Miller SPECTRUM 750 User manual

oWNERS
MANUAL
IMPORTANT:
Read and understand the entire
contents
of this
manual,
with
special emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER
ELECTRIC
Mfg.
Co.
AM~o~pud..co~y
installing, operating,
or
maintaining
this
equipment.
This
unit and these
instructions
are
for
use
only by
persons
trained
and
experienced In
the safe
1079
Appleton,
WI
54912
USA
operation
of
welding equipment.
Do
not
allow
untrained
persons
to
Install,
Tel.
414-734-9821
operate,
or
maintain this unit.
Contact
your
distributor
if
you
do
not
fuily
understand these instructions.
Miller
February
1990
FORM: OM-2201A
Effective
With
Serial
No.
KA780044
MODEL:
Spectrum1M
750
SB-134
696
PRINTED
IN
U.S.A

ui
LIMITED WARRANTY
EFFECTIVE: FEBRUARY
1,
1990
This
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
lE
LIMITED WARRANTY

Subject
to
the
terms
and
conditions
hereof,
Miller Electric
Mtg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that all
new
and unused
Equipment
fur
nished
by
Miller
is
free
from defect
in
workmanship
and
material
as
of
the
time and
place
of
delivery by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and other items
are
sold
subject
to
the warranties
of
their
respective
manufacturers,
if
any.
All
engines
are warran
tied
by
their
manufacturer
fortwo
years
from date
of
original
pur
chase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
Millers
warranty
does not
apply
to
components
having
normal useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire includ
ing
nozzles
and nozzle
insulators where
failure
does
not
result
from
defect
in
workmanship
or
material.
Millershall
be
required
to
honor
warranty
claims
on
warranted
Equipment
in
the
event
of failure
resulting
from
a
defect
within
the
following periods
from the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and torches
.. .
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair parts,
exclusive of labor
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty (30) days
of
the date
of
such
failure.
As
a
matter
of
general policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive remedies
therefore
shall
be,
at
Millers
option
(1)
repairor
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service station
or
(4)
payment
of orcredit for the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at Customers
risk
and
expense.
MILLERs
option
of
repairor
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB. at
a
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be allowed.
Upon receipt
of
notice
of
apparent
defect
or failure,
Miller shall instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be followed.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN
AND
ANY IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND ANY
REMEDY
FOR BREACH
OF CONTRACT
WHICH,
BUT FOR THIS PRO
VISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION OF
LAW,
CUSTOM OF
TRADE
OR COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF MERCHAN
TABILITY
OR OF
FITNESS FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY AND
ALL
EQUIPMENT FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT AS EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE USE AND MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS OR
CON
SUMER
USE.
MILLERS WARRANTIES DO NOT EXTEND
TO,
AND
NO
RESELLER IS AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
5.

ERRATA
SHEET
June
3,
1991
FORM:
OM-2201A
AMENDMENT TO SECTION
5
OPERATOR CONTROLS
Amend Section
5-4.
TEST/RUN
SWITCH
a
AMENDMENT
TO
SECTION
6
SEOUENCE
OF
OPERATION
Add Section
6-4.
PLASMA
ARC
GOUGING
(PAG)
a
1.
Install and
connect
unit
according
to
Section
4.
a
2.
Wear
dry
insulating gloves
and
clothing.
3.
Connect
work
clamp
to
clean,
bare metal
at
workpiece.
4.
Place the
TEST/GOUGE/RUN
switch
in the
TEST
position.
a
After this manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
In
this
manual.
The
TEST/GOUGE/RUN
switch
provides
a means
for
adjusting
the air
filter/regulator
without
energizing
the
cutting
circuit.
Placing
the
TEST/GOUGE/RUN
switch
in
the
TEST
position
energizes
the air
solenoids
allowing
the
air
filter/regulator
to
be
properly
set to
64
psi (4.3
bars).
Placing
the
TEST/GOUGE/RUN
switch
in
the
GOUGE
position
provides
gas/air
to
the torch
for
normal
gouging
operations
when
the
torch switch
is
pressed.
Placing
the
TEST/GOUGE/RUN
switch
in
the
RUN
position provides
gas/air
to
the
torch
for normal
cutting
operations
when the
torch
switch
is
pressed.
CAUTION:
CUTTING
WHEN
THE
GAS/AIR
SWITCH
IS
IN
GOUGE POSITION
will
damage
torch.

Do
not
cut
when
in
GOUGE
position.

Use
GOUGE
position
for
gouging
only.
The
GOUGE
position
provides
an
inadequate
supply
of
airflow
for
cooling
during
cutting.
IMPORTANT:
For
gouging
operations,
install
a
G
style
gouging
tip
in
the
torch.
Follow
the instructions
in
the torch
Owner~s
Manual.
WARNING: Read and follow
safety
information
at
beginning
of
entire
Section
6
before
proceeding.
CAUTION:
TIP
AND
ELECTRODE
WEAR
BEYOND
RECOMMENDED
VALUES
or
OPERATION
WITHOUT
TIP
OR
ELECTRODE
in
place
can
damage
torch.

