Miller XMT 304 User manual

0
Visit
our
website
at
www.MillerWelds.com
OM-193
084H
December
2002
Processes
Multiprocess
Welding
Description
Arc
Welding
Power Source
OWNERS
MANUAL
CE
Miller
XMTfi
304
(460
Volt
Models)
CC/CV
and
CC Models

ISO 0001:2000
IREGISTERED
IQUALITY
SYSTEM
Miller is the
first
welding
equipment
manufacturer
in
the
U.S.A.
to
be
registered
to
the
ISO
9001:2000
Quality
System
Standard.
~1Uf1rll11~
Working
as
hard
as
you
do

every
power
source
from
Miller
is
backed
by
the
most
hassle-free
warranty
in
the
business.
From
Miller
to
You
Thank
you
and
congratulations
on
choosing
Miller. Now
you
can
get
the
job
done and
get
it done
right.
We
know
you
dont
have time
to
do
it
any
other
way.
Thats
why
when
Niels Miller
first started
building
arc
welders in
1929,
he
made
sure
his
products
offered
long-lasting
value and
superior
quality.
Like
you,
his
customers
couldnt
afford
anything
less.
Miller
products
had
to
be
more
than the best
they
could
be.
They
had
to
be
the
best
you
could
buy.
Today,
the
people
that
build
and
sell Miller
products
continue
the
tradition.
Theyre
just
as
committed
to
providing equipment
and service
that
meets
the
high
standards of
quality
and value
established
in
1929.
This
Owners
Manual
is
designed
to
help
you
get
the
most out
of
your
Miller
products.
Please take
time
to
read the
Safety precautions.
They
will
help
you
protect
yourself
against potential
hazards
on
the
worksite.
Weve
made
installation and
operation
quick
and
easy.
With Miller
you
can
count
on
years
r
of
reliable service with
proper
maintenance.
And
if
for
some reason
the unit
needs
repair,
______________
theres
a
Troubleshooting
section
that
will
help
you
figure
out
what the
problem
is.
The
parts
list
will then
help
you
to
decide
the
exact
part
you may
need
to
fix the
problem.
Warranty
and service
information for
your
particular
model
are
also
provided.
.
j.æilleroffers
a
Technical
Manual
vthich
provides
more
detailed service
and
parts
Information
for
your
unit.
To
obtain
a
Technical
Manual,
contact
your
local
distnbuto,
Your
distributor
can
also
supply
you
with
Welding
Process
Manuals
such
as
SMAW, GTAW,
GMAW,
and
GMAW-P.
Miller
Electric manufactures
a
full
line
of welders
and
welding
related
equipment.
For
information
on
other
quality
Miller
products,
contact
your
local
Miller distributor
to
receive
the
latest
full
line
catalog
orindividual
catalog
sheets.
To
locate
your
nearest
distributor
or
service
agency
call
1-800-4-A-Miller,
or
visit
us
at
www.MillerWelds.com
on
the
web.
I
~/1A
Miller

a
WARNING
This
product,
when
used
for
welding
or
cutting,
produces
fumes
or
gases
which
contain
chemicals
known
to
the
State
of
California
to
cause
birth
defects
and,
in
some
cases,
cancer.
(California
Health &
Safety
Code
Section
25249.5
et
seq.)
TABLE
OF
CONTENTS
3
3
4
5
5
5
7
8
8
9
9
11
12
13
13
13
14
15
16
16
17
17
18
18
19
20
21
22
22
22
23
24
24
25
26
SECTION
1

SAFETY
PRECAUTIONS
-
READ BEFORE
USING
1-1.
Symbol Usage
1-2.
Arc
Welding
Hazards
1-3.
Additional
Symbols
For
Installation,
Operation,
And Maintenance
1-4.
Principal
Safety
Standards
1-5.
EMF Information
SECTION
1

CONSIGNES
DE
SECURITE

LIRE AVANT
UTILISATION
1-1.
Signification
des
symboles
1-2.
Dangers
relatifs
au
soudage
a
Iarc
1-3.
Dangers supplementaires
en
relation
avec
linstallation,
le tonctionnement
et
Ia maintenance
1-4.
Principales
normes
de
sØcuritØ
1-5.
Information
sur
les
champs
electromagnetiques
SECTION
2
DEFINITIONS
2-1.
Manufacturers
Warning
Label
Definitions
2-2.
Manufacturers
Rating
Labels
2-3.
Symbols
And
Definitions
SECTION 3INSTALLATION
3-1.
Specifications
3-2.
Duty Cycle
And
Overheating
3-3.
Volt-Ampere
Curves
3-4.
Selecting
A
Location
3-5.
Weld
Output
Terminals And
Selecting
Cable Sizes
3-6.
Remote
14
Receptacle
Information
3-7.
Electrical Service Guide
3-8.
Connecting
Input
Power
SECTION
4OPERATION
4-1.
Front Panel Controls
4-2.
Meter Functions
4-3. Mode Switch
Sethngs
4-4.
Lift-Arc
Trigger
Hold TIG
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine Maintenance
5-2.
Blowing
Out Inside
Of
Unit
5-3.
Voltmeter/Ammeter
Help
Displays
5-4.
Circuit Breakers CB1 And CB2
5-5.
Troubleshooting
SECTION
6
ELECTRICAL DIAGRAM
SECTION
7
PARTS LIST
WARRANTY
The
following
terms
are
used
interchangeably
throughout
this manual:
TIG
=
GTAW
Stick
=
SMAW
OM-193
084

Declaration
of
Conformity
For
European Community
(CE)
Products
.
Manufacturers
Name:
Manufacturers
Address:
Declares
that the
product:
Miller
Electric
Mfg.
Co.
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
XMTfi
304
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:
December 1995
Safety
Requirements
for Arc
Welding
Equipment
part
1:
EN
60974-1:1989
Degrees
of
Protection
provided
by
Enclosures
(IP
code):
IEC
529:1989
Insulation coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles,
requirements
and
tests:
IEC
664-1:1992
European
Contact:
Telephone:
Fax:
Mr.
Danilo
Fedolfi,
Managing
Director
11W
WELDING
PRODUCTS
ITALY
S.r.I.
Via
Privata
lseo
6/E
20098
San Giuliano
Milanese,
Italy
39(02)98290-1
39(02)98290-203
dec_con
1
_11/02

SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING

1-1.
Symbol
Usage
som
_nd_7/02
a
Means
Warning!
Watch
Out
There
are
possible
hazards
with this
procedure!
The
possible
hazards
are
shown in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
U~
Means
Wote;
not
safety
related.
1-2. Arc
Welding
Hazards
A
The
symbols
shown below
are
used
throughout
this
manual
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 the
more
complete
safety
information found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
A
Only qualified
persons
should
install,
operate,
maintain,
and
repair
this unit.
A
During
operation,
keep everybody,
especially
children,
away.
ELECTRIC SHOCK
can
kill.
~
Touching
live electrical
parts
can
cause
fatal shocks
or severe
bums. 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.

