Miller A-500 User manual

March

1979

FORM:

OM-233

Effective

With

Serial

No.

HK243705

MODEL

A-500

OWNERS

MANUAL

fullER

MILLER

ELECTRIC

MFG.

CO.

718

BOUNDS

ST.

P.O.

Box

1079

APPLETON

54912

USA

ADDITIONAL

COPY

PRICE

CENTS

NWSA

CODE

NO.

4579

PRINTED

USA.

LIMITED

WARRANTY

EFFECTIVE:

JANUARY

1979

This

warranty

supersedes

all

MILLER

warranties

and

clusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTYSubject

the

terms

and

conditions

matter

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

submitted

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

Miller

free

from

defect

workmanship

and

material

the

case

Millers

breach

warranty

any

other

duty

time

and

place

delivery

Miller.

warranty

made

Miller

with

respect

the

quality

any

goods,

the

exclusive

remedies

therefor

shall

be,

Millers

option,

(1)

repair

(2)

replacement

or,

with

respect

engines,

trade

accessories

other

items

manu-

where

authorized

writing

Miller

appropriate

cases,

(3)

the

factured

others.

Such

engines,

trade

accessories

and

other

items

are

sold

subject

the

warranties

their

respective

manu-

reasonable

cost

repair

replacement

authorized

Miller

ser

facturers,

any.

the

present

time,

the

manufacturers

warranty

vice

station

(4)

payment

credit

for

the

purchase

price

(less

the

Mag-Diesel

engine

DEL-200

limited

six

months

and

reasonable

depreciation

based

upon

actual

use)

upon

return

the

all

other

engines

one

year.

goods

Customers

risk

and

expense.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

instruct

the

claimant

the

Except

specified

below,

Millers

warranty

does

not

apply

warranty

claim

procedures

followe

components

having

normal

useful

life

less

than

one

(I)

year,

such

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

ANY

IMPLIED

WARRANTY

GUARANTY

REPRESENTA

that

come

contact

with

the

welding

wire

including

nozzles

and

lION

PERFORMANCE,

AND

ANY

REMEDY

FOR

nozzle

insulators

where

failure

does

not

result

from

defect

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

workmanship

material.

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUS

TOM

TRADE

COURSE

DEALING

INCLUDING

ANY

Miller

shall

required

honor

warranty

claims

warranted

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

Equipment

the

event

failure

resulting

from

defect

within

the

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

following

periods

from

the

date

delivery

Equipment

the

ALL

EQUIPMENT

FURNISHED

MILLER

EXCLUDED

original

user:

AND

DISCLAIMED

MILLER.

Arc

welders,

power

sources

and

components

. .

year

EXCEPT

EXPRESSLY

PROVIDED

MILLER

WRIT-

(labor.

year

only)

PURCHASE

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

Original

main

power

rectifiers 3

years

ING

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

3. All

welding

guns

and

feeder/guns

days

OPERATION

PERSONS

TRAINED

AND

EXPERIENCED

All

other

Millermatic

Feeders

year

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

Replacement

repair

parts,

exclusive

labor

. .

days

NOT

FOR

CONSUMERS

CONSUMER

USE.

MILLER

WAR

Batteries

months

RANTIES

NOT

EXTEND

TO,

AND

RESELLER

provided

that Miller

notified

writing

within

thi;ty(30)

days

AUTHORIZED

EXTEND

MILLERS

WARRANTIES

TO,

the

date

such

failure

ANY

CONSUMER.

5,

b...5,

- -

Section

No.

Page

No.

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

-1.

Introduction

General

Precautions

Arc

Welding

Standards

Booklet

Index

SECTION

2

INTRODUCTION

2-1.

General

Receiving

Handling

Description

2-4.

Safety

SECTION



INSTALLATION

3-1.

Location

Electrical

Input

Connections

Weld

Output

Connections

Open

Circuit

Voltage

Selection

Contactor

Control

Receptacle

Water

Connections

Wire

Feeder

Shutdown

Control

Volts

Receptacle

Overload

Protection

3-10.

Duty

Cycle

3-11.

Volt-Ampere

Curve

8

SECTION

4

SEQUENCE

OPERATION

Gas

Metal-Arc

Welding

Shutting

Down

SECTION

5

TROUBLESHOOTING

PARTS

LIST

SECTION

1-SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

1-2.

learn

experience.

Learning

safety

through

personal

experience,

child

touching

hot

Stove

harmful,

wasteful,

and

unwise.

Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

weld

ing

and

cutting

are

described

this

manual.

Research,

devel

opment,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

operation,

and

servicing

practices.

Acci

dents

occur

when

equipment

improperly

used

main

tained.

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

attempting

install,

operate,

service

the

equipment.

Comply

with

these

procedures

applicable

the

particular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

serious

in,

jury

death.

When

safety

becomes

habit,

the

equipment

can

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

procedures

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

spection

requirements

also

provide

basis

for

equipment

stallation,

use,

and

service.