Inspect
shield
cup,
tip,
and electrode before each
use,
hourly
during
operation,
or
whenever
cutting
speed
has been
significantly
reduced
(see
Torch
Owners
Manual).

Do
not
operate
torch
without
a
tip
or
electrode
in
place.
IMPORTANT:
For
gouging
operations,
install
a
G
style
gouging
tip
in
the
torch.
Follow
the instructions
in
the torch
Owners
Manual.
5.
Place the
POWER
switch
in
the
ON
position.
The
POWER
light
will
come
on.
CAUTION:
INCORRECT
PLASMA GAS
can cause
torch
and
power
source
damage.

Use
only
air
or
nitrogen
for
the
plasma
gas
supply.

Do
not
use
any
other
gas
or
combination of
gases.

6. Turn
on
gas/air
supply
at
the
source,
and
adjust
air
filter/regulator
to
64
psi
(4.3
bars)
while
observing
air
pressure
gauge
on
rear
of
unit.
For
proper
regulation,
the
recommended
output
from
the
gas/air
supply
should
provide
a
minimum
of 80
psi
(5.5 bars)
and
a
maximum
of
150
psi
(10.3
bars).
Make
pressure
adjustment
according
to
Figure
4-4
as
follows:
a.
Loosen
locking
screw
in
center
of
air
filter/regulator
adjustment
knob.
b.
Turn
air
filter/regulator
adjustment
knob clockwise
to
increase
pressure
setting
and counterclockwise
to
decrease
pressure
setting.
c.
Tighten
locking
screw.
7.
Place
the
THICKNESS
OUTPUT
CONTROL
in
the desired
position
(see
Section
5-3).
8.
Place
the
TEST/GOUGE/RUN
switch
in
the
GOUGE
position.
The
READY
light
will
come
on
indicating
that
the
unit is
ready
for
operation.
a
CAUTION: CUTTING
WHEN THE
GAS/AIR
SWITCH
IS
IN
GOUGE
POSITION
will
damage
torch.

Do
not
Cut
when
in
GOUGE
position.

Use
GOUGE
position
for
gouging
only.
The
GOUGE
position
provides
an
inadequate
supply
of airflow
for
Cooling
during
Cutting.
9.
Wear
safety goggles
with
correct
filter
shade
according
to
ANSI
Z49.1.
10.
Place
tip
of torch
on
metal
to
be
gouged
at
approximately
a
40
angle
to
the line
of
travel
and
press
torch switch.
There
will
be
approximately
2
seconds of
preflow
air followed
by
approximately
2-1/2
seconds
of
pilot
arc.
If
the
gouge
arc
is
not
started
within
the
2-1/2
seconds
of
pilot
arc,
the
pilot
arc
will
stop.
The
torch
switch
will have
to
be
released,
and the
startup
procedure repeated.
11.
Once
gouging
arc
starts,
establish
an
arc
length
of
approximately
ito
1-1/2
in.
(25mm
to
38mm),
and
slowly
and
smoothly begin
moving
torch
across
material.
12.
Adjust
torch
speed
and
angle
for
desired
depth
of
groove
and
so
that
sparks
are
directed
away
from
the
operator.
Do
not
attempt
to
remove
too
much
metal
in
one
pass.
Additional
passes
can
be made
to
achieve the desired
depth.
13. Pause
briefly
at
end
of
gouge,
and then
release
torch
switch.
Postflow
gas/air
will
flow
for
approximately
20
seconds
to
cool the torch.
If
another
gouge
is
started
before
postflow
ends,
the
arc
will
start
immediately.
AMENDMENT
TO
SECTION 8-
ELECTRICAL
DIAGRAMS
Amend
Diagram
8-1.
Circuit
Diagram
For
Power
Source
(see
Page
3
on
this
Errata
Sheet)
Amend
Diagram
8-3.
Wiring
Diagram
For Power
Source
(see
Pages
4
and
5
on
this
Errata
Sheet)
Add
Diagram
8-8A.
Circuit
Diagram
For Trouble
Light
Board
PC4
(see
Page
6
on
this
Errata
Sheet)
Amend
Diagram
8-8B
on
this
Errata
Sheet. Circuit
Diagram
For
Trouble
Light
Board
PC4
(see
Page
6
on
this Errata
Sheet)
OM-2201A
Page
2

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With
Serial
No. KB058453
OM-2201A
Page
6