Do
not
touch live electrical
parts.

Wear
dry,
hole-free
insulating gloves
and
body protection.

Insulate
yourself
from work and
ground
using dry
insulating
mats
or
covers
big enough
to
prevent
any
physical
contact
with the work
or
ground.

Do
not
use
AC
output
in
damp areas,
if
movement
is
confined,
or
if
there is
a
danger
of
falling.

Use AC
output
ONLY if
required
for the
welding
process.

If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.

Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment
Lockout/tagout
input
power
according
to
OSHA
29
CFR 1910.147
(see
Safety
Standards).

Properly
install and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.

Always
verify
the
supply
ground

check
and
be
sure
that
input
power
cord
ground
wire is
property
connected
to
grDund
terminal
in
disconnect
box
or
that cord
plug
is connected
to
a
properly
grounded
receptacle
outlet.

When
making
input
connections,
attach
proper
grounding
conduc
tor
first

double-check
connections.

Frequently
inspect input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.

Turn
off all
equipment
when
not
in
use.

Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.

Do
not
drape
cables
over
your
body.
This
group
of
symbols
means
Waming!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and I-lOT
PARTS hazards.
Consult
symbols
and related
instructions below for
necessary
actions
to
avoid
the
hazards.

If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable.

Do
not
touch electrode
If
you
are
in
contact
with the
work,
ground,
or
another electrode
from
a
different machine.

Use
only
well-maintained
equipment
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.

Wear
a
safety
hamess
if
working
above floor level.

Keep
all
panels
and
covers
securely
in
place.

Clamp
work cable with
good
metal-to-metal
contact to
workpiece
or
worktable
as near
the
weld
as
practical.

Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.

Do
not connect
more
than
one
electrode
or
work cable
to
any
single
weld
output
terminal.
SIGNIFICANT
DC VOLTAGE
exists after removal
of
input
power
on
inverters.

Turn Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in Maintenance
Section
before
touching
any
parts.
I
r-~~~
~.
FUMES
AND
GASES
can
be
hazardous.
I(~12
L..._
\Q
Welding
produces
fumes
and
gases.
Breathing
fl
y
these
fumes
and
gases
can
be hazardous
to
your
health.

Keep
your
head
out
of
the
fumes. Do
not
breathe
the
fumes.

If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.

If ventilation is
poor,
use
an
approved air-supplied
respirator.

Read
the Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers instructions
for
metals, consumables,
coatings,
cleaners,
and
degreasers.

Work
in
a
confined
space
only
if it is well
ventilated,
or
while
wearing
an
air-supplied
respirator. Always
have
a
trained
watch-
person
nearby.
Welding
fumes and
gases
can
displace air
and
lower
the
oxygen
level
causing
injury
or
death. Be
sure
the breath
ing
air
is
safe.

Do
not
weld in
locations
near
degreasing,
deaning,
or
spraying
op
erations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic and
irritating
gases.

Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is removed
from the weld
area,
the
area
is well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these elements
can
give
off toxic fumes if welded.
OM-193
084
Page
1

ARC
RAYS
can
burn
eyes
and
skin.
Arc
rays
from the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Sparks fly
off from
the
weld.

Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).

Wear
approved
safety
glasses
with side
shields
under
your
helmet.

Use
protective
screens
or
bafflers
to
protect
others
from flash and
glare;
warn
others
not to
watch the
arc.

Wear
protective
dothing
made
from
durable,
flame-resistant
mate
rial
(leather
and
wool)
and foot
protection.
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
bums. 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.

Protect
yourself
and others
from
flying
sparks
and hot metal.

Do
not
weld where
flying
sparks
can
strike
flammable
material.

Remove
all flammables within 35 ft
(10.7 m)
of
the
welding
arc.
If
this is
not
possible, tightly
cover
them with
approved
covers.

Be alert that
welding
sparks
and hot materials from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.

Watch for
fire,
and
keep
a
fire
extinguisher
nearby.

Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the hidden side.

Do
not
weld
on
closed containers such
as
tanks, drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.i
(see
Safety
Standards).

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.

Do
not
use
welder
to
thaw frozen
pipes.

Remove stick
electrode from holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.

Wear oil-free
protective
garments
such
as
leather
gloves, heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.

Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING METAL
can
injure
eyes.

Welding, chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal. As welds
cool,
they
can
throw
off
slag.

Wear
approved
safety glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP OF
GAS
can
injure
or
kill.

Shut off
shielding
gas
supply
when
not
in
use.

Always
ventilate
confined
spaces
or use
approved
air-supplied
respirator.
HOT
PARTS
can cause severe
burns.

Do
not
touch hot
parts
bare handed.

Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC FIELDS
can
affect
pacemakers.

Pacemaker
wearers
keep
away.

Wearers should consult their doctor
before
going
near arc
welding, gouging,
or
spot
welding operations.
NOISE
can
damage hearing.
Noise
from
some
processes
or
equipment
can
damage hearing.

Wear
approved
ear
protection
if
noise level is
high.
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,
mechani
cal
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.
Never
drape
a
welding
torch
over a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never weld
on a
pressurized cylinder

explosion
will result.
Use
only
correct
shielding
gas
cylinders, regulators,
hoses,
and fit
tings designed
for the
specific application;
maintain them
and
associated
parts
in
good
condition.

Tum face
away
from
valve outlet
when
opening cylinder
valve.

Keep protective
cap
in
place
over
valve
except
when
cylinder
is
in
use or
connected for
use.

Read and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
S

S
S
S
OM-193
084
Page
2

1-3.
Additional
Symbols
For
Installation,
Operation,
And Maintenance
FIRE
OR EXPLOSION hazard.

Do
not
install
or
place
unit
on, over,
or
near
combustible
surfaces.

Do
not
install unit
near
flammables.

Do
not
overload
building wiring

be
sure
power
supply
system
is
properly
sized,
rated,
and
protected
to
handle
this unit.
FALLING
UNIT
can cause
injury.

