below for
necessary
actions
to
avoid the
hazards.
1-2.
Arc
Welding
Hazards
a
WARNING
The
symbols
shown below
are
used
throughout
this
manuai
to
call
attention
to
and
identify
possible
hazards. When
you
see
the
symbol,
watch
out,
and
follow
the related
instructions
to
avoid the hazard.
The
safety
information
given
below
is
only
a
summary
of I:he
more
complete safety
information found
in the
Safety
Standards listed
in
Section
1-4. Read and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintalin,
and
repair
this unit.
During operation, keep everybody,
especially children,
away.
1.
Do
not
touch
live electrical
parts.
2.
Wear
dry,
hole-free
insulating gloves
and
body
protection.
3. Insulate
yourself
from work and
ground using dry insulating
mats
or covers
big enough
to
prevent
any
physical
contact
with
the work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191 0.147
(see Safety Standards).
5.
Properly
install and
ground
this
equipment
according
to
its
Owners Manual and
national,
state,
and local codes.
6.
Always verify
the
supply ground

check and be
sure
that
input
oower
cord around
wire is orooerlv connected
to
around
terminal
in
disconnect box
or
that cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first

double-check connections.
B.
Frequently inspect input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work
cable.
13. Do
not
touch electrode
it
you
are
in
contact
with
the
work,
ground,
or
another electrode from
a
different machine.
14.
Use
only
well-maintained
equipment. Repair
or
replace
damaged
parts
at
once.
Maintain unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work cable with
good
metal-to-metal
contact to
workoiece
or
worktable
as
near
the
weld
as
Dractical.
ELECTRIC SHOCK
can
kill.
Touching
live electrical
parts
can cause
fatal
shocks
or
severe
burns.
The
electrode
and work
circuit is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit and machine internal
circuits
are
also live when
power
is
on.
In
semiautomatic
or
automatic wire
welding,
the
wire,
wire
reel,
drive roll
housing,
and all metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly grounded
equipment
is
a
hazard.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG OR SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet fitted with
a
proper
shade of filter
to
protect
your
face and
eyes
when
welding orwatching
(see
ANSI
Arc
rays
from the
welding
process
produce
intense
Z49.1
and Z87.1 listed in
Safety
Standards).
visible and invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved safety glasses
with side shields.
that
can
burn
eyes
and skin. Noise
from
some
processes
can
damage
hearing. Chipping,
4.
Use
protective
screens or
barriers
to
protect
others from flash
grinding,
and welds
cooling
throw
off
pieces
of
and
glare;
warn
others
not to
watch the
arc.
metal
or
slag.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or ear
muffs
if
noise level is
high.
material
(wool
and
leather)
and
foot
protection.
I
FUMES AND
GASES
can
be
5.
Work in
a
confined
space
only
if
it is well
ventilated,
or
while
hazardous
to
your
health.
wearing
an
air-supplied respirator.
Always
have
a
trained
Welding
produces
fumes
and
gases.
Breathing
watchpersonnearby.Weldingfumesandgasescandisplaceair
~
v . these
fumes
and
gases
can
be
hazardous
to
your
and lower the
oxygen
level
causing injury
or
death. Be
sure
the
health.
breathing
air
is
safe.
I
6.
Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes. Do
not
breathe
the fumes,
operations.
The heat and
rays
of
the
arc can
react
with
vapors
to
form
highly
toxic and
irritating
gases.
2.
If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use an
approved
air-supplied respirator.
cadmium
plated
steel,
unless the
coating
is
removed
from
the
4.
Read the
Material
Safety
Data Sheets
(MSDS5)
and the
weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
manufacturers instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers. containing
these elements
can
give
off toxic fumes if
welded.
OM-167
302
Page
1

