Miller Electric Tandem Systems User manual

Millerﬁ

OWNERS

MANUAL

Read

and

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.

Call

your

distributor

you do

not

understand

the

directions.

''~~

__~'

~'~1~3

April

1993

Effective

With

Style

No.

JD-25

Form:

OM-1553

Tandem

Systems



For

help,

call

your

distributor



or:

MILLER

ELECTRIC

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

54912

414-734-9821

cover

8/92

ST

784-A

PRINTED

USA

u-I.

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective January

1992

(Equipment

with

serial

number

preface

ICC

newer)

This

limited

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY

Subject

the

terms

and

conditions

below.

MILLER

Electric

Mtg.

Co..

Appleton.

WIsconsin,

warrants

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

this

limited

warranty

free

lads

material

and

workmanship

the

time

shipped

MILLER.

TIltS

WAR

RANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

IMPLIED,

INCLUDING

TNE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within the

warranty

periods

listed

below.

MILLER

will

repair

replace

any

war

ranted

parts

components

that

tail

due

such

defects

matenal

workmanship.

MILLER

must

notified

writing

within

thIrty

130)

days

such

defect

tsilure,

which

time

MILLER

will

provide

instructions

the

warranty

claim

procedures

followed.

MILLER

shall

honor

warranty

claims

warranted

eguloment

lIsted

below

the

event

such

lailure

within

the

warranty

time

periods.

All

warranty

time

periods

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser.

one

year

after

the

equipment

sent

the

distributor

Years

Parts

3

Years

Labor

Original

main

power

rectifiers

Years



Parts

and

Labor

Transtormer/Ractifler

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

Robots

3.,

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE

Engines

are

warranted

separately

the

engine

manufacturer.)



Air

Compressors

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



Units



Grids



Soot

Welders



Load

Banks



SDX

Transtormers



Running

Gear/Trailers



Field

Options

(NOTE.

Field

options

are

covered

under

True

Bluer

for

the

remaining

warranty

period

the

product

they

are

installed

in,

for

minimum

one

year



whichever

greater

Months



Batteries

Days



Pans

and

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Pans

MILLERS

True

Bluer

Limited

Warranty

shall

not

apply

to:

Items

tumished

MILLER,

but

manutactured

others,

such

engines

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

any.

Consumable

components;

such

contact

tips,

cutting

nozzles,

contactors

and

relays

pans

that

tail

due

normal

wear

Equipment

that

has

been

modified

any

party

other

than

MILLER.

equip

ment

that

has

been

improperly

installed,

improperly

operaled

misused

based

upon

industry

standards.

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

equipment

which

has

been

used

tor

operation

outside

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIEHCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

the

event

warranty

claim

covered

this

warranty,

the

exclusive

remedies

shall

be,

MILLERS

option

(1)

repair;

(2)

replacement;

or.

where

authorized

writing

MILLER

appropriate

cases,

(3)

the

reasonable

cost

repair

replace

ment

authorized

MILLER

service

station;

(4)

payment

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

usel

upon

return

the

goods at

customers

risk

and

expense.

MILLERS

option

repair

replacement

will

FOB.,

Factory

Appleton,

Wisconsin.

F.O.

MILLER

authorized

ser

vice

tacility

determined

MILLER.

Therefore

compensation

reimburse

ment

for

transportation

costs

any

kind

will

allowed.

THE

EXTENT

PERMItTED

LAW.

THE

REMEDIES

PROVIDED

HEREIN

ARE THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT,

INDIRECt

SPECIAL,

INCIDENTAL

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

PROFIT).

WHETHER

BASED

CON

TRACt

TORT

OR.ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY.

GUARANTY

REPRESENTATION

PERFORMANCE.

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL

THEORY

WHICH.

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW.