Use
lifting
eye
to
lift unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other accessories.

Use
equipment
of
adequate capacity
to
lift and
support
unit.

If
using
lift forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond opposite
side
of
unit.
OVERUSE
can cause
OVERHEATING

Allow
cooling
period;
follow
rated
duty cycle.

Reduce
current
or
reduce
duty cycle
before
starling
to
weld
again.

Do
not
block
or
filter airflow
to
unit.
STATIC
(ESD)
can
damage
PC boards.

Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.

Use
proper
static-proof
bags
and boxes
to
store,
move,
or
ship
PC
boards.
MOVING
PARTS
can cause
injury.

Keep
away
from
moving
parts.

Keep
away
from
pinch points
such
as
drive
rolls.
WELDING
WIRE
can
cause
injury.

Do
not
press
gun
trigger
until instructed
to
do
so.

Do
not
point
gun
toward
any
part
of the
body,
other
people,
or
any
metal
when
threading
welding
wire.
MOVING PARTS
can
cause
injury.

Keep
away
from
moving
parts
such
as
fans.

Keep
all
doors,
panels, covers,
and
guards
closed
and
securely
in
place.
H.F. RADIATION
can cause
interference.

High-frequency
(HF.)
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.

Have
only
qualified
persons
familiar with
electronic
equipment
perform
this installation.

The
user
is
responsible
for
having
a
qualified
electrician
prompt
ly
correct
any
interference
problem
resulting
from the installa
tion.

If notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have the installation
regularly
checked and maintained.
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.
ARC WELDING
can
cause
interference.

Electromagnetic
energy
can
interfere with
sensitive electronic
equipment
such
as
computers
and
computer-driven equipment
such
as
robots.

Be
sure
all
equipment
in the
welding
area
is
electromagneticallycompatible.

To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and down
low,
such
as on
the
floor.

Locate
welding
operation
100 meters
from
any
sensitive elec
tronic
equipment.

Be
sure
this
welding
machine is installed and
grounded
according
to
this
manual.

If
interference still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
I
OM-193
084
Page
3

1-4.
Principal
Safety
Standards
Safetyin Welding,
Cutting,
and Allied
Processes,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W. LeJeune
Rd,
Miami
FL
33126
(phone:
305-443-9353,
website:
www.aws.org).
RecommendedSafe
Practices
for
the
Preparation
for
Welding
and
Cut
ting
of Containers
and
Piping,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W. LeJeune
Rd,
Mi
ami,
FL
33126
(phone:
305-443-9353,
website:
www.aws.org).
National
Electncal
Code,
NFPA
Standard
70,
from
National
Fire Protec
tion
Association,
P.O. Box
9101,
1
Battery
March
Park,
Quincy,
MA
022699101
(phone:
6177703000,
website:
www.nfpa.org
and
www.
sparky.org).
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1735
Jefferson Davis
Highway,
Suite
1004,
Arlington,
VA 222024102
(phone:
7034120900,
web-
site:
www.cganet.com).
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
1-5.
EMF Information
Considerations
About
Welding
And The Effects
Of
Low
Frequency
Electric And
Magnetic
Fields
Welding
current,
as
it
flows
through
welding
cables,
will
cause
electro
magnetic
fields.
There has been and still is
some
concern
about
such
fields.
However,
after
examining
more
than 500 studies
spanning
17
years
of
research,
a
special
blue ribbon committee
of
the
National
Research
Council concluded
that: The
body
of
evidence,
in the
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
frequency
electric and
magnetic
fields
is
a
human-health hazard.
However,
studies
are
still
going
forth
and
evidence
continues
to
be
examined.
Until the
final conclusions
of
the research
are
reached,
you
may
wish
to
minimize
your
exposure
to
electromagnetic
fields when
welding
or
cuffing.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3
(phone:
8004636727
or
in
Toronto
4167474044,
website:
www.csa-~n
temational.org).
Practice For
Occupational
And Educational
Eye
And Face
Protection,
ANSI
Standard
Z87.1,
from American
National Standards
Institute,
11
West 42nd
Street,
New
York,
NY 100368002
(phone:
212642-4900,
website:
www.ansi.org).
Standard for
Fire Prevention
During Welding,
Cutting,
and
Other
Hot
Worl
NFPA
Standard
51
B,
from
National Fire
Protection
Association,
P.O.
Box
9101,1
Battery
March
Park,
Quincy,
MA
022699101
(phone:
61
77703000,website:
www.nfpa.org
and
www.
sparky.org).
OSHA,
Occupational
Safety
and Health
Standards
for
General
Indus
try,
Title
29,
Code
of
Federal
Regulations
(CFR),
Part
1910,
Subpart
0,
and
Part
1926,
Subpart
J,
from U.S.
Government
Printing
Office,
Super
intendent
of
Documents,
RO.
Box
371954,
Pittsburgh,
PA 15250
(there
are
10
Regional
Officesphone
for
Region
5,
Chicago,
is
3123532220,
website:
www.osha.gov).
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
your
body.
4.
Keep
welding
power
source
and
cables
as
tar
away
from
opera
tor
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the weld
as
possi
ble.
AbOUt Pacemakers:
Pacemaker
wearers
consult
your
doctor
first. If cleared
by
your
doctor,
then
following
the above
procedures
is
recommended.
.
.
OM-i93
084
Page
4

SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTI
LISATION
1T1~
Signification
des
symboles
a
Signifie
Mise
en
garde!
Soyez vigilant!
Cette
procedure
presente
des
nsques
de
danger!
Ceux-ci sont
identifies
par
des
symboles
adjacents
aux
directives.
A
Identifie
un
message
de
sØcuritØ
particulier.
~
Signifie
NOTA
nestpas
relatif
Ia
sØcuritØ.
1
-2.
Dangers
relatifs
au
soudage
a
Iarc
A
Les
symboles
presentes
ci-apres
sont
utilisØs
tout
au
long
du
present
manuel
pour
athrer
votre
attention
et
identifier les
nsques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez
les
directives mentionnØes at
in
dØviter tout
danger.
Les
consignes
de
sØcuritØ
presentØes
ci-aprŁs
ne
font
que
rØsumer
Iinformation
contenue
dans les
normes
de sØcuritØ
ØnumØrØes
a
Ia
section
1-4.
Veuillez
lire
et
respecter
toutes
ces normes
de
sØcuritØ.
A
Linstallation, lutilisation,
lentretien
et
les
reparations
ne
doi
vent
Œtre
confiØs
qu
des
personnes
qualifiØes.
A
Au
cours
de
lutilisation,
tenir
toute
personne
a lecart
et
plus
par
ticuliŁrement
les
enfants.
UN
CHOC
ELECTRIQUE
peut
tuer~
tin
simple
contact
avec
des
piŁces
etectriques
peut
provoquer
une
electrocution
ou
des blessures
graves.
LØlectrode
et
le circuit de
soudage
sont sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrØe
et
les
circuits intemes
de
lappareil
sont
Øgalement
sous
tension
a
ce
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
fil,
le
dØvidoir,
le
logement
des
galets
dentraInement et
les
piŁces
mŁtalliques
en
contact
avec
le
til
de
soudage
sont
sous
tension. Des
matŁriels mal
installŁs
ou
mal mis
a
Ia
terre
prØsentent
un
danger.