AMENDMENT
TO SECTION
10
PARTS LIST
Amend
Parts List
as
follows:
Dia.
Part
Replaced
**
Mkgs.
No. With
Description
Quantity
39-12 T2
Added
130 534
TRANSFORMER,
kVA
1/3 24-18-230/460/575
1
39-16
Ti
132 879
140 276
TRANSFORMER,
pwr
main
200/230/460
(Eff
w/KA885936)
(consisting
of)
1
140 084
COIL,
pri/sec
200/230/460
center
&
RH
2
140
083
.
COIL,
pri/sec
200/230/460
LH
1
39-16
Ti
Added
136 200
TRANSFORMER,
pwr
main
230/460/575
(consisting
of)
1
39-17
135 984
.
COIL,
pri/sec
230/460/575
center
&
RH
2
39-18
135 983
COIL,
pri/sec
230/460/575
LH
1
39-37 Zi
132 943
135
860
STABILIZER,
(Prior
to
KA834898)
1
39-37
Zi
135 860 137 762
STABILIZER,
(Eff
w/KA834898
thru
KA873919)
1
39-37
Zi
137 762 139
709
STABILIZER,
(Eff
w/KA873920
thru
KA885935))
1
39-37
139709
140 118
STABILIZER,
(Effw/KA885936)
1
39-
132463
132463
SLEEVE,
(APT
7000)
1
39-
132657
132657
GUIDE,
(APT 7000)
2
39-
Added
132
658
GUIDE,
stand-off
(APT 5000)
2
39-
Added
138
755
TIP,
gouge
GH
(Eff
w/KA880002
thru
KB079750)
5
39-
138
755
143 983
TIP,
gouge
70A
(Eff
w/KB079751)
5
41-3
089 085
089
085
SWITCH,
(qty
chg
deleted
S4) (Effw/KA880002)
1
41-4
098
691 115 443
STAND-OFF,
No. 6-32
x
.750
(Eff w/KB058453)
2
41-6
PC4
125 057
135 748
CIRCUIT
CARD,
display
(Prior
to
KB058453)
1
41-6
PC4
135 748 143
514
CIRCUIT
CARD,
display
(Eff w/KB058453)
1
41-17
PCi
127
184
136687
CIRCUITCARDASSEMBLY,
regulator
1
41-22
126 696
138 377
PANEL,
front
(Eff w/KA880002)
1
41-
S4
Added
088409
SWITCH,
tgl
DPDT
i5A
125VAC
(Effw/KA880002)
1
41-26
124 729
136 156
LABEL,
precautionary
plasma
cutting
1
42-
R65
108
442
RESISTOR,
MF
.25W 392 ohm
1
45-
VR5O
081 632 083 772
IC,
linear
7815
1
47-
024
103
BLANK,
snap
in
nyl
.750
mtg
hole
1
48-2
C4,14
128 256 142
133
CAPACITOR
2
~First
digit
represents
page
no

digits following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING REPLACEMENT
PARTS.
OM-2201
A
Page
7

OM-2201-2190
RECEIVING-HANDLING
Before
unpacking equipment,
check
carton
for
any
dam- Use
the
following
spaces
to
record the Model
Designa
age
that
may
have occurred
during shipment.
File
any
tion and
Serial
or
Style
Number of
your
unit. The
infor
claims for loss
or
damage
with
the
delivering
carrier. mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor and/or
the
equipment
manufactur-
Model
__________________________________________
ers
Transportation
Department.
Serial
or
Style
No.
_____________________________
When
requesting
information about this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
______________________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY RULES
FOR PLASMA
ARC
CUTTING
(PAC)
1-1.
Introduction
1
1-2. General Precautions
1
1-3.
Plasma
Arc
Cutting (PAC)
4
1-4. Standards
Booklet
index
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SiECTION
3SPECIFICATIONS
3-1.
Duty
Cycle
7
3-2.
Description
8
3-3.
Cutting
Speed
8
SECTION
4
INSTALLATION
OR
RELOCATION
4-1.
Site
Selection
8
4-2.
Transporting
Methods
9
4-3.
Work
Clamp
Installation
9
4-4.
Connections
For
Remote
Operation
(Optional)
10
4-5.
Gas/Air
Input
Connection
11
4-6.
Electrical
Input
Connections
12
4-7.
Stand-on
Guide
Installation
(Figure
4-6)
13
SECTION
5-
OPERATOR
CONTROLS
5-1.
Power Switch
And Power
Light
15
5-2.
Ready
Light
15
5-3.
Thickness
Output
Control
15
5-4.
Test/Run
Switch
15
5-5.
Trigger
Hold Switch
15
SECTION
6
SEQUENCE
OF
OPERATION
6-1.
Plasma
Arc
Cutting
(PAC)
16
6-2.
Cutting
Problems
And
Recommendations
17
6-3.
Shutting
Down
17