CUSTOM

TRADE

COURSE

DEALING,

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

Some

states

the

U.S.A.

not

allow

limitations

how

long

implied

warranty

lasts,

the

exclusion

incidental,

indirect,

special

consequential

damages.

the

above

limitation

exclusion

may

not

apply

you.

This

warranty

provides

spa

cilic

legal

rights,

and

other

rights

may

available,

but

may

vary

from

slate

state.

Canada,

legislation

some

provinces

provides

(or

certain

additional

warranties

remedies

other

than

stated

herein,

and

the

extent

that

they

may

not

waived,

the

limitations

and

esclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

available,

but

may

vary

from

province

province.

al-

RECEIVING-HANDLING

Before

Unpacking

equipment,

Check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

Claims

for

loss

damage

with

the

delivering

carrier.

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportatton

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

Style

Number

Use

the

following

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit,

The

information

located

the

rating

label

nameplate.

Model

_________

Serial

Style

No,

Date

Purchase

miller

5/93a

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

Introduction

General

Precautions

Arc

Welding

Standards

Booklet

Index

SECTION

INTRODUCTION

General

Information

And

Safety

Receiving-Handling

Description

SECTION

INSTALLATION

3-1.

Location

Drive

Roll

And

Wire

Guide

Installation

Welding

Gun

Connections

-4.

Drive

Motor

Connections

Trailing

Gun

Position

Adjustment

Flux

Hopper

Connections

Flux

Nozzle

Adjustment

Gun

Component

Changes

When

Changing

Wire

Size

Weld

Cable

Connections

SECTION

SEQUENCE

OPERATION

Welding

Wire

Threading

Submerged

Arc

Welding

(SAW)

Shutting

Down

SECTION

MAINTENANCE

Inspection

And

Upkeep

Cleaning

Drive

Rolls:

Brush

Inspection

Replacement

SECTION

TROUBLESHOOTING

6-1.

General

Troubleshooting

Chart

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

personal

experience,

child

touching

hot

stove

harmful,

wasteful,

and

wise.

Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

welding

and

cutting

are

described

this

manual.

Research,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

improperly

used

maintained.

The

reason

for

the

safe

practices

may

not

always

given.

Some

are

based

common

sense,

others

may

require

technical

volumes

explain.

wiser

the

rules.

Read

and

understand

these

safe

practices

before

tempting

install,

operate,

service

the

equipment.

Comply

with

these

procedures

applicable

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

serious

injury

death.

When

safety

becomes

habit,

the

equipment

can

be used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

General

Precautions,

common

arc

welding

and

cutting;

and

Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

safety

are

also

available

for

additional

and

complete

pro

cedures

than

those

given

this

manual.

They

are

listed

the

Standards

Index

this

manual.

ANSI

Z49.1

the

most

complete.

The

National

ElectricalCode,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Different

arc

welding

processes,

electrod.

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radiation

levels.

addItion

the

information

this

manual,

sure

consult

flux

and

alec

trode

manufacturers

for

specific

technical

data

and

precautionary

measures

concerning

their

material.

Burn

Prevention

Wear

protective

clothing

gauntlet

gloves

designed

for

use

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuftless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

glasses

with

side

shields

underneath,

appropriate

filter

lenses

plates

(protected

clear

cover

glass).

This

MUST

for

welding

cutting,

(and

chipping)

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

spattered.

See

-3A.2.

Avoid

oily

greasy

clothing.

spark

may

ignite

them.

Hot

metal

such

electrode

stubs

and

workpieces

should

never

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

qualified

first

aid

person

should

available

for

each

shift

unless

medical

facilities

are

for

mediate

treatment

flash

burns

the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

used

per

sons

intending

weld

cut.

Toxic

Fume

Prevention

Severe

discomfort,

illness

death

can

result

from

fumes,

vapors,

heat,

oxygen

enrichment

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

described

ANSI Stan

dard.Z49.1

listed

Standards

index.

NEVER

ventilate

with

oxygen.