N
N
N
-.
/
~--~_,
N
I

,
N)
1
N
N
~_
-
,j
/
N
NN
,
~N
N
N
~-
N
\
2

CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
Protect
compressed
gas
cylinders
from excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep cylinders
away
from
any
welding
or
other electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never weld
on
a
pressurized
cylinder

explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings designed
for the
specific application;
maintain
them and
associated
parts
in
good
condition.
8. Turn face
away
from
valve outlet when
opening cylinder
valve.
9.
Keep protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected for
use.
10.
Read and follow instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can cause
them
to
blow
up.
Sparks
can
fly
off from
the
welding
arc.
The
flying sparks,
hot
workpiece,
and hot
equipment
can cause
fires
and burns. Accidental
contact
of
electrode
to
metal
objects
can cause
sparks, explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is safe before
doing
any
welding.
1.
Protect
yourself
and others from
flying sparks
and hot metal.
2. Do
not
weld where
flying sparks
can
strike flammable material.
3.
Remove all flammables
within
35
ft
(10.7 m)
of
the
welding
arc.
If
this is
not
possible,
tightly
cover
them with
approved
covers.
4. Be alert that
welding
sparks
and hot materials from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch for
fire,
and
keep
a
fire
extinguisher
nearby.
6. Be
aware
that
welding
on a
ceiling,
floor, bulkhead,
or
partition
can cause
fire
on
the
hidden side.
7.
Do
not
weld
on
closed containers such
as
tanks,
drums,
or
pipes,
unless
they
are
properly prepared
according
to
AWS F4.
1
(see
Safety
Standards).
8.
Connect
work cable
to
the work
as
close
to
the
welding
area as
practical
to
prevent
welding
current
from
traveling long,
possibly
unknown
paths
and
causing
electric shock
and
fire
hazards.
9. Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove stick
electrode
from holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear oil-free
protective
garments
such
as
leather
gIove~, heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12. Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR EXPLOSION
can
result from
placing
unit
on, over,
or near
combustible surfaces.
1. Do
not
locate unit
on,
over,
or near
combustible
surfaces.
2.
Do
not
install unit
near
flammables.
FALLING
EQUIPMENT
can cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate capacity
to
lift
unit.
If
using
lift forks
to
move
unit,
be
sure
forks
are
long enough
to
extend
beyond opposite
side
of
unit.
HOT
PARTS
can cause
severe
burns.
1.
Do
not
touch hot
parts
bare handed.
2.
Allow
cooling period
before
working
on
gun
or
torch.
MOVING
PARTS
can cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
FIELDS FROM HIGH
can
affect
pacemaker
Pacemaker
wearers
keep
away.
Wearers should consult their doctor before
going
near arc
welding, gouging,
or
spot
welding
operations.
MOVING PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch points
such
as
drive rolls.
FLYING PIECES
OF METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side shields
or
face
shield.
WELDING
WIRE
can
cause
puncture
wounds.
1.
Do
not
press gun
trigger
until instructed
to
do
so.
2. Do
not
point
gun
toward
any
part
of the
body,
other
people,
or
any
metal when
threading welding
wire.
HIGH-FREQUENCY RADIATION
can
interfere with radio
navigation, safety
services,
computers,
and
communications
equipment.
1.
Have
only
qualified
persons
familiar with
electronic
equipment perform
this installation.
2. The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from the installation.
3.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
4.
Have the installation
regularly
checked and
maintained.
5.
Keep high-frequency
source
doors and
panels
tightly
shut,
keep spark
gaps
at correct
setting,
and
use
grounding
and
shielding
to
minimize the
possibility
of interference.
1.
2.
3.
MAGNETIC
CURRENTS
operation.
2:
OM-167
302
Page
2

OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Follow rated
duty
cycle.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
boards
grounded
wrist
strap
BEFORE
handlinf
or
parts.
Use
proper
static-proof bags
and
boxes
to
store,
move,
or
ship
PC
boards.
SIGNIFICANT
DC
VOLTAGE
exists after
removal of
input
power
on
inverters.
1.
Turn Off
inverter,
disconnect
input
power,
and
discharge input
capacitors
according
to
instructions in
Maintenance
Section
before
touchinq
any
parts.
BUILDUP OF
SHIELDING
GAS
can
harm
health
or
kill.
1-4.
Principal
Safety
Standards
1-5. EMF
Information
II
~
1.
Shut
off
shielding
gas
supply
when
not
in
use.
Safety
in
Welding
and
Cutting,
ANSI Standard
Z49.1,
from
American
Welding Society,
550 N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended Safe Practices for
the
Preparation
for
Welding
and
Cutting
of
Containers
That Have Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.i,
from American
Welding Society,
550 N.W. LeJeune
Rd, Miami,
FL 33126
National Electrical
Code,
NFPA Standard
70,
from
National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA 22202.
Code for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.i,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Considerations
About
Welding
And
The
Effects Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the General Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects of Power
Frequency
Electric
&
Magnetic
Fields