Section
No.
Page
No.
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine
Maintenance
18
7-2.
Torch
And
Work
Cable
Inspection
And
Connections
18
7-3.
Spark Gap
19
7-4.
Overload
Protection
19
7-5.
Trouble
Lights
20
7-6.
Circuit
Board
Handling
Precautions
20
7-7.
Troubleshooting
20
SECTION
8
ELECTRICAL DIAGRAMS
Diagram
8-1.
Circuit
Diagram
For
Power
Source
24
Diagram
8-2.
Circuit
Diagram
For
Regulator
Board
PCi
25
Diagram
8-3.
Winng
Diagram
For
Power
Source
26
Diagram
8-4A.
Circuit
Diagram
Portion
For
Timer/Control
Board
PC2(1
of
2)
28
Diagram
8-4B.
Circuit
Diagram
Portion
For
Timer/Control
Board
PC2(2
of
2)
30
Diagram
8-5.
Circuit
Diagram
For
Relay
Board
PC3
32
Diagram
8-6.
Circuit
Diagram
For
Filter
Board PC5
32
Diagram
8-7.
Circuit
Diagram
For Hall
Device
HD1
33
SECTION
9
PLASMA ARC CUTTING
(PAC)
INSTALLATION GUIDELINES
9-i.
General
34
9-2.
Definitions
34
9-3.
High-Frequency
Radiation
35
9-4.
Location
35
9-5.
General
Installation
Procedures
35
9-6.
Guidelines
For
Installation
Of
Plasma Arc
Cutting (PAC)
Power
Sources
36
9-7.
Installation
Guidelines
Checklist
37
SECTION
10
PARTS
LIST
Figure
10-1.
Main
Assembly
38
Figure
10-2.
Panel,
Front
-
w/Components
40
Figure
10-3.
Circuit
Card,
Timer/Control
PC2
42
Figure
10-4.
Circuit
Card,
Regulator
PCi
44
Figure
10-5.
Circuit
Card,
Relay
PC3
46
Figure
10-6.
Circuit
Card,
Filter
PC5
46
Figure
10-7.
Panel,
Rear
-
W/Components
47
Figure
10-8.
HF
Panel
48
Figure
10-9.
Rectifier,
Main
49
Figure
10-10. Terminal
Assembly,
Pri
3Ph
3V
50
LIST OF
CHARTS
AND
TABLES
Table
3-i.
Specifications
7
Chart
3-i.
Cutting
Speed
8
Table
4-1.
Input
Conductor
And
Fuse Size
13
Table
7-i.
Maintenance
Schedule
18
Table
7-2.
Troubleshooting
21

SECTION
1

SAFETY
RULES
FOR
PLASMA ARC
CUTflNG
(PAC)
1-1. INTRODUCTION
We learn
by experience. Learning
safety through
per
sonal
experience,
like
a
child
touching
a
hot
stove,
is
harmful,
wasteful,
and unwise. Let the
experience of
oth
ers
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
From
research,
development,
and
field
expenence
have
evolved
reliable
equipment
and safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
rea
son
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense;
others
may
require
technical volumes
to
explain.
It is
wiser
to
follow
the
rules.
Read
and
understand these
safe
practices
before
at
tempting
to
install,
operate,
or
service the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction manuals for
personal safety
and for the
safety
of
others.
Failure
to
observe these
safe
practices
may
cause
seri
ous
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1-General
Precautions,
common
to
arc
welding
and
cut
ting;
and 2-Plasma
Arc
Cutting (PAC).
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
metals and
metal
coatings
can
produce
different
fumes,
gases,
and radiation
levels.
In
addi
tion
to
the
Information
In
this
manual,
be
sure
to
consult the
manufacturers
Material
Safety
Data
Sheets
(MSDSs)
for
specific
technical
data
and
pre
cautionary
measures
concerning
any
materials
or
coatings
on
materials
cut
with
this
equipment.
A.
Burn Prevention
Wear
protective
clothinggauntlet
gloves
designed
for
use
in
welding
or
cutting,
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
and
appropriate
filter
lenses
or
plates
(protected by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting
(and
chipping
or
grinding)
to
pro-
tect
the
eyes
from
radiant
energy
or
flying
metal.
Re
place coverglasswhen
broken,
pitted, orspattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal,
such
as
the
workpiece,
should
never
be
han
dled
without
gloves.
Medical first aid
and
eye
treatment.
First aid
faciiities
and
a
qualified
first
aid
person
should be available for each
shift
unless medical facilities
are
close
by
for immediate
treatment
of flash
burns
of the
eyes
and
skin
burns.
Ear
plugs
should be
worn
when
working
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 this
with
adequate
ventilation
as
described
in
ANSI
Standard
Z49.1
listed in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead-,
cadmium-,
zinc-,
mercury-,
and
beryllium-bear
ing
and similar
materials,
when welded
or
cut,
may pro
duce
harmful concentrations
of toxic fumes.
Adequate
local exhaust ventilation
must
be
used,
or
each
person
in
the
area as
well
as
the
operator
must
wear an
air-sup
plied
respirator.
For
beryllium,
both methods
must
be
used.
Metals
coated
with
orcontaining
materials
that emit
toxic
fumes should
not
be
heated
or
cut
unless
coating
is
re
moved from the work
surface,
the
area
is well
ventilated
or,
if
necessary,
while
wearing
an
air-supplied
respirator.
Work
in
a
confined
space
only
while it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
When
leaving
a
confined
space,
shut OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream valves
have been
accidentally
opened
or
left
open.
Check
to
be
sure
that the
space
is
safe
before
reentering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
to
form
PHOSGENE,
a
highly
toxic
gas,
and other
lung
and
eye
irritating
products.
The
ultra
violet
(radiant)
energy
of the
arc can
also
decompose
tnchloroethyiene
and
perchioroethylene
vapors
to
form
phosgene.
DO NOT
WELD
OR CUT
where
solvent
Va-
OM-2201
Page
1