GENERAL

PRECAUTIONS

Burn

Prevention

Wear

protective

clothing

leather

(or

asbestos)

gauntlet

gloves,

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

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

1-3A.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

availthle for

each

shift

unless

medical

facilities

are

for

immediate

treatment

flash

burns

of the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should be

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

used

bypersons

intending

weld

Cut.

Toxic

Fume

Prevention

Adequate

ventilation.

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.

Adequate

local

exhaust

ventilation

must

used,

each

person

the

area

well

the

operator

must

wear

airsupplied

respirator.

For

beryllium,

both

must

used.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

removed

from

the

work

surface,

the

area

well

ventilated,

the

operator

wears

air-supplied

respirator.

Work

confined

space

only

while

it is

being

ventilated

and,

necessary,

while

wearing

air-supplied

respirator.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large

quantities

can

change

oxygen

concentration

danger.

ously.

Do-not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source

prevent

possible

accumulation

gases

the

space

down

stream

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,

highly

toxic

gas,

and

other

lung

and

eye

irritating

products.

The

ultra

violet

(radiant)

energy

the

arc

can

also

decompose

chloroethylene

and

perchloroethylene

vapors

form

phos

gene.

NOT

WELD

cut

where

solvent

vapors

can

drawn

into

the

welding

cutting

atmosphere

where

the

radiant

energy

can

penetrate

atmospheres

con

taiiiing

even

minute

amounts

trich

loroethylene

perchloroethylene.

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,

ventilators.

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

tinguishing

equipment

during

and

for

some

time

after

weld

ing

cutting

if:

appreciable

combustibles

(including

building

Construc

tion)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

Iconcealed

visible)

floors

walls

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

combustibles,

that

can

pro

duce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O.

listed

Standards

index.

OM-233

Page

This

includes:

thorough

steam

caustic

cleaning

(or

solvent

water

washing,

depending

the

combustibles

solubility(

followed

purging

and

inerting

with

nitrogen

carbon

dioxide,

and

using

protective

equipment

recom

mended

AGO.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

container

with

unknown

content

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

gaso

Iine(.

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

this

manual,

and

those

detailed

CGA

Standard

P-i,

PRECAU

TIONS

FOR

SAFE

HANDLING

COMPRESSED

GASES

CYLINDERS,

listed

Standards

index,

Pressure

Regulators

Regulator

relief

valve

designed

protect

only

the

regula

tor

from

overpressure;

it is

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

including

third

rails,

electrical

wires,

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

serious

accident.

(See

i-3C.(

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

con

tent.

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

support

such

platform

cradle.

NOT

lift

cylinders

off

the

ground

their

valves

caps,

chains,

slings,

mag

nets.

NOT

expose

cylinders

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

not

allow

contents

exceed

i30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

fittin~

should

never

modified

exchanged.

Hose

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

ordinary

wire

other

substitute(

binding

connect

hoses

fittings.

copper

tubing

splices.

Use

only

standard

brass

fittings

splice

hose.

Avoid

long

runs

prevent

kinks

and

abuse.

Suspend

hose

off

ground

keep

from

being

run

over,

stepped

on,

other

wise

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

connec

tions.

Immerse

pressured

hose

water;

bubbles

indicate

leaks.

Repair

leaky

worn

hose

cutting

area

out

and

splicing

(i-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

lint-

less

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

CON

NECT

regulator

designed

for

particular

gas

gases

cylindercontaining

any

other

gas.

Tighten

connections.

When

assembling

threaded

connections,

clean

and

smooth

seats

where

necessary.

Tighten.

connec

tion

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

CGA

adapter

(available

from

your

supplier(

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

fuel

gas.

Pressurizing

Steps:

Drain

regulator

residual

gas

through

suitable

vent

before

opening

cylinder

(or

manifold

valve)

turning

adjusting

screw

(clockwise(.

Draining

prevents

excessive

compression

heat

high

pressure

seat

allowing

seat

open

pressur

ization.

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

regu

lator

maximum(

leave

cylinder

valve

following

position:

For

oxygen,

and

inert

gases,

open

fully

seal

stem

against

possible

leak.

For

fuel

gas,

open

less

than

one

turn

permit

quick

emer~ency

shutoff.

Page

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipmentdesign

occurred.

This

sheet

lists

exceotions

data

appearing

later

this

manual.

AMENDMENT

SECTION

TROUBLESHOOTING.

Figure

5-1.

Circuit

Diagram

Eftective

With

Serial

No.

HK282806

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

02T

038

0,33

032

031

0/6

0/4

OM-233

Page

Amend

Figure

5-1.

Circuit

Diagram

_______I~

CircuitDiagramNo.

B-048674-A

Item

Dia.

Part

Replaced

Page

No.

Mkgs.

No.