Background
Paper,
OTA-BP-E-53
(Washington,
DC: U.S.
Government
Printing
Office,
May 1989):
.
. .
there
is
now
a
very
large
volume of
scientific
findings
based
on
experiments
at
the
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
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw definite
conclusions
about
questions
of
possible
risk
or
to
offer clear
science-based advice
on
strategies
to
minimize
or
avoid
potential
risks.
To reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables around
the
body.
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.
About
Pacemakers:
The
above
procedures
are
also
recommended for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
OM-167
302
Page
3

SECTION
2-
DEFINITIONS
2-1.
Manufacturers
Warning
Label
Definitions
Warningt
Watch Outl
There
are
possible
hazards
as
shown
by
the
symbols.
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry
insulating
gloves.
Do
not
touch electrode
with
bare hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
1.3
Disconnect
input
plug
or
power
before
working
on
machine.
2
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of the
fumes.
2.2
Use forced
ventilation
or
local
exhaust
to
remove
the fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
Welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Do
not
weld
near
flammables.
3.2
Welding
sparks
can
cause
fires.
Have
a
fire
extinguisher
nearby,
and have
a
watchperson
ready
to
use
it.
3.3 Do
not
weld
on
drums
or
any
closed
containers.
4
Arc
rays
can
burn
eyes
and
injure
skin.
4.1
Wear
hat and
safety
glasses.
Use
ear
protection
and
button
shirt
collar. Use
welding
helmet with
correct
shade
of
filter.
Wear
complete
body
protection.
5
Become
trained
and read the
instructions
before
working
on
the
machine
or
welding.
6 Do
not
remove
or
paint
over
(cover)
the
label.
1/96
OM-167
302
Page
4

Warning!
Watch Out!
There
are
possible
hazards
as
shown
by
the
symbols.
Electric
shock from
wiring
can
kill.
Disconnect
input
plug
or
power
before
working
on
the
machine.
Read the
Owners
Manual before
working
on
this machine.
1
Consult
rating
label for
input
power
requirements,
and
check
power
available
at
the
job
site

they
must
match.
2 Read
Owners
Manual
and
inside labels for connection
points
and
procedures.
3 Move
jumper
links
as
shown
on
inside label
to
match
voltage
at
job
site.
4
Having
a
loop
of
extra
length,
connect
grounding
conductor
first.
5
Connect
line
input
conductors
as
shown
on
inside label

double-check
all
connections,
jumper
link
positions,
and
input
voltage
before
applying
power.
1
Warning!
Watch Out! There
are
possible
hazards
as
shown
by
the
symbols.
2
Electric shock from
wiring
can
kill.
3
Disconnect
input
plug
or
power
before
working
on
machine.
4
Hazardous
voltage
remains
on
input capacitors
after
power
is
turned
off.
5
Always
wait
60 seconds after
power
is
turned
off before
working
on
unit.
6
Check
input
capacitor
voltage,
and be
sure
it is
near
0 before
touching
parts.
1/96
OM-167
302
Page
5

2-2.
Rating
Labels
For
CE
Products
~OfI-
I
EN
60974-1
h
5*. 1W 585.4 4W
D
,
X.
50% 80% 100%
Un
00
12.
585 515 400
U2.
43 41 38
1=
80.
12V
515A
4W
A
~>
.
=
X
80% 100%
Un
00
12.
515 400
~~tS
fl5Df0O
H
Ui
=415
(jMAX=4M
I1EFF 35*.
1P21$
/
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
/
/
/
2
When
power
is
applied
failed
parts
can
explode
or cause
other
parts
to
explode.
3
Flying
pieces
of
parts
can
cause
injury.
a
4
Always
wear a
face
shield
when
servicing
unit.
5
Always
wear
long
sleeves
and
button
your
collar
when
servicing
unit.
1/96
380V
415V
1
Warning!
Watch Out! There
are
possible
hazards
as
shown
by
the
symbols.
2 Electric
shock from
wiring
can
kill.
3
Disconnect
input
plug
or
3
power
before
working
on
machine.
4
Look
at
inside
label,
and
properly
position
jumper
links
to
match
available
input
voltage.
4
1/96
Ref. 5T-177 139
OM-167
302
Page
6