pors
can
be drawn
into the
welding
or
cutting
atmos
phere,
or
where
the radiant
energy
can
penetrate
to at
mospheres
containing
even
minute
amounts
of
tnchloroethyiene
or
perchloroethyiene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire and
expiosion
are as
follows: combus
tibies 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
wail
or
floor
openings,
out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
travel
great
dis
tances.
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 the
area,
do
NOT weld
or
cut.
Move the
work,
if
practicable,
to
an
area
free of comb
ustibles. Avoid
paint
spray
rooms,
dip
tanks,
storage
ar
eas,
and
ventilators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35 feet
away
out
of reach of
sparks
and
heat;
or
protect
against
ignition
with suitable and
snug-fitting,
fire-resistant
covers or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be
welded
on or
cut.
Walls,
ceilings,
and floor
near
work should be
protected
by
heat-resistant
covers or
shields.
Fire watcher
must
be
standing by
with
suitable fire extin
guishing equipment during
and for
some
time afterweld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35 feet
b.
appreciable
combustibles
are
further than 35
feet but
can
be
ignited
by sparks
c.
openings
(concealed
or
visible)
in
floors
orwalls
within
35 feet
may expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted heat.
Hot
work
permit
should
be obtained before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have been
taken.
After
work is
done,
check that
area
is free
of
sparks,
glowing
embers,
and flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
F4.
1,
listed
7 in
Standards
Index.
This
includes
a
thorough
steam or
caustic
cleaning
(or
a
solvent
or
waterwashing,
depend-
ing
on
the
combustibles
solubility)
followed
by purging
with
nitrogen
or
carbon
dioxide,
and
using protective
equipment
as
recommended
in F4.1.
A
container with unknown
contents
should be cleaned
(see preceding paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it is safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting. They
can
explode.
Explosive
atmospheres.
Never weld
or
cut
where
the air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
EquIpment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA Standard
P-i
,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
ii
in
Standards Index.
1.
Pressure
Regulators
Regulator
relief valve is
designed
to
protect
only
the
regulatorfromoverpressure;
itis
not
intended
to
protect
any
downstream
equipment.
Provide such
protection
with
one or more
relief devices.
Never
connect
a
regulator
to
a
cylinder containing
gas
other than that for
which the
regulator
was
designed.
Remove
faulty regulatorfrom
service
immediately
for
re
pair (first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty regulator:
External
gas
leaks.
Excessive
Creep.
If
delivery
pressure
continues
to
rise with
downstream
valve closed.
Faulty
Gauge.
If
gauge
pointer
does
not
move
off
stop
pin
when
pres
surized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
to
repair.
Send
faulty
regulators
for
re
pair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
person-
nel.
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,
and
welding
or
cutting
cir
cuits.
They
can
produce
short circuit
arcs
that
may
lead
to
a
serious accident.
(See 1-3G.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked. NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on a
cylinder.
It
is
illegal
and
hazardous.
OM-2201
Page
2

Empties:
Keep
valves
closed,
replace
caps
securely,
mark
M1
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.
Never
cut
on
a
cylinder.
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
orcradie.
Do
NOT lift
cylinders
off
the
ground
by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to arcs,
excessive
heat,
sparks,
slag,
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
cannot
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
exchanged.
3.
Hose
Prohibited
use.
Neveruse hose
other
than that
designed
for
the
specified
gas.
A
general
hose
identification
rule is
as
follows:
red for
fuel
gas, green
for
oxygen,
and
black
for inert
gases.
Use
ferrules
or
clamps designed
for
the
hose
(not
ordi
nary
wire
or
other
substitute)
as
a
binding
to connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose from
damage
by
sharp edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressurized
hose
in
water;
bubbles
indicate leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing (1-203).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices and
damage
seats
before
connecting regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition. Wipe
with
a
clean
lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that the
regulator
label and
cylinder marking
area,
and
thatthe
regulator
inlet and
cylinderoutlet
match.
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.
Regulatoroutlet (or
hose)
connections
may
be
identified
by
right-hand
threads
for
oxygen
and left-hand
threads
(with grooved
hex
on
nut
or
shank)
for fuel
gas.
5.
Pressurizing
Steps
Drain
regulator
of
residual
gas
through
suitable
vent
be
fore
opening
cylinder
(or
manifold
valve)
by turning
ad
justing
screw
in
(clockwise). Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged slightly
on
single-stage regulators.
Stand
to side
of
regulator
while
opening
cylinder
valve.
Open cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator maximum),
leave
cylinder
valve
in
fol
lowing position:
For
oxygen
and
inert
gases, open
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
thereafter.
Brush with
soap
solution
(capfull
of
Ivory Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak. Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope may
burn.
Trademark
of Proctor
&
Gamble.
OM-2201
Page
3