Ne
jamais
toucher
es
piŁces
Łlectnques
sous
tension.

Porter
des
gants
et
des vŁtements de
protection
secs ne
comportant
pas
de
trous.

Sisoler
de Ia
piŁce
et
de
Ia
terre au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empŒcher
le
contact
phy
sique
Łventuel
avec
Ia
piŁce
ou
Ia
terre.

Ne
pas
Se
servir
de
source
electnque
courant
Ølectiique
dans les
zones
humides,
dans
es
endroits confines
ou
l oU
on
risque
de tomber.

Se
servir dune
source
Ølectiique
courant
Ølectrique
UNIQUEMENT si le
procØdØ
de
soudage
fe
demande.

Si
Iutilisation dune
source
electrique
courant
Ølectnque
savŁre neces
saire,
se
servir
de Ia
fonction
de telecommande si
lappareil
en
est
equipe.

Couper
alimentation
ou
arrŒter
le
moteur avant
de
procØder
a
linstal
lation,
a
a
reparation
ou
a lentretien de
Iappareil.
DŁverrouiller
lalimentation selon
Ia
norme
OSHA
29
CFR
1910.147
(voir
nornies
de
sŁcuritŁ).

Installer
et
mettre
a
a
terre
correctement cot
appareil
conformŁment a
son
manuel dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.

Toujours
verifier Ia
terre
du
cordon
dalimentation

Verifier
et
sassu
rer
que
le
fil
de
terre
du
cordon dalimentation
est
bien
raccordŁ a
Ia
borne
de
terre
du
sectionneur
ou
que
a
fiche
du
cordon
est
raccordŁe
a
une
pnse
correctement mise
a
Ia
terre.

En
eflectuant
les
raccordements
dentrŁe
fixer
dabord
le conducteur
de
mise a Ia
terre
appropnØ
et
contre-vØrifler
les
connexions.

Verifier
frequemment
le
cordon dalimentation
pour
voir
sit
nest
pas
endommagŁ
ou
dØnudŁ

remplacer
le cordon
immØdiatement
sil
est
endommage

un
cable
dŁnudØ
peut provoquer
une
electrocution.

Mettre
rappareil
hors
tension
quand
on ne
lutilise
pas.

Ne
pas
utiliser
des
cables
uses,
endommages,
de
grosseur
insuffi
sante
ou
mat
episses.

Ne
pas
enrouler
Ies
cables
autour
du
corps.

Si
Ia
piŁce
soudŁe
dolt
etre
mise
ala
terre,
Ie
faire
directement
avec un
cable
distinct.

Ne
pas
toucher
IØlectrode
quand
on
est
en contact avec
Ia
piŁce,
Ia
terre
ou une
electrode
provenant
dune
autre
machine.
som
_nd_tre
7/02
Ce
groupe
de
symboles
signifle
Mise
en
garde! Soyez
vigilant!
II
y
a
des
risques
de
danger
relies
aux
CHOCS
ELECTRIQUES,
aux
PI¨CES
EN
MOUVEMENT
et
aux
PIECES CHAUDES.
Reportez-vous
aux
symboles
et aux
directives
ci-dessous
afin de
connaItre
les
mesures
a
prendre
pour
Łviter
tout
danger.

Nutiliser
quun
materiel
en
bon
Łtat.
RŁparer
ou
remplacer
sur-le
champ
les
piŁces
endommagees.
Entretenir
lappareil
conformŁment
ace
manuel.

Porter
un
hamais de
sØcuntØ
quand
on
travaille
en
hauteur.

Maintenir
solidement
en
place
tous
les
panneaux
et
capots.

Fixer le
cable
de
retour
de
faon
a
obtenir
un
bon
contact
mØtal-mØtal
avec
Ia
piŁce
a souder
ou
Ia
table
de
travail,
le
plus
prŁs
possible
de Ia
soudure.

Isoler Ia
pince
de
masse
quand
pas
mis a Ia
piŁce
pour
Łviter
le contact
avec
tout
objet
mØtallique.
Ily
a
DU
COU
RANT
CONTINU IMPORTANT
dans les
convertisseurs
aprŁs
Ia
suppression
de
Ialimenta
tion
Ølectrique.

ArrŒter les
convertisseurs,
dŁbrancher
te
courant
electrique,
et
de
charger
les
condensateurs
dalimentation selon les instructions
indiquees
dans
Ia
partie
entretien
avant
de
toucher les
piŁces.
I
rj~
LES
FUMEES
ET LES GAZ
peuvent
I ~-~
~Y
Œtre
dangereux.
L..._
Le
soudage
gŁnŁre
des
fumØes
et
des
gaz.
Leur
inhalation
peut
Œtre
dangereux
pour
votre
sante.
_____________

Eloigner
votre
tŒte
des
fumŁes.
Ne
pas
respirer
les fumØes.

A
lintØneur,
ventiler Ia
zone
etlou
utiliser
un
echappement
au
niveau
de Iarc
pour
evacuation
des
fumØes
et
des
gaz
de
soudage.

Si Ia ventilation
est
insuffisante,
utiliser
un
respirateur
a
alimenta
tion dair
homologue.

Lire les
specifications
de
sØcurite
des
matŁnaux
(MSD55)
et
les
instructions
du
fabricant
concernant
es
mŁtaux,
es
consomma
bles,
les
revŒtements,
les
nettoyants
et
les
degraisseurs.