Lead

cadmium

zinc

mercury

and

beryllium

bearing

and

similar

materials,

when

welded

(or

cut)

may

produce

harmful

concentrations

toxic

fumes.

Ade

quate

local

exhaust

ventilation

must

used,

each

person

the

area as

well

the

operator

must

wear

air-supplied

respirator.

For

beryllium,

both

must

ed.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

removed

from

the

work

surface,

the

area

well

ven

tilated,

the

operator

wears

air-supplied

respirator.

Work

confined

space

only

while

being

ven

tilated

and,

necessary,

while

wearing

air-supplied

respirator.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large

quantities

can

change

oxygen

con

centration

dangerously.

not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source

prevent

possible

accumulation

gases

the

space

downstream

valves

have

been

accidently

opened

left

open.

Check

sure

that

the

space

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

decomposed

the

heat

the

arc

(or

flame)

form

PHOSGENE,

OM-1553

Page

highly

toxic

gas,

and

other

lung

and

eye

irritating

pro

ducts.

The

ultraviolet

(radiant)

energy

the

arc

can

also

decompose

trichioroethylene

and

per

chloroethylene

vapors

form

phosgene.

NOT

WELD

cut

where

solvent

vapors

can

drawn

into

the

welding

cutting

atmosphere

where

the

radiant

energy

can

penetrate

atmospheres

containing

even

minute

amounts

trichioroethylene

per

chioroethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

material;

misuse

compressed

gases

and

cylinders;

and

short

circuits.

AWARE

THAT

flying

sparks

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

doors,

and

through

wall

floor

openings,

Out

sight

the

goggled

operator.

Sparks

and

slag

can

fly

feet.

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

oil,

grease,

and

(in

electrical

parts)

metallic

particles

that

can

cause

short

circuits.

combustibles

are

area,

NOT

weld

cut.

Move

the

work

practicable,

area

free

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

yen

.tilators.

the

work

cannot

moved,

move

com

bustibles

least

feet

away

Out

reach

sparks

and

heat;

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

shields.

Walls

touching

combustibles

opposite

sides

should

not

welded

(or

cut).

Walls,

ceilings1

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

tinguishing

equipment

during

and

for

some

time

after

welding

cutting

if:

appreciable

combustibles

(including

building

construction)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

visible)

floors

walls

within

feet

may

expose

com

bustibles

sparks

combustibles

adjacent

walls,

ceilings,

roofs,

metal

partitions

can

ignited

radiant

conducted

heat.

Hot

work

permit

should

obtained

before

operation

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

done,

check

that

area

free

sparks,

glowing

embers,

and

flames.

empty

container

that

held

combustibles,

that

can

produce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O,

listed

Standards

index.

This

includes:

thorough

steam

caustic

cleaning

(or

solvent

water

washing,

depending

the

com

bustibles

solubility)

followed

purging

and

inerting

with

nitrogen

carbon

dioxide,

and

using

protective

equipment

recommended

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

container

with

unknown

contents

should

cleaned

(see

paragraph

above).

NOT

depend

sense

smell

sight

determine

safe

weld

cut.

Hollow

castings

containers

must

vented

before

welding

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

cut

where

the

air

may

contain

flammable

dust,

gas,

liquid

vapors

(such

gasoline).

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

this

manual,

and

those

detailed

CGA

Standard

P-i,

PRECAUTIONS

FOR

SAFE

HANDLING

COMPRESSED

GASES

CYLINDERS,

listed

Standards

index.

Pressure

Regulators

Regulator

relief

valve

designed

protect

only

the

regulator

from

overpressure;

not

intended

protect

any

downstream

equipment.

Provide

such

protection

with

one

relief

devices.

Never

connect

regulator

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

repair

(first

cylinder

valve).

The

following

symptoms

indicate

faulty

regulator:

Leaks

gas

leaks

externally.

Excessive

Creep

delivery

pressure

continues

rise

with

downstream

valve

closed.