1-3.
PLASMA
ARC
CUllING
(PAC)
Comply
with
precautions
in
1-1,
1-2,
and this section.
Plasma Arc
Cutting, 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,
workpieces
are
hot,
and
com
pressed
gases may
be used.
The wise
operator
avoids
unnecessary
risks and
protects
himself
and others
from
accidents.
Precautions
are
described
here
and in
stan
dards referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The electric
arc
used
in
cutting
is intense
and
visibly
bright.
Its
radiation
can
damage
eyes,
penetrate
light
weight clothing,
reflect from
light-colored
surfaces,
and
burn
the skin and
eyes.
Skin
bums
resemble
acute
sun
burn;
those
from
gas-shielded
arcs are
more
severe
and
painful.
DON~T GET
BURNED;
COMPLY
WITH
PRE
CAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve clothing
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 fire-resistant
leggings.
Avoid
outer
garments
of
untreated
cotton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button collar
to
protect
chest and
neck,
and button
pock
ets to
prevent
entry
of
sparks.
2.
Eye
and Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER look
at
an
electric
arc
without
protection.
A
properwelding
helmet
or
shield
containing
a
filter
plate
shade
according
to
ANSI
Z49.
1
and
ANSI
Z87.1
must
be
used
when
cutting.
Place
over
face before
beginning
to
cut.
Protect filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filler
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the face
before
cutting
is
started.
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
cutting
area.
For
production cutting,
a
sepa
rate
room
or
enclosed
bay
is
best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens or
panels.
Allow
for free air
circulation,
par
ticularly
at
floor level.
Viewing
the
cut.
Provide
proper
face shields for all
per
sons
who
will
be
looking directly
at
the
cut.
Others
working
in
area.
See
that all
persons
are
wearing
proper
flash
goggles.
Before
starting
to
cut,
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
cutting
equipment.
It
may
overheat cables
and
cause a
fire.
Loose cable connections
may
overheat
or
flash and
cause a
fire.
Never
cut
on a
cylinder
or
other
pressure
vessel. It
can
cause a
violent
rupture
or
lead
to
such
a
rupture
under
rough handling.
D.
Compressed
Gas
EquIpment
Comply
with
precautions
in
1
-2D.
E.
Shock
Prevention
Exposed
hot conductors
or
other bare metal in
the
cut
ting
circuit,
or
in
ungrounded,
electrically-HOT
equip
ment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO NOT
STAND, SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface when
cutting
without
suitable
pro
tection.
To
protect
against
shock:
Wear
dry
insulating
gloves
and
body
protection.
Keep
body
and
clothing dry.
Never
work
in
a
damp
area
with
out
adequate
insulation
against
electrical shock.
Stay
on
a
dry
duckboard
or
rubber
mat
when
dampness
or
sweat
cannot
be avoided.
Sweat,
sea
water,
or
moisture be
tween
the
body
and
an
electrically
HOT
part
orgrounded
metal
reduces the electrical
resistance,
and
could
en
able
dangerous
and
possibly
lethal
currents to
flow
through
the
body.
A
voltage
will
exist between
the
cutting
torch electrode
and
any
conducting object
in
the
work
circuit.
Examples
of
conducting objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
power
source
cases,
workpieces,
etc.
Never touch
the
cutting
torch
electrode
and
any
metal
object
unless
the
power
source
Is
OFF.
1.
Grounding
the
Equipment
Plasma
arc
cutting
equipment
must
be
grounded
ac
cording
to
the National Electrical
Code,
and the work
must
be
grounded
according
to ANSI
Z49.1,
Safety
In
Welding
And
Cutting.
Locate
grounding
terminal
or
grounding
lead
(green
or
green
with
yellow stripe).
This
is
the first
connection
that should
be
made.
OM-2201
Page
4