Travailler
dans
un
espace
ferrnŁ
seulement
sit
est
bien
ventilØ
ou en
portant
un
respirateur
a
alimentation
dair. Demander
toujours
a
un
surveillant
dOment
formŁ
de
se
tenir
a
proximite.
Des
fumØes
et
des
gaz
de
soudage
peuvent
deplacer
air
et
abaisser
le
niveau
doxy
gene
provoquant
des
blessures
ou
des accidents
mortels.
Sassu
rer
que
lair
de
respiration
ne
prŁsente
aucun
danger.

Ne
pas
souder
dans des
endroits
situŁs a
proximite
doperalions
de
degraissage,
de
nettoyage
ou
de
putverisation.
La chaleur
et
las
rayons
de
larc
peuvent
reagir
en
presence
de
vapeurs
et
former
des
gaz
hautement
toxiques
et
imtants.

Ne
pas
souder des
mŁtaux munis
dun
revŒtement,
tels
que
lacier
galvanise, plaque
en
p10mb
ou au
cadmium a moms
que
le
revŒte
ment
nail
ØtŁ
enlevØ
dans Ia
zone
de
soudure,
que
rendroil soil
bien
ventilØ,
et
si
nŁcessaire,
en
portant
un
respirateur
a alimentation
dair. Les
revŒtements
et
tous
les
mØtaux
renferrnant
ces
ØlŁments
peuvent
degager
des
turnees
toxiques
en
cas
de
soudage.
OM-193
084
Page
5

LES
RAYONS
DE LARC
peuvent
pro
voquer
des
brUlures
dans les
yeux
et
sur
Ia
peau.
Le
rayonnement
de larc du
procØdØ
de
soudage
gØnŁre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des
brOlures
dans
les
yeux
et
sur
Ia
peau.
Des ehncelles
sont
projetØes
pendant
le
soudage.

Porter
un
casque
de
soudage
muni
dun Øcran de filtre
appropne
pour
protegervotre
visage
et
vos
yeux
pendant
le
soudage
Cu
pour
regar
der
(voir
ANSI
Z49.1 etZ87.1
ØnumØrØ
dans les
normes
de
sØcunte).

Porter
des
protections
approuves
pour
los oreilles Si le niveau
sondre
est
trop
ØlevØ.

Utiliser
des
Øcrans
ou
des
barriŁres
pour
proteger
des tiers de
lØclair
et
de
lØblouissement;
demander
aux
autres
personnes
de
ne
pas
ro
garder
larc.

Porter
des
vŒtements
de
protection
conslituØ
dans
une
matiŁre
dura
ble,
resistant
au
feu
(cuir
ou
lame)
et
une
protection
des
pieds.

Se
proteger
et
dautres
personnes
de Ia
projection
dŁtmncelles
et
de
metal chaud.

Ne
pas
souder
dans
un
endroit
l oO des Øtincelles
peuvent
tomber
sur
des
substances
inflammables.

DØplacer
toutos
les substances
inflammables a
une
distance do
10,7
m
de arc de
soudage.
En
cas
dimpossibilitØ
les
recouvrir
soigneuse
mont avec
des
protections
homologuØs.

Des
etincelles
et
des
matØriaux chauds
du
soudage
peuvent
facile
mont
passer
dans
dautres
zones en
traversant
de
petites
fissures
et
des
ouvertures.

Surveillor
tout
dØclenchement
dincendie
et
tenir
un
extincteur
a
proxi
mite.

Le
soudage
effectuØ
sur
un
plafond, plancher,
paroi
ou
separation
peut
dØclencher
un
incendie
de Iautre
ctØ.

Ne
pas
effectuer
0
soudage
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours,
ou
conduites,
a
moms
quils
naient
ete
prØpa
rØs
correctement
confomiØment
a
AWS
F4. 1
(voir
les
normes
de
sØcurite).

Brancher
le
cable
sur
Ia
piŁce
le
plus
prŁs
possible
de Ia
zone
do
sou
dage
pour
Øviter
le
transport
du
courant
sur
une
longue
distance
par
des
chemins inconnus
Øventuels
en
provoquant
des
risques
dØlec
trocution
01
dincendie.

We
pas
utiliser
le
poste
do
soudage
pour
degeler
des
conduites
go
lees.

En
cas
de
non
utilisation,
enlever
Ia
baguette
dØlectrode
du
porte
electrode
ou
couper
le
fil
a
Ia
pointe
de
contact.

Porter
des
vØtements
de
protection
dØpourvus dhuilo
tels
que
des
gants
en
cuir,
une
chemise
en
matØnau
lourd,
des
pantalons
sans
re
vers,
des chaussures
hautes
et
un couvre
chef.

Avant
do
souder,
retirer
toute
substance
combustible de
vos
poches
telles
quun
allumeur
au
butane
ou
des allumottes.
DES
PARTICULES
VOLANTES
~
peuvent
blesser les
yeux.

Le
soudage,
lØcaillement,
to
passage
do
Ia
piŁce
a Ia
brosse
en
fil
de
fer,
et
le
meulage
gØnØrent
des
Øtincelles
01
des
particules metalliques
vo
lantes.
Pendant
Ia
periode
de
ref roidissement des
soudures,
ellos
ns
quent
de
projeter
du
laitier.

Porter
des
lunettos
de
sØcuntØ
avec
Øcrans latØraux
ou un
Øcran
tacial.
LES
ACCUMULATIONS
DE GAZ
ris
quent
de
provoquer
des blessures
ou
mŒme
Ia
mort.

Former lalimentatlon dv
gaz
protecteur
en
cas
de
non
utilisation.

Voiller
toujours
a
bien
aØrer los
espaces
confines
ou
so
servir
cfun
respi
rateur
dadduction
dair
homologue.
DES
PI¨CES
CHAUDES
peuvent
pro
voquer
des
br!ures
graves.
-

Ne
pas
toucher des
parties
chaudos a
mains
nues

PrØvoir
une
periode
de
refroidissement
avant
dutilisor
le
pistolot
ou
Ia
torche.
Si
des
BOUTEILLES
sont
endomma
gØes,
elles
pourront
exploser.
Des bouteilles do
gaz
protecteur
contionnent
du
gaz
sous
haute
prossion.
Si
une
boutoille
est
ondomma
gee,
elle
pout
oxploser.
Du
fait
quo
les
bouteilles
do
gaz
font
normalement
partie
du
procedŁ
de
soudago,
los
manipuler
avec
precaution.

Protegor
los
bouteillos
do
gaz
comprime
dune
chaleur
excessive,
des chocs
mecaniques,
du
laitier,
des
flammes
ouvertos,
des
Łtin
celles
ot
dos
arcs.

