Miller Ps-100 User manual

June

1988

Millerﬁ

F~1LE

COPY

RETURN

FOLDER

OWNERS

MANUAL

iMPORTANT

Read

and

understand

the

entire

contents

this

manual.

with

special

emphasis

the

safety

material

throughout

the

manual.

Miller

Electilc

Mfg.

Co.

A~L~C~at~

before

installing,

operating,

maintaining

this

equipment.

This

unit

and

P0.

Box

1079

these

instructions

are

for

use

only

persons

trained

and

experienced

Appleton,

54912

USA

the

safe

operation

welding

equipment.

not

allow

untrained

persons

Tel.

414-734-9821

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

FORM:F2544B

Effective

With

Serial

No.

JJ393769

MODEL

ps-100

PRINTED

U.S.A.

ACOITIONAL

COPY

PRCE

CENTS

EFFECTIVE:

FEBRUARY

16.

1988

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY

Subject

the

terms

and

condi-

the

case

Millers

breech

warranty

any

other

duty

dons

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

with

respect

the

quality

any

goods,

the

exclusive

rwi~diemi

warrants

its

Distributor/Dealer

that

all

new

and

unused

therefore

shall

be,

Millers

option

(1)

repair

(2)

replacement

Equipment

furnished

Miller

free

from

defect

workman-

or,

where

authorized

writing

Miller

appropriate

cases,

(3)

ship

and

material

the

time

and

place

delivery

Miller.

the

reasonable

coat

repair

replacement

authorized

warranty

made

Miller

with

respect

engines,

trade

Miller

service

station

(4)

pa~mant

credit

for

the

purchase

accessories

other items

manufactured

others.

Such

pnce

(lees

reasonable

depreciation

based

upon

actual

use)

upon

engines,

trade

accessories

and

other

items

are

sold

subject

return

the

goode

Customers

risk

and

expense.

MILLERs

the

warranties

their

respective

manufacturers,

any

All

option

repair

replacement

will

F.O.B.,

Factory,

engines

are

warranted

their

manufacturer

for

one

year

from

Appleton,

Weconsin,

F.O.B.,

MILLER

authorized

service

date

original

purchase,

except

Tecurnseh

engines

which

facility,

therefore,

compensation

for

transportation

costs

have

two

year

warranty.

any

kind

will

allowed.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

insmact

the

claimant

the

warranty

Except

specified

below,

Millers

warranty

does

not

apply

claim

procedures

followed.

components

having

normal

useful

life

lees

then

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

come

contact

with

the

welding

ANY

EXPRESS

WARRANTY

NOT

PROViDED

HEREIN

AND

wire

including

nozzles

and

nozzle

insulators

where

failure

dose

ANY

IMPUED

WARRANTY.

GUARANTY

REPRESENTA

not

result

from

defect

workmanship

material.

liON

AS TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

ThIS

PROVISION,

Miller

shall

required

honor

warranty

claims

war-

MIGHT

ARISE

IMPUCA11ON,

OPERATION

LAW,

ranted

Equipment

the

event

failure

resulting

from

defect

CUSTOM

TRADE

COURSE

DEAUNG.

INCLUDING

within

the

following

periods

from

the

date

delivery

Equip-

ANY

IMPUED

WARRANTY

MERCHANTABIUTY

merit

the

original

user:

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

ANY

AND

AU.

EQUIPMENT

FURNISHED

MILLER

~.f

Arc

weldais,

p~re~irces,

robots,

and

,or~nts

yeer

CLUDED

AND

DISCLAIMED

MILLER.

Loadbanks

year

Original

main

power

rectifiers

years

(labor

year

only)

EXCEPT

EXPRESSLY

PROVIDED

MILLER

~

All

welding

guns,

feeder/gun,

and

torches

days

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

r1~

5. All

other

Millermatic

Feeders

year

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

Replacement

repair

parts,

exclusive

labor

days

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

ij(

Batteries

months

EXPERIENCED

ThE USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

~

provided

that

Miller

notified

writing

within

thirty

(30)

days

CONSUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

the

date

such

failure.

TO,

AND

RESELLER

AUTHORIZED

EXTEND

matter

general

policy

only,

Miller

cay

honor

dims

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

the

original

user

within

die

foreyoing

periods

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

SAFETY

RULES FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTiON

2-INTRODUCTION

2-1.

Vott-Ampere

Curves

2-2.

Duty

Cycle

2-3.

General

Information

And

Safety

2-4.

Receiving-Handling

2-5.

Description

SECTION

3

INSTALLATION

3-1.

Location

3-2.

Weld

Output

Connections

3-3.