When
installing,
connect
the frames
of
each
unit,
such
as
power
source,
control, worktable,
and
water
circula
torto
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made electri
cally
HOT
by
stray
current
may
shock,
possibly fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
car
rying
ANY
gas
or
flammable
liquid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
to
the third
(live)
wire,
or
the
equipment
will
become
electrically
HOTa
dangerous
condition that
can
shock,
possibly
fatally.
Before
cutting,
check
ground
for
continuity.
Be
sure
con
ductors
are
touching
bare
metal
of equipment
frames
at
connections.
If
a
line
cord with
a
ground
lead is
provided
with
the
equipment
br
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added
for connection
to
a
grounded mating
re
ceptacle,
the
ground
lead
must
be connected
to
the
ground
prong
only.
It
the
line
cord
comes
with
a
three-
prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or use a
plug
with
a
broken
oft
ground
prong.
2.
Plasma
Cutting
Torches
Fully
insulated torches should be
used.
Do
NOT
use
torches with
protruding
screws.Do NOTuse
torches
with
cracks
on
pieces
missing
or
with
loose
or
missing
screws.
3.
Cables
Frequently inspect
cables for
wear,
cracks,
and
dam
age.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to avoid
possibly
lethal
shock from
bared
cable.
Cables
with
damaged
areas
may
betapedto
give
resistance
equivalenttooriginalca
ble.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
4.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of electrical
units
should have
insulating
covers
secured
before
operation.
5.
Cutting
Torch
Disassembly
Even
though
there
are
several
safety
shutdown
devices
provided
as
standard
equipment
on the
cutting
torch,
it
is
still
a
recommended
safe
practice
to
turn
off
the
power
source
before
touching
any
torch
parts.
Power
sources
used
for
the
Plasma
Arc
Cutting
(PAC)
process
normally
are
equipped
with
devices
that
permit
on-off
control of
the
cutting
power
output.
As
a
result,
the
cutting
torch
electrode
and
tip
become
electrically
HOT
whenever the
power
source
is
ON
and
the
cutting
torch
switch
is closed
(pressed).
Never touch
the
torch
tip
or
electrode and
any
conduct
ing
object
in
contact
with the
cutting
circuit
unless
the
power
source
is
OFF.
6.
Safety
Devices
Safety
devices,
such
as
interlocks
and circuit
breakers,
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service
of
equipment,
shut
OFF
all
power,
and
remove
line
fuses
(or
lock
or
red-tag switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect all
cables
from
power
source,
and
re
move
all
115 volts
line-cord
plugs
from
receptacles.
Do
not
open power
circuit while
cutting.
If,
in
an
emer
gency,
it
must
be
disconnected,
guard against
shock,
burns,
or
flash
from
switch
arcing.
Never leave
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment
before
leaving.
Power disconnect
switch
must
be available
near
the
plasma cutting
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions,
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING,
obtainable from
the
American
Welding
Society,
550 N.W.
LeJeune
Rd,
Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING,
obtainable
from
the
Superintendent
of
Documents,
U.S. Gov
ernment
Printing
Office,
Washington,
D.C. 20402.
3.
OSHA,
SAFETY
AND HEALTH
STANDARDS,
29
CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.t,
PRACTICE FOR
OCCUPA
TIONAL
AND
EDUCATIONAL
EYE
AND FACE
PROTECTION,
obtainable
from
the
American Na
tional
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 Broad
way,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF CUTTING
AND
WELDING
PROCESSES,
obtainable
from the
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
American
Welding Society
Standard
AWS
F4.1,
RECOMMENDED
SAFE
PRACTICES
FOR THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF CONTAINERS
THAT
HAVE
HELD
HAZARD
OUS
SUBSTANCES,
obtainable
from the
American
Welding
Society,
550
N.W.
LeJeune
Ad,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES,
obtainable
from the
National
Fire
OM-2201
Page
5

Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE,
obtainable from the
National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES,
obtainable
from
the National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE HANDLING OF COM
PRESSED GASES
IN
CYLINDERS,
obtainable
from
the
Compressed
Gas
Association,
1235 Jeffer
son
Davis
Highway,
Suite 501
,
Arlington,
VA
22202.
12.
CSA
Standard
W117.2,
CODE
FOR SAFETY
IN
WELDING
AND
CUTTING,
obtainable from
the
Ca-
nadian
Standards
Association,
Standards
Sates,
178
Rexdale
Boulevard,
Rexdale, Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRA
PHY,
obtainable from
the National
Welding
Supply
Association,
1900 Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWS
C5.2,
RECOMM
ENDED
PRACTICES FOR
PLASMA
ARC
CUTTING,
obtainable
from the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI Standard
Z88.2,
PRACTICE
FOR
RESPIRA
TORY
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed for the safe
and effective
use
of
this
equipment.
The
nameplate
of this
unit
uses
international
symbols
for
labeling
the
front
panel
controls. The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those listed
at
the
end
of
Section 1

Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call attention
to
and iden
tify
different levels of
hazard and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss of life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
OM-2201
Page
6

SECTION
3-
SPECIFICATIONS
Table 3-1.
SpecificatIons
Rated
Output
At
60%
Duty
Cycle
70
Amperes
At
120 Volts
DC
Maximum
Open-
Circuit
Voltage
270
Volts
DC
Input
At
Rated Load
Output
60
Hz
Three-Phase