Placer los
bouteillos debout
en
los
fixant
dans
un
support
stationnai
ro ou
dans
un
porte-bouteillos
pour
los
ompŒcher
do tombor
ou
do
so ronversor.

Tenir los bouteilles
eloignees
dos circuits
do
soudago
ou
autres
cir
cuits
eloctriques.

No
jamais
placer
une
torche do
soudago
sur
une
bouteille
a
gaz.

Uno
electrode do
soudage
no
dolt
jamais
ontror en
contact
avoc une
bouteillo.

Ne
jamais
souder
une
boutoille
prossurisŁe

risque
doxplosion.

Utilisor
soulement
dos
bouteillos do
gaz
protectour,
rŁgulatours,
tuyaux
ot
raccords convenables
pour
cette
application
spŁcifique;
los maintonir
ainsi
quo
los
elements
associŁs
en
bon
Øtat.

No
pas
tenir
Ia
tŒte
en
face do
Ia
sortie
en
ouvrant
Ia
soupape
de Ia
boutoillo.

Mamntonir
0
chapeau
do
protection
sur
Ia
soupapo,
said
en
cas
duti
lisation
ou
do branchemont
do
Ia
boutoille.

Lire
ot
suivre los
instructions
concomant
los
boutomlles
do
gaz
corn
prime,
los
Øquipoments
associØs
et
los
publications
P-i
CGA Ønu
mŁrØos dans
los
normos
do
sØcuritØ.
.
LE SOUDAGE
peut
provoquer
un
incendie
ou une
explosion.
Le
soudage
effectuØ
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours
ou
des conduites
pout
provoquer
leur
Øclatement.
Des Øtincelles
peuvent
Œtre
projetØes
de
larc de
soudure. La
projection
dØtincel
les,
des
piŁces
chaudes
et
des
equipements
chauds
peut
provoquer
des
incendies
et
des
brOlures.
Le
contact
accidentel
de
lØlectrode
avec
des
objets
metalliques
peut
provoquer
des
Øtincelles,
une
explosion,
un
surchauffement
ou
un
incendie.
Avant de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
presente
pas
de
danger.
LES CHAMPS
MAGNETIQUES
peuvent
affecter
les
stimulateurs
cardiaques.

Porteurs do
stimulateur
cardiaque,
restez
a
distance.

Les
portours
dun
stimulateur
cardiaque
doivent
dabord
consulter leur
mØdecmn
avant
do
sapprother
des
operations
do
soudage
a
larc,
do
gougeage
ou
do
soudage
par
points.
LE BRUIT
peut
affecter
Iouie.
Le bruit des
processus
et
des
Øquipements
pout
affecter
louie.

Porter des
protections approuvØs
pour
los oreilles Si
le
niveau sondre
est
trop
ØlevØ.
OM-193
084
Page
6

I
I
~
~
Risque
DINCENDIE
OU
DEXPLOSION.
6
A

Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proxi
mite
de
surfaces infilammables.

Ne
pas
installer
lappareil
a
proximite
de
produits
inflammables

Ne
pas
surcharger
installation
electrique

sassurer
que
alimen
tation
est correctement
dimensionnØ et
protØgØ
avant
de
mettre
lappareil
en
service.
LA
CHUTE DE
LAPPAREIL
peut
blesser.

Utiliser lanneau de
levage
uniquement
pour
sou
lever
lappareil,
NON PAS
les
chariot,
es
bouteil
les de
gaz
ou
tout autre
accessoire.

Utiliser
un
engin
dune
capacitØ
appropnee
pour
soulever
lappareil.

En
utilisant des
fourches de
levage
pour
dØplacer
IunitØ,
sassurer
que
les
fourches
sont
suffisamment
longues
pour
dØpasser
du
ctØ
oppose
de
lappareil.
LEMPLOI EXCESSIF
peut
SURCHAUFFER
LEOUIPEMENT.

PrØvoir
une
periode
de
refroidissement,
respec
ter
le
cycle
opØratoire
nominal.

RØduire
le
courant
ou
le
cycle
opØratoire
avant
de
recommancer
le
soudage.

Ne
pas
obstnier les
passages
dair du
poste.
LES CHARGES
ELECTROSTATI
QUES
peuvent
endommager
les
circuits
imprimØs.

Etablir
Ia connexion
avec
Ia barrette de
terre
avant
de
manipuler
des
caries
ou
des
piŁces.

Utiliser des
pochettes
et
des
boltes
antistatiques
pour
stocker,
dØplacer
ou
expØdier
des
caries
de
circuits
imprimes.
DES ORGANES MOBILES
peuvent
provoquer
des
blessures.

Ne
pas
sapprocher
des
organes
mobiles.

Ne
pas
sapprocher
des
points
de coincement
tels
que
des rouleaux de commande.
LES FILS DE
SOUDAGE
peuvent
provoquer
des blessures.

Ne
pas appuyer
sur
Ia
gachette
avant
den
avoir
reu
linstruction.

Ne
pas
diriger
le
pistolet
vers
soi,
dautres
person
nes ou
toute
piŁce
mecanique
en
engageant
le
fil
de
soudage.
DES
ORGANES
MOBILES
peuvent
provoquer
des blessures.

Rester a IØcart
des
organes
mobiles
comme
le
ventilateur.

Maintenir fermØs
et
fixement
en
place
les
portes,
panneaux,
recouvrements et
dispositifs
de
protection.
LE RAYONNEMENT HAUTE
FRE
QUENCE
(H.F.) risque
de
provoquer
des
interferences.

Le
rayonnement
haute
frequence
peut
provoquer
des
interferences
avec
les
equipements
de
ra
dionavigation
et
de
communication,
les services
de
secuntØ
et
les
ordinateurs.

Demander seulement
ades
personnes
qualifiees
familiansØes
avec
des
Øquipements electroniques
de faire fonctionner
linstalla
lion.

Lutilisateur
est tenu
de
faire
cornger
rapidement
par
un
electncien
qualifie
les
interferences resultant de linstallation.

Si
le
FCC
signale
des
interferences,
arrŁter immØdiatement
lappa
reil.

Effectuer
rŁguliŁrement
le contrle
et
lentretien
de
linstallation.