Faulty

Gauge

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

stop

after

pressure

release.

Repair.

NOT

attempt

repair.

Send

faulty

regulators

for

repair

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

trained

personnel.

Cylinders

must

handled

carefully

prevent

leaks

and

damage

their

walls,

valves,

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

cluding

third

rails,

electrical

wires,

welding

cir

cuits.

They

can

produce

short

Circuit

arcs

that

may

lead

serious

accident.

(See

i-3C.)

OM-1553

Page

ICC

DOT

marking

must

each

cylinder.

assurance

safety

when

the

cylinder

properly

handled.

Identifying

gas

content.

Use

only

cylinders

with

name

gas

marked

them;

not

rely

color

identify

gas

content.

Notify

supplier

unmarked.

NEVER

DEFACE

alter

name,

number,

other

markings

cylinder.

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

Prohibited

use.

Never

use

cylinder

its

contents

for

other

than

its

intended

use,

NEVER

support

roller.

Locate

secure

cylinders

they

cannot

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

areas

where

they

may

struck.

Transporting

cylinders.

With

crane,

use

secure

sup

port

such

platform

cradle.

NOT

lift

cylinders

off

the

ground

their

valves

caps,

chains,

slings,

magnets.

NOT

expose

cylinders

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

not

allow

contents

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.

NOT

use

hammer

wrench

open

cylinder

valve

that

can

not

opened

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

mix

any

gases

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

modified

exchang

ed.

Coil

excess

hose

prevent

kinks

and

tangles.

Protect

hose

from

damage

sharp

edges,

and

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

water;

bubbles

dicate

leaks.

Repair

leaky

worn

hose

cutting

area

Out

and

splic

ing

(1-2D3).

NOT

use

tape.

Proper

Connections

Clean

cylinder

valve

outlet

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

ignition.

Wipe

with

clean

lintless

cloth.

Match

regulator

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

agree,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

regulator

designed

for

particular

gas

gases

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

one

required.

Use

two

wrenches

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

iden

tified

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

nut

shank)

for

fuel

gas.

Pressurizing

Steps:

Drain

regulator

residual

gas

through

suitable

vent

before

opening

cylinder

(or

manifold

valve)

turning

adjusting

screw

(clockwise).

Draining

prevents

cessive

compression

heat

high

pressure

seat

allowing

seat

open

pressurization.

Leave

adjusting

screw

engaged

slightly

single-stage

regulators.

Hose

Stand

side

regulator

while

opening

cylinder

valve.

Prohibited

use.

Never

use

hose

other

than

that

designed

for

the

specified

gas.

general

hose

identification

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

clamps

designed

for

the

hose

(not

dinary

wire

other

substitute)

binding

connect

hoses

fittings.

copper

tubing

splices.

Use

only

standard

brass

fit

tings

splice

hose.

Avoid

long

runs

prevent

kinks

and

abuse.

Suspend

hose

off

ground

keep

from

being

run

over,

stepped

on,

otherwise

damaged.

Open

cylinder

valve

slowly

that

regulator

pressure

creases

slowly.

When

gauge

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

following

position:

For

oxygen,

and

inert

gases,

open

fully

seal

stem

against

possible

leak.

For

fuel

gas,

opento

less

than

one

turn

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

regulators.

Check

for

leaks

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capful

Ivory

OM-1553

Page

Liquid

equivalent

per

gallon

water).

Bubbles

dicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

combustible.

User

Responsibilities

Remove

leaky

defective

equipment

from

service

mediately

for

repair.

See

User

Responsibility

statement

equipment

manual.

Leaving

Equipment

Unattended

gas

supply

source

and

drain

gas.

Rope

Staging-Support

Rope

staging-support

should

not

used

for

welding

cutting

operation;

rope

may

burn.

1-3.

ARC

WELDING

Comply

with

precautions

1-1,

1-2.

and

this

section.