Control

Module

Receptacle

Information

And

Connection

3-4.

Electrical

Input

Connections

SECTION

OPERATOR

CONTROLS

4-1.

PilotLight

4-2.

Circuit

Breaker

4-3.

Control

Module

Receptacle

SECTION

SEQUENCE

OPERATiON

5-1.

Operation

5-2.

Shutting

Down

SECTION

MAINTENANCE

TROUBLESHOOTING

6-1.

Routine

Maintenance

6-2.

Fan

Motor

6-3.

Overload

Protection

6-4.

Troubleshooting

Chart

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

per

sonal

experience,

child

touching

hot

stove

harmful,

wasteful,

and

unwise.

Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

welding

and

cutting

are

described

this

manual.

search,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

improperly

used

maintained.

The

rea

son

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

sale

practices

may

cause

seri

ous

injury

death.

When

safety

becomes

habit,

the

equipment

can

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1-General

Precautions,

common

arc

welding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

safety

are

also

ava~able

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

Electrical

Code,

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, electrode

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radIation

levels.

addition

the

informatIon

thIs

manual,

sure

consult

flux

and

electrode

manufacturers

Material

Safety

Data

Sheets

(MSDSs)

for

specIfic

technical

data

and

precautIon

ary

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

cuffless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

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-bear

ing

and

similar

materials,

when

welded

(or

cut)

may

pro

duce

harmful

concentrations

toxic

fumes.

Adequate

local

exhaust

ventilation

must

used,

each

person

the

area

well

the

operator

must

wear

air-sup

plied

respirator.

For

beryllium,

both

must

used.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

moved

from

the

work

surface,

the

area

well

ventilated

and,

necessary,

while

wearing

air-supplied

respira

tor.

Work

confined

space

only

while

being

ventilated

and,

necessary,

while

wearing

air-supplied

respira

tor.

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

accidentally

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,

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

the

arc

can

also

decompose

trichloroethylene

and

perchloroethylene

F2544

Page

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

perchioroethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

mate

rial;

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,

verdi

lators.

the

work

cannot

moved,

move

combustibles

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,

ceilings,

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

extin

guishing

equipment

during

and

for

some

time

afterweld

ing

cutting

if:

appreciable

combustibles

(including

building

construction)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

orvisible)

floors

orwalls

within

feet

may

expose

combustibles

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

corrtustibles,

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

orwaterwashing,

depending

the

combusti

bles

solubility)

followed

purging

and

inerting

with

trogen

carbon

dioxide,

and

using

protective

equip

ment

recommended

A6.O.

Waterfilling

just

below.

working

level

may

substitute

for

inerting.

container

with

unknown

contents

should

cleaned

(see

preceding

paragraph).

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

SAFE

HANDLING

COMPRESSED

GASES

CYLIN

DERS,

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

symp

toms

indicate

faulty

regulator:

Leaks-if

gas

leaks

externally.

Excessive

Creep-if

delivery

pressure

continues

rise

with

downstream

valve

closed.

Faulty

Gauge-if

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

stop

after

pres

sure

release.

Repair.

NOT

attempt

repair.

Send

faulty

regula

tors

for

repair

manufacturers

designated

repair

cen

ter,

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

including

third

rails,

electrical

wires,

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

serious

cident.

(See

-3C.)

ICC

DOT

marking

must

each

cylinder.

assurance

safety

when

the

cylinder

properly

han

dled.

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.

F2544

Pace

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,

stings,

magnets.

NOT

expose

cylinders

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

not

low 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

changed.

Hose

Prohibited

use.

Never

use

hose

other

than

that

signed

for

the

specified

gas.

general

hose

identifica

tion

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

clamps

designed

for

the

hose

(not

ordi

nary

wire

other

substitute)

as a

binding

connect

hoses

fittings.

copper

tubing

splices.

Use

only

standard

brass

tings

splice

hose.

Avoid

long

runs

prevent

kinks

and

abuse.

Suspend

hose

off

ground

keep

from

being

run

over,

stepped

on,

otherwise

damaged.

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

(1-203).

NOT

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

soui~es

ignition.

Wiper

with

clean

lintiess

cloth.

Match

regulator

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

area,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

regulatordesigned

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

identified

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

nut

shank)

for

fue

gas.

Pressurizing

Steps:

Drain

regulator

residual

gas

through

suitable

vent

fore

opening

cylinder

(or

manifold

valve)

turning

justing

screw

(clockwise).

Draining

prevents

exces

sive

compression

heat

high

pressure

seat

allowing

seat

open

pressurization.