Maintenir
soigneusement
fermØs les
portes
et
les
panneaux
des
sources
de haute
frequence,
maintenir
es
Øclateurs a
une
distance
correcte et
utiliser
une
terre et et
un
blindage
pour
rØduire les interfe
rences
Øventuelles.
LE
SOUDAGE
A
LARC
risque
de
provoquer
des
interferences.

Lenergie
electromagnetique
risque
de
provoquer
des
interferences
pour
lequipement
electronique
sensible tel
que
es
ordinateurs
et
lequipement
commandØ
par
ordinateur tel
que
les
robots.

Veiller
a
ce
que
tout
lequipement
de Ia
zone
de
soudage
soit
com
patible
electromagnetiquement.

Pour
rØdu
ire Ia
possibilitØ
dinterference,
maintenir les
cables
de
soudage
aussi
courts
que
possible,
les
grouper,
et
les
poser
aussi
bas
que
possible (ex.
par
terre).

Veiller
a souder a
une
distance de ioo metres de
tout
equipement
electronique
sensible.

Veiller
a
ce
que
ce
poste
de
soudage
soit
pose
et
mis
a
Ia
terre
conformØment a
ce
mode
demploi.

En
cas
dinterfØrences
aprŁs
avoir
pns
les
mesures
precedentes,
il
incombe
a lutilisateur de
prendre
des
mesures
supplementaires
tel
les
que
le
dØplacement
du
poste,
lutilisation de
cables
blindØs,
luti
lisation de
flitres
de
ligne
ou
Ia
pose
de
protecteurs
dans Ia
zone
de
travail.
LES
CHAMPS
MAGNET1QUES
peuvent
affecter
les
stimulateurs
cardiaques.

Porteurs
de stimulateur
cardiaque,
restez
a dis
tance.

Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter leur mØdecin
avant
de
sappro
cher des
operations
de
soudage
a
arc,
de
gou
geage
ou
de
soudage
par
points.
1-3.
Dangers
supplØrnentaires
en
relation
avec
linstallation,
le
fonctionnement
et
Ia
maintenance
OM-193
084
Page
7

1-4.
Principales
normes
de
sØcuritØ
Safety
in
Welding,
Cutting,
and
Allied
Processes,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W. LeJeune
Rd,
Miami FL
33126
(phone:
305-443-9353,
website:
www.aws.org).
RecommendedSafe
Practices
for
the
Preparation
for
Welding
and
Cut
ting
of Containers
and
Piping,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W. LeJeune
Ad,
Mi
ami,
FL 33126
(phone:
305-443-9353,
website:
www.aws.org).
National
Electrical
Code,
NFPA Standard
70,
from
Naliona] Fire Protec
tion
Association,
P.O.
Box
9101,
1
Battery
March
Park,
Quincy,
MA
022699101
(phone:
6177703000,
website:
www.nfpa.org
and
www.
sparky.org).
Safe
Handling
of
Compressed
Gases
in
Cyllnders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1735
Jefferson Davis
Highway,
Suite
1004,
Arlington,
VA
222024102
(phone:
7034120900,
web-
site:
www.cganet.com).
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 1R3
(phone:
8004636727
or
in Toronto
4167474044,
website:
www.csain
temational.org).
Practice For
Occupational
And
Educational
Eye
And Face
Protection,
ANSI Standard
Z87.i,
from
American National
Standards
Institute,
11
West 42nd
Street,
New
York,
NY
100368002
(phone:
2126424900,
website:
www.ansi.org).
Standard for Fire Prevention
During Welding,
Cutting,
and
Other
Hot
Worl
NFPA Standard
SiB,
from National Fire
Protection
Association,
P.O.
Box
9101,
1
Battery
March
Park,
Quincy,
MA 02269-9101
(phone:
6177703000,
website:
www.nfpa.org
and
www.
sparky.org).
OSHA,
Occupational
Safety
and Health
Standards
for
General
Indus
try,
Tille
29,
Code of Federal
Regulations
(CFR),
Part
1910,
Subpart
0,
and Part
1926,
Subpart
J,
from
U.S.
Govemment
Printing
Office,
Super
intendent
of
Documents,
P0. Box
371954,
Pittsburgh,
PA
15250
(there
are
10
Regional
Officesphone
for
Region
5,
Chicago,
is
3123532220,
website:
www.osha.gov).
1-5.
Information
sur
les
champs
ØlectromagnØtiques
DonnØes
sur
le
soudage
electnque
et
sur
les
effets,
pour
lorganisme,
des
champs
magnetiques
basse
frØquence
Le
courant
de
soudage,
pendant
son
passage
dans les
cables
de
sou
dage,
causera
des
champs
electromagnØtiques. Ily
a eu
et
ily
a encore
un
certain souci
a
propos
de tels
champs.
Cependant, aprŁs
avoir
ex
amine
plus
de
500
etudes
qui
ont
ØtØ
faites
pendant
une
pØriode
de
recherche de
17
ans,
un
comitØ
special
ruban bleu du National Re
search
Council
a
conclu:
Laccumulation de
preuves,
suivant le
jugement
du
comitØ,
na
pas
dØmontrØ
que
lexposition
aux
champs
magnetiqueset
champs
electriques
a haute
frequence reprØsente
un
risque
a Ia sante humaine.
Toutefois,
des
etudes
sont
toujours
en
cours
et
les
preuves
conhinuent a Œtre
examinØes.
En attendant
que
les
con
clusions
finales de
Ia
recherche soient
Øtablies,
ii
vous
serait
souhaitable de
rØduire
votre
exposition
aux
champs
electromagnØti
ques
pendant
le
soudage
ou
le
coupage.
At in de
rØduire
les
champs
electromagnetiques
dans lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder les cables ensembles
en
les torsadant
ou
en
les
attachant
avec
du ruban
adhØsif.
2 Mettre
tous
les
cables du
ctØ
oppose
de
Ioperateur.
3
Ne
pas
courber
pas
et
ne
pas
entourer
pas
les cables
autour
de
votre
corps.
4
Garder le
poste
de
soudage
et
les
cables
le
plus
loin
possible
de
vous.
5
Relier Ia
pince
de
masse
le
plus pres
possible
de
Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
personnes
qui
portent
un
stimulateur
cardiaque
doivent
avant tout
consulter leur docteur.
Si
vous
Œtes declare
apte
par
votre
docteur,
il
est
alors
recommandØ
de
respecter
les
consignes
cidessus.
.
.
OM-i
93084
Page
8

SECTION
2- DEFINITIONS
2-1.
Manufacturers
Warning
Label
Definitions
Warning!
Watch
Out!
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 electnc
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
bum
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-193
084
Page
9