Arc

Welding,

properly

done,

safe

process,

but

careless operator

invites

trouble.

The

equipment

carries

high

currents

significant

voltages.

The

arc

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

infrared

energy

radiates,

weidments

are

hot,

and

compressed

gases

may

ed.

The

wise

operator

avoids

unnecessary

risks

and

pro

tects

himself

and

others

from

accidents.

Precautions

are

described

here

and

standards

referenced

index.

Burn

Protection

Comply

with

precautions

1-2.

The

welding

arc

intense

and

visibly

bright.

Its

radia

tion

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-shielded

arcs

are

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAU

TIONS.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

addition

gloves,

hat,

and

shoes

(1-2A).

necessary,

use

additional

protective

clothing

such

leather

jacket

sleeves,

flame-proof

apron,

and

fire-

resistant

leggings.

Avoid

outergarments

untreated

cotton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

protect

chest

and

neck

and

button

pockets

prevent

entry

sparks.

Eye

and

Head

Protection

Protect

eyes

from

exposure

arc.

NEVER

look

electric

arc

without

protection.

Welding

helmet

shield

containing

filter

plate

shade

no.

denser

must

used

when

welding.

Place

over

face

before

striking

arc.

Trademark

Proctor

Gamble.

Protect

filter

plate

with

clear

cover

plate.

Cracked

broken

helmet

shield

should

NOT

worn;

radiation

can

pass

through

cause

burns.

Cracked,

broken,

loose

filter

plates

must

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

broken,

pitted,

spattered.

Flash

goggles

with

side

shields

MUST

worn

under

the

helmet

give

some

protection

the

eyes

should

the

helmet

not

lowered

over

the

face

before

arc

struck.

Looking

arc

momentarily

with

unprotected

eyes

(particularly

high

intensity

gas-shielded

arc)

can

cause

retinal

burn

that

may

leave

permanent

dark

area

the

field

vision.

Protection

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

separate

room

enclosed

bay

best.

open

areas,

surround

the

operation

with

low-reflective,

non-

combustible

screens

panels.

Allow

for

free

air

circula

tion,

particularly

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

looking

directly

the weld.

Others

working

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

weld,

make

sure

that

screen

flaps

bay

doors

are

closed.

Toxic

Fume

Prevention

Comply

with

precautions

1-2B.

Generator

engine

exhaust

must

vented

the

outside

air.

Carbon

monoxide

can

kill.

Fire

and

Explosion

Prevention

Comply

with

precautions

-2C.

Equipments

rated

capacity.

not

overload

arc

welding

equipment.

may

overheat

cables

and

cause

fire.

Loose

cable

connections

may

overheat

flash

and

cause

fire.

Never

strike

arc

cylinder

other

pressure

vessel.

creates

brittle

area

that

can

cause

violent

rupture

lead

such

rupture

later

under

rough

handling.

Compressed

Gas

Equipment

Comply

with

precautions

-2D.

OM1553

Page

Shock

Prevention

Electrode

Holders

Exposed

hot

conductors

other

bare

metal

the

welding

circuit,

ungrounded,

electrically-HOT

equipment

can

fatally

shock

person

whose

body

becomes

conductor.

NOT

STAND,

SIT,

LIE.

LEAN

ON,

TOUCH

wet

surface

when

welding,

without

suitable

protection.

protect

against

shock:

Keep body

and

clothing

dry.

Never

work

damp

area

without

adequate

insulation

against

electrical

shock.

Stay

dry

duckboard,

rubber

mat

when

damp

ness

sweat

can

not

avoided.

Sweat,

sea

water,

moisture

between

body

and

electrically

HOT

part

grounded

metal

reduces

the

body

surface

electrical

resistance,

enabling

dangerous

and

possibly

lethal

currents

flow

through

the

body.