Leave

adjusting

screw

engaged

slightly

single-stage

regulators.

Stand

side

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

that

regulator

pressure

creases

slowly.

When

gauge

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

fol

lowing

position:

For

oxygen,

and

inert

gases,

open

fully

seal

stem

against

possible

leak.

For

fuel

gas,

open

less

than

one

turn

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

sale

and

efficient,

recommended

pressure

settings

regulators.

Check

for

leaks

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capfull

Ivory

Liquid

equivalent

per

gallon

water).

Bubbles

indi

cate

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

Stag

lng~Support

Rope

staging-support

should

not

used

for

welding

cutting

operation;

rope

may

burn.

Trademark

Proctor

Gamble:

F2544

Page

1-3.

ARC

WELDING

Comply

with

precautions

1-1,

1-2,

and

this

section.

Arc

Welding,

properly

done,

sale

process,

but

careless

operator

invites

trouble.

The

equipment

cames

high

currents

significant

voltages.

The

arc

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

frared

energy

radiates,

weidments

are

hot,

and

com

pressed

gases

may

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

stan

dards

referenced

index.

Burn

Protection

Comply

with

precautions

1-2.

The

welding

arc

intense

and

visibly bright.

its

radiation

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

bums

resemble

acute

sunburn,

those

from

gas-

shielded

arcs

are

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

addition

gloves,

hat,

and

shoes

-2A).

nec

essary,

use

additional

protective

clothing

such

leather

jacket

sleeves,

flame-proof

apron,

and

fire-re

sistant

leggings.

Avoid

outer

garments

untreated

cot

ton.

Bare

skin

protection.

Wear

dark,

substantIal

clothing.

Button

collar

protect

chest

and neck

and

button

pock

ets

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

am.

Protect

filter

plate

with

clear

cover

plate.

Cracked

broken

helmet

shield

should

NOT

worn;

radiation

can

pass

through

cause

bums.

Cracked,

broken,

loose

filter

plates

must

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

bro

ken,

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

bum

that

may

leave

permanent

dark

area

the

field

of vision.

Protection

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

sepa

rate

room

enclosed

bay

best.

open

areas,

sur

round

the

operation

with

low-reflective,

non-combusti

ble

screens

panels.

Allow

for

free

air

circulation,

par

ticularly

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

-2B.

Generator

engine

exhaust

must

vented

the

outside

air.

Carbon

monoxide

can

kilt.

Fire

and

Explosion

Prevention

Comply

with

precautions

1-2C.

Equipments

rated

capacity.

not

overload

arc

weld

ing

equipment.

may

overheat

cables

and

cause

fire.

Loose

cable

connections

may

overheat

flash

and

cause

fire.

Never

strike

arc

cylinder

other

pressure

ves

sel.

creates

brittle

area

that

can

cause

violent

rup

ture

lead

such

rupture

under

rough

handling.

Compressed

Gas

Equipment

Comply

with

precautions

-2D.

Shock

Prevention

Exposed

hot

conductors

other

bar

metal

the

weld

ing

circuit,

ungrounded,

electrically-HOT

equip

ment

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

dampness

sweat

can

not

avoided.

Sweat,

sea

water,

mois

ture

between

body

and

electrically

HOT

part-or

grounded

metal-reduces

the

body

surface

electrical

sistance,

enabling

dangerous

and

possible

lethal

cur

rents

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

usafety

Welding

And

Cut

ting,

voltage

may

exist

between

the

electrode

and

any

conducting

object.

Examples

conducting

objects

clude,

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

oft.

When

installing,

connect

the

frames

each

unit

such

welding

power

source,

control,

work

table,

and

water

cir

culatorto

the

building

ground.

Conductors

must

ade

quate

carry

ground

currents

safely.

Equipment

made

electrically

HOT

stray

current

may

shock,

possibly

tally.

NOT

GROUND

electrical

conduit,

orto

pipe

carrying

ANY

gas

ortlammable

liquid

such

oil

fuel.

F2544

Pace

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

to

the

third

(live)

wire,

the

equipment

will

become

electrically

HOT-a

dangerous

condition

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

ceptacle,

the

ground

lead

must

connected

the

ground

prong

only.

the

line

cord

comes

with

three-

prong

plug,

connect

grounded

mating

receptacle.

Never

remove

the

ground

prong

from

plug,

use

plug

with

broken

off

ground

prong.

Electrode

Holders

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

opera

tion.

Electrode

Equipment

with

output

on/off

control

(contactor)

Welding

power

sources

for

use

with

the

gas

metal

arc

welding

(GMAW),

gas

tungsten

arc

welding

(GTAW)

and

similar

processes

nor

mally

are

equipped

with

devices

that

permit

on-

off

control

the

welding

power

output.