.
S
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. Do
not
touch
fully charged
capacitors.
5
Always
wait
60 seconds
after
power
is turned
off
before
working
on
unit,
OR
6
Check
input
capacitor
voltage,
and be
sure
it is
near
0
before
touching
any
parts.
7
When
power
is
applied
failed
parts
can
explode
or cause
other
parts
to
explode.
8
Flying
pieces
of
parts
can
cause
injury. Always
wear a
face shield when
servicing
unit.
9
Always
wear
long
sleeves
and
button
your
collar when
servicing
unit.
10
After
taking
proper
precautions
as
shown,
connect
power
to
unit.
11/98
7 8 9
10
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Falling
equipment
can cause
injury
and
damage
to
unit.
3
Always
lift
and
support
unit
using
both handles.
Keep
angle
of
lifting
device less
than 60
degrees.
4
Use
a
proper
cart to
move
unit.
5
Do
not
use one
handle
to
lift
or
support
unit.
1/96
2
3
4
5
OM-193
084
Page
10

2-2.
Manufacturers
Rating
Labels
EN 60974-1
5A
by
400A
36V
350160
Hz
I
P23
EN
60974-1
50A by
400A
36V
~JcD~
350160
Hz
1P23
OM-193
084
Page
11

2-3.
Symbols
And
Definitions
S
S
OM-193
084
Page
12

3-1.
Specifications
SECTION
3-INSTALLATION
Rated
Welding
Output
Voltage
Range
(CC/CV
Models
Only)
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
IP
Rating
Amperes
Input
at
Rated Load
Output
50/60 Hz
460V
KVA
I
KW
I
300A
@
32
Volts
DC,
60%
Duty
Cycle
1035
5400
90
23
18.5
(0.15*)
14.9
11.4
(0.09*)
I
(0.041
I
*While
idling
3-2.
Duty
Cycle
And
Overheating


S

~
- - - -
-
 

 -
 
~aJ
4~
(I)
Id
~3W
2~O
<
225
Duty Cycle
is
percentage
of 10
min
utes
that unit
can
weld
at
rated load
without
overheating.
If
unit
overheats,
output stops,
a
Help
message
is
displayed
(see
Section
5-3),
and
cooling
fan
runs.
Wait
fifteen minutes for unit
to
cool.
Reduce
amperage
or
duty cyde
be
fore
welding.
IJ ~
2] 2530
40 ~~70~~1W
ZDUTY
CYcLE
A
Exceeding duty
cycle
can
damage
unit and void
war
ranty.
60%
Duty
Cycle
6 Minutes
Welding
Overheating
4
Minutes
Resting
A
Ret.
SA-1
78651
OM-193
084
Page
13

3-3.
Volt-Ampere
Curves
.
S
OM-193
084
Page
14

3-4.
Selecting
A
Location
Dimensions
And
Weight
87 lb
(39.5
kg)
12-1/2 in
(318
~
17 in
(432
mm)
Movement
Location
18
in
(460
mm)
Do
not
move or
operate
unit
where
it could
tip.
1
Lifting
Handles
Use
handles
to
lift unit.
2
Hand
Cart
Use
cart
or
similar
device
to
move
unit.
3
Plate Label
Use
label
to
determine
input
power
needs.
4
Une
Disconnect Device
Locate unit
near correct
input
power
supply.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present

see
NEC Article 511
or
CEC
Section
20.
Ioc_2
3196-
ST-aOl
192
I
18
in
(460mm)
OM-193
084
Page
15

3-5.
Weld
Output
Terminals
And
Selecting
Cable Sizes
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
~~$
To
reduce
possible
interference,
keep
weld cables
as
short
as
possible,
dose
together,
and
down
low,
such
as on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive electronic
equipment.
Be
sure
this
welding
machine is installed
and
grounded according
to
this
manual.
If
interference
still
occurs,
the
user
must
take extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Weld
Output
Terminals
Welding
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
100
(30 m)
Or Less
150ft
(45
m)
200ft
(60 m)
250ft
(70 m)
300ft
(90
m)
350ft
(105
m)
400ft
(120
m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10
100%
Duty Cycle
+
Output Receptacles
100
44
4 3
2
1
1/0 1/0
150
3
3
2 1
1/0
2/0
3/0 3/0
200 3
2
1
1/0 2/0 3/0 4/0 4/0
250
2
1
1/0
2/0 3/0 4/0 2-2/0 2-210
300
1
1/0 2/0
3/0
4/0 2-2/0
2-3/0 2-3/0
350
1/0 2/0 3/0 4/0
2-2/0 2-3/0
2-3/0
2-4/0
400
1/0 2/0 3/0
4/0
2-2/0 2-3/0 2-4/0 2-4/0
500
2/0 3/0 4/0 2-2/0
2-3/0 2-4/0
3-3/0
3-3/0
600
3/0
4/0 2-2/0
2-3/0
2-4/0
3-3/0 3-4/0 3-4/0
Weld cable size
(AWG)
is
based
on
either
a
4
volts
or
less
drop
or a
current
density
of
at
least 300 circular
mils
per ampere.
S-ooo7-D
3-6.
Remote
14
Receptacle
Information
~$~ł~
~/
ST-801
192
~aom
14
Socket*
Socket Information
24
VOLTS
AC
OUTPUT
(CONT~TOR)
A
24
volts
ac.
Protected
by
circuit
breaker
CB2.
B Contact closure
to
A
completes
24
volts
ac
con
tactor
control circuit.
115
VOLTS AC
OUTPUT
(CONT?CTORJ
I 115
volts
ac.
Protected
by
circuit
breaker
CB1.
J
Contact
closure
to
I
completes
115
volts
ac con
tactor
control
circuit.
REMOTE
OUTPUT
CONTROL
C
Output
to remote
control;
0
to
+10 volts
dc,
+10
volts
dc
in
MIG mode.
D Remote control
circuit
common.
E
0
to
+10 volts dc
input
command
signal
from
re
mote
control.
A/V
AMPERAGE
VOLTAGE
H
Voltage
feedback;
1
volt
dc
per
10
output
recep
tade volts.
F
Current
feedbacl
+1
volt
dc
per
100
amperes.
M
CC/CV
select
(CCICV
models
only).
GND
G
Circuit
common
for
24
and
115
volts
ac
circuits.
K
Chassis
common.
The
remaining
sockets
are
not
used.
.
OM-193
084
Page
16