Grounding

the

Equipment

When

arc

welding

equipment

grounded

according

the

National

Electrical

Code,

and

the

work

grounded

according

ANSI

Z49.1

Safety

Welding

And

Cut

ting,

voltage

may

exist

between

the

electrode

and

any

conducting

object.

Examples

conducting

objects

include,

but

are

not

limited

to,

buildings,

electrical

tools,

work

benches,

welding

power

source

cases,

workpieces,

etc.

Never

touch

the

electrode

and

any

metal

object

unless

the

welding

power

source

off.

When

installing,

connect

the

frames

each

unit

such

welding

power

source,

control,

work

table,

and

water

circulator

the

building

ground.

Conductors

must

adequate

carry

ground

currents

safely.

Equipment

made

electrically

HOT

stray

current

may

shock,

possibly

fatally.

NOT

GROUND

electrical

conduit,

pipe

carrying

ANY

gas

flammable

quid

such

oil

fuel.

Three-phase

connection.

Check

phase

requirements

equipment

before

installing,

only

3-phase

power

available,

connect

single-phase

equipment

only

two

wires

the

3-phase

line.

NOT

connect

the

equip

ment

ground

lead

the

third

(live)

wire,

the

equip

ment

will

become

electrically

HOT

dangerous

condi

tion

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

for

continuity.

sure

conductors

are

touching

bare

metal

equipment

frames

connections.

line

cord

with

ground

lead

provided

with

the

equipment

for

connection

switchbox,

connect

the

ground

lead

the

grounded

switchbox.

three-

prong

plug

added

for

connection

grounded

mating

receptacle,

the

ground

lead

must

connected

the

ground

prong

only.

the

line

cord

comes

with

three-prong

plug,

connect

grounded

mating

recep

tacle.

Never

remove

the

ground

prong

from

plug,

use

plug

with

broken

oft

ground

prong.

Fully

insulated

electrode

holders

should

used.

NOT

use

holders

with

protruding

screws.

Connectors

Fully

insulated

lock-type

connectors

should

used

join

welding

cable

lengths.

Cables

Frequently

inspect

cables

for

wear,

cracks

and

damage.

IMMEDIATELY

REPLACE

those

with

excessively

worn

damaged

insulation

avoid

possibly

lethal

shock

from

bared

cable.

Cables

with

damaged

areas

may

taped

give

resistance

equivalent

original

cable.

Keep

cable

dry,

free

oil

and

grease,

and

protected

from

hot

metal

and

sparks.

Terminals

And

Other

Exposed

Parts

Terminals

and

other

exposed

parts

electrical

units

should

have

insulating

covers

secured

before

operation.

Electrode

Equipment

with

output

on/off

control

(con

tactor)

Welding

power

sources

for

use

with

the

gas

metal

arc

welding

(GMAW),

gas

tungsten

arc

welding

(GTAW)

and

similar

processes

normally

are

equipped

with devices

that

per

mit

on-off

control

the

welding

power

out

put.

When

equipped

the

electrode

wire

becomes

electrically

HOT

when

the

power

source

switch

and

the

welding

gun

switch

closed.

Never

touch

the

electrode

wire

any

conducting

object

contact

with

the

electrode

circuit

unless the

welding

power

source

off.

Equipment

without

output

on/off

control

(no

contactor)

Welding

power

sources

used

with

shielded

metal

arc

welding

(SMAW)

and

similar

pro

cesses

may

not

equipped

with

welding

power

output

on-off

control

devices.

With

such

equipment

the

electrode

electrically

HOT

when

the

power

switch

turned

ON.

Never

touch

the electrode unless

the

welding

power

source

off.

Safety

Devices

Safety

devices

such

interlocks

and

circuit

breakers

should

not

disconnected

shunted

out.

Before

installation,

inspection,

service,

equip

ment,

shut

OFF

all

power

and

remove

line

fuses

(or

lock

OM-1553

Page

red-tag

switches)

prevent

accidental

turning

power.