When

equipped

the

electrode

wire

becomes

elec

trically

HOT

when

the

power

source

switch

and

the

welding

gun

switch

closed.

Never

touch

the electrode

wire

any

conducting

ject

contact

with

the

electrode

circuit

unless

the

welding

power

source

is off.

Equipment

without

output

on/off

control

(no

contactor)

Welding

power

sources

used

with

shielded

metal

arc

welding

(SMAW)

and

similar

proc

esses

may

not

equipped

with

welding

power

output

on-off

control

devices.

With

such

equip

ment

the

electrode

electrically

HOT

when

the

power

switch

turned

ON.

Never

touch

the

electrode

unless

the

welding

power

source

is.

off.

Safety

Devices

Safety

devices

such

Interlocks

and

circuit

breakers

should

not

disconnected

shunted

out.

Before

installation,

inspection,

service,

equipment,

shut

OFF

all

power

and

remove,

line

fuses

(or

lock

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

weld

ing.

If,

emergency,

must

disconnected,

guard

against

shock

bums,

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

Sup

port

Devices

(Pacemakers)

Magnetic

fields

from

high

currents

can

affect

pacemaker

operation.

Persons

wearing

electronic

life

support

equipment

(pacemaker)

should

consult

with

theirdoctor

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

N.W.

LeJeune

Ad,

Miami,

33126.

NIOSH,

SAFETY

AND

HEALTH

ARC

WELDING

AND

GAS

WELDING

AND

CUTTING

obtainable

from

the

Superintendent

Documents,

U.S.

Gov

ernment

Printing

Office,

Washington,

D.C.

20402.

OSHA,

SAFETY

AND

HEALTH

STANDARDS,

29CFR

1910,

obtainable

from

the

Superintendent

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

ANSI

Standard

Z87.1,

SAFE

PRACTICES

FOR

OCCUPATION

AND

EDUCATIONAL

EYE

AND

FACE

PROTECTION

obtainable

from

the

Amen

can

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

PROCESSES

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

F2544

Page

AWS

Standard

A6.0,

WELDING

AND

CUTTiNG

CONTAINERS

WHICH

HAVE

HELD

COMBUS

TIBLES

obtainable

horn

the

American

Welding

ciety,

550

N.W.

LeJeune

Rd.

Miami,

33126.

NFPA

Standard

51,

OXYGEN-FUEL

GAS

SYS

TEMS

FOR

WELDING,

CUTTING,

AND

ALLIED

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

NFPA

Standard

70,

NATIONAL

ELECTRICAL

CODE

obtainable

from

the

National

Fire

Protection

Association,

Batterymamh

Park,

Quincy,

02269.

10.

NFPA

Standard

51B,

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

11.

CGA

Pamphlet

P-i,

SAFE

HANDLING

COM

PRESSED

GASES

CYLINDERS

obtainable

from

the

Compressed

Gas

Association,

1235

Jet-

ferson

Davis

Highway,

Suite

501,

Atlington,

22202.

12.

CSA

Standard

W117.2,

CODE

FOR

SAFETY

WELDING

AND

CUTTING

obtainable

from

the

nadian

Standards

Association,

Standards

Sales,

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,

19103.

14.

American

Welding

Society

Standard

AWSF4.1,

RECOMMENDED

SAFE

PRACTICES

FOR

THE

PREPARATION

FOR

WELDING

AND

CUTTING

CONTAINERS

AND

PIPING

THAT

HAVE

HELD

HAZARDOUS

SUBSTANCES,

obtainable

from

the

American

Welding

Society,

550

N.W.

LeJeune

Ad, Miami,

33126.

15.

ANSI

Standard

Z88.2,

PRACTICE

FOR

RESPIRA

TORY

PROTECTION,

obtainable

from

the

Ameri

can

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

SECTiON

INTRODUCTION

Rated

Welding

Amperes

100%

Duty Cycle

Range

Max.

Open-

Circuit

Voltage

Amperes

Input

Rated

Load

Output



Dimensions

Weight

Three-Phase



200V 230V

460V

575V



~ss

160

128

KVA

Net

Ship

1200A@

80V

20-1500

Amperes

ioov~c

128

104

Height:37in.

(940mm)

Width:271n.

(686

mm)

Length:

27in

(686mm)

1155

lbs.

(524

kg)

1370

lbs.

(621

kg)

B-i

834

FIgure

21.

SpecificatIons

~PS

Figure

2-2.

Volt-Ampere

Curves

F2544

Pape

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