Amperes
At
200V1230V 460V1575V
KVA
KW
I
I
62 54
27
22
21
10
Plasma Gas
Nitrogen/Air Only
Weight
Flow/Pressure
5.9
CFM
(170
LJmin)
At
64
PSI
(442
kPa)
Net
405
lbs.
(184
kg)
Ship
465 lbs.
(211 kg)
**
Add
3-3/4
In.
(95
mm)
for
aIr
filter/regulator.
Figure
3-1.
Overall
Dimensions
And
Base
Mounting
Hole
Locations
SB-134
696
3-1.
DUTY
CYCLE
The
duty
cycle
is the
percentage
of
a
ten
minute
period
that the
power
source
and torch
can
be
operated
at
a
giv
en
output
without
overheating
and
damaging
the
power
source
and
torch. This
power
source
and torch
are
rated
at
60
percent
duty
cycle
when
operated
at
70
amperes.
The unit
can
be
operated
at
70
amperes
for
six
consecu
tive
minutes,
but
it
must
operate
at
no
toad
for the
re
maining
four minutes
to
allow
proper
cooling.
If
the
cut
ting
amperes
decrease,
the
duty cycle
increases.
a
CAUTION:
EXCEEDING
THE
DUTY
CYCLE
RATINGS
will
damage
the
power
source
and
torch.

Do
not exceed
indicated
duty
cycles.
22-1/4
In.
(565mm)
1-1/Sin.
(29 mm)
OM-2201
Page
7

3-2.
DESCRIPTION
a
CAUTION:
INCORRECT
PLASMA
GAS
can
cause
torch
and
power
source
dam
age.

Use
only
airornitrogen
forthe
plasma
gas
supply.

Do
not
use
any
other
gas
or
combination
of
gases.
This unit
is
a
direct
current,
straight
polarity
(electrode
negative),
Plasma
Arc
Cutting
(PAC)
power
source
re
quiring
60
Hz
three-phase
electrical
input.
The unit
can
cut
through
all
metals
with
the
capacity
to cut
3/4
in.
(19
mm)
mild
steel,
stainless
steel,
and
aluminum
using
the
Plasma
Arc
Cutting
(PAC)
process.
This unit is
designed
to
be used
with
any
of the
following
torches:
*
APT
-
7000H 93
Torch
*
APT-5000H
110
Torch
*
APT
-
5000MH
180
(Straight)
Torch
This
unit
has
capabilities
for
making
connections
for
re
mote
operation.
Rated
output
is
70
amperes
at
120 volts
dc,
60
percent
duty
cycle.
Plasma
is
gas/air
which has been
heated
to
an ex
tremely high
temperature
and ionized
so
that the
gas/air
becomes
electrically
conductive. The electrode is
lo
cated
inside the
tip
of
the
torch. The torch
tip
has
a
small
opening
(orifice)
which constricts the
arc.
The
com
pressed
gas/air
flows
through
the
arc
where it is heated
to
the
plasma
temperature
range.
Since
the
gas/air
can
not
expand
due
to
the constriction of the
tip,
the
gas/air
is
forced
through
the orifice and
emerges
in
the form of
a
highly
compressed
airstream. The heat
formed
by
the
arc
and
the
plasma
melts the
metal,
and the
airstream
forces
the
molten metal
from
the
cut.
3-3.
CuttIng
Speed
(Chart
3-1)
The
Cutting speed
chart enables
the
operator
to
deter
mine
the
maximum
cutting speed
for
various
thickness
of
mild steel
within
the
capabilities
of the
power
source.
The
curve
indicates
the
proper
speeds
at
which
cutting
may
be
done,
although
the
speeds
indicated
may
not
be
achieved
instantaneously.
Cutting
may
have
to
begin
at
a
slower
speed,
with
an
increase
in
speed
until the
opti
mum
speed
is
reached.
Cutting
at
speeds
above
the
proper
speeds
shown
by
the
curve
will
cause
rapid
ero
sion of the
tip
and
electrode
and
should
be
avoided.
a
CAUTION:
EXCEEDING
RECOM
MENDED
CUTTING
SPEEDS
wIll
cause
rapId
erosion
of the
tIp
and
electrode.

Do
not
exceed
indicatedcutting speeds.
SECTION
4-INSTALLATION
OR RELOCATION
IMPORTANT: Read entire
Section
9
regarding plasma
arc
cutting equipment
installation
guidelines
before
in
stalling
this unit.
4-1.
SITE
SELECTION
(Figure
3-1)
Select
an
installation site which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply (if applicable)
3.
Water
supply (if applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5. No flammables
6.
A
clean and
dry
area
7.
Proper
temperature
that avoids
extremes
of heat
or
cold
8.
Proper
airflow
around
unit
9.
Adequate
space
for
removing
top
cover
and
outer
panels
for
installation, maintenance,
and
repair
functions.
Base
mounting
holes
provide
the
capability
to
install and
secure
the unit
in
a
permanent
location.
Figure
3-1
gives
overall dimensions and base
mounting
hole
locations.
Holes
are
also
provided
in
the base for
installing
an
op
tional
running
gear.
Chart
3-1.
Cutting
Speed
z
2
2
z
2
z
a
U
0
z
F
90
(2.3)
60
(1.6)
30
(0.8)
0
0
1/4
3/4
5/4
I
I
I
I
.25(6.4)
.75(19.0)
1.25(31.7)
PLATE
ThICKNESS.
IN. (MM)
B-135
587
OM-2201
Page
8