Disconnect

all

cables

from

welding

power

source,

and

pull

all

115

volts

line-cord

plugs.

not

open

power

circuit

change

polarity

while

welding.

If,

emergency,

must

disconnected,

guard

against

shock

burns,

flash

from

switch

arcing.

Leaving

equipment

unattended.

Always

shut

OFF

and

disconnect

all

power

equipment.

Power

disconnect

switch

must

available

near

the

welding

power

source.

Protection

For

Wearers

Electronic

Life

Support

Devices

(Pacemakers)

Magnetic

fields

from

high

currents

can

affect

pacemaker.

operation.

Persons

wearing

electronic

life

support

equipment

(pacemaker)

should

consult

with

their

doctor

before

going

near

arc

welding,

gouging,

spot

welding

operations.

1-4.

STANDARDS

BOOKLET

INDEX

For

information,

refer

the

following

standards

their

latest

revisions

and

comply

applicable:

ANSI

Standard

Z49.1,

SAFETY

WELDING

AND

CUTTING

obtainable

from

the

American

Welding

Society,

550

Jeune

Rd.

P.O.

Box

351040,

Miami,

33135.

NIOSH,

SAFETY

AND

HEALTH

ARC

WELDING

AND

GAS

WELDING

AND

CUTTING

obtainable

from

the

Superintendent

Documents,

U.S.

Government

Printing

Office.

Washington,

D.C.

20402.

OSHA,

SAFETY

AND

HEALTH

STANDARDS,

29CFR

1910,

obtainable

from

the

U.S.

Govern

ment

Printing

Office,

Washington,

D.C.

20402.

ANSI

Standard

Z87.1,

SAFE

PRACTICES FOR

OCCUPATION

AND

EDUCATIONAL

EYE

AND

FACE

PROTECTION

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

ANSI

Standard

Z41.1,

STANDARD

FOR

MENS

SAFETY-TOE

FOOTWEAR

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

ANSI

Standard

Z49.2,

FIRE

PREVENTION

THE

USE

CUTTING

AND

WELDING

PRO

CESSES

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

AWS

Standard

A6.0,

WELDING

AND

CUT

TING

CONTAINERS

WHICH

HAVE

HELD

COM

BUSTIBLES

obtainable

from

the

American

Welding

Society,

550

Jeune

Rd.

P.O.

Box

351040,

Miami

33135.

NFPA

Standard

51,

OXYGEN

FUEL

GAS

SYSTEMS

FOR

WELDING

AND

CUTTING

tainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

02210.

NFPA

Standard

70-1978,

NATIONAL

ELEC

TRICAL

CODE

obtainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

02210.

10.

NFPA

Standard

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

02210.

ii.

CGA

Pamphlet

P-i,

SAFE

HANDLING

COM

PRESSED

GASES

CYLINDERS

obtainable

from

the

Compressed

Gas

Association,

500

Frfth

Avenue,

New

York,..NY

10036.

12.

CSA

Standard

17.2,

CODE

FOR

SAFETY

WELDING

AND

CUTTING

obtainable

from

the

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1R3.

13.

NWSA

booklet,

WELDING

SAFETY

BIBLIOGRAPHY

obtainable

from

the

National

Welding

Supply

Association,

1900

Arch

Street,

Philadelphia,

19103.

14.

American

Welding

Society

Standard

AWSF4.1

Recommended

Safe

Practices

for

the

Prepara

tion

for

Welding

and

Cutting

Containers

and

Piping

That

Have

Held

Hazardous

Substances,

obtainable

from

the

American

Welding

Society,

560

LeJeuneRd.

P.O.

B~351040,

Mam,

FL33135.

15.

ANSI

Standard

Z88.2

Practice

for

Respiratory

Protection

obtainable

from

the

American

tional

Standards

Institute,

1430

Broadway,

New

York,

10018.

OM-1553

Page

Table of contents

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