With

Description

Quantity

Q50,51

024

207 037 236

TRANSISTOR,

amp

100

volts

NPN

081

516

048560

PANEL,

rear

010

337

023365

WEDGE,3/16x1x4-i/2

SRi 035 224

083

971

RECTIFIER,

SCR/silicondiode(EffW/JB556978)



603

105

603

105

HOSE,

neoprene

No.1

5/161D(orderbyft)(qtychg)

R1-3

030

026

Deleted

(EffW/JB556978)

Qi-3

039

526

083

936

THYRISTOR,

SCR

300

amp

300

volts

(EffW/JB556978)

(con



sisting

of)

-3

030

026

RESISTOR,

carbon

0.5

watt

560

ohm

-6

031

689

CAPACITOR,

ceramic

0.01

500

volts

(Eff

W/HK282806).

000

914

LINK,

connecting

12/8/81

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

Liquid

equivalent

per

gallon

water).

Bubbles

indicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

combustible.

User

Responsibilities

Remove

leaky

defective

equipment

from

service

immed

iately

for

repair.

See

User

Responsibility

statement

equip

ment

manual.

Leaving

Equipment

Unattended

gas

supply

source

and

drain

gas.

Rope

Staging-Support

Rope

staging-support

should

not

used

for

welding

cut

ting

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

opera

tor

invites

trouble.

The

equipment

carries

high

currents

significant

voltages.

The

arc

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

infrared

energy

radiates,

weld

ments

are

hot,

and

compressed

gases

may

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

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

radiation

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

PRECAUTIONS.

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

pre

vent

entry

sparks.

Eye

and

Head

Protection

Protect

eyes

from

exposure

arc.

NEVER

look

elec

tric

arc

without

protection.

Welding

helmet

shield

containing

filter

plate

shade

no.

denser

must

be used

when

welding.

Place

over

face

before

striking

arc.

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

MEDIATELY.

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

she

operation

with

low.reflective.

non-combustible

screens

panels.

Allow

for

free

air

circulation,

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

1-2C.

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

1-2D.

Shock

Prevention

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

sur

face

when

welding,

without

suitable

protection.

protect

against

shock:

Keep

body

and

clothing

dry.

Never

work

damp

area

with

out

adequate

insulation

against

electrical

shock.

Stay

dry

duckboard,

rubber

mat

when

dampness

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

installing,

connect

the

frames

each

unit

such

welding

power

source,

control,

work

table,

and

water

circula

tor

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

liquid

such

oil

fuel,

Three-phase

connection.

Check

phase

requirement

equip

ment

before

installing.

only

3-phase

power

available.

connect

single-phase

equipment

only

two

wires

the

3-phase

line.

NOT

connect

the

equipment

ground

lead

the

third

(live)

wire,

the

equipment

will

become

electri

cally

HOT

dangerous

condition

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

for

continuity.

sure

conduc

tors

are

touching

bare

metal

equipment

frames

connec

tions.

line

cord with

ground

lead

provided

with

the

equip

ment

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

receptacle.

Never

remove

the

ground

prong

from

plug,

use

plug

with

broken

off

ground

prong.

Trademark

Proctor

Gamble,

OM-233

Page

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

operation.

Electrode

Wire

Electrode

wire

becomes

electrically

HOT

when

the

power

switch

gas

metal-arc

welding

equipment

and

welding

gun

trigger

pressed.

Keep

hands

and

body

clear

wire

and

other

HOT

parts.

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.

Discon

nect

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

dis

connect

all

power

equipment.

Power

disconnect

switch

must

available

near

the

welding

power

source.

1-4.

STANDARDS

BOOKLET

INDEX

For

information,

refer

the

following

standards

their

latest

revisions

and

comply

applicable:

ANSI

Standard

Z49.i,

SAFETY

WELDING

AND

CUTTING

obtainable

from

the

American

Welding

Society,

2501

7th

St.,

Miami,

Fla.

33125.

ANSI

Standard

Z87.i,

SAFE

PRACTICE

FOR

OCCUPA

TION

AND

EDUCATIONAL

EYE

AND

FACE

PROTEC

TION,

obtainable

from

American

National

Standards

Institute.

1430

Broadway,

New

York,

N.Y.

10018.

American

Welding

Society

Standard

A6.0,

WELDING

AND

CUTTING

CONTAINERS

WHICH

HAVE

HELD

COMBUSTIBLES,

obtainable

same

item

NFPA

Standard

51,

OXYGEN-FUEL

GAS

SYSTEMS

FOR

WELDING

AND

CUTTING,

obtainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

Mass.

02210.

NFPA

Standard

51B,

CUTTING

AND

WELDING

PRO

CESSES,

obtainable

same

item

CGA

Pamphlet

P-i.

SAFE

HANDLING

COM

PRESSED

GASES

CYLINDERS,

obtainable

from

the

Compressed

Gas

Association,

500

Fifth

Avenue,

New

York,

10036.

OSHA

Standard

CFR,

Part

1910,

Subpart

WELD

ING,

CUTTING

AND

BRAZING.

Page

Table of contents

Other Miller Welding System manuals

Miller

Miller Big Blue 600 Pro User manual

Miller

Miller XMT 350 User manual

Miller

Miller XR-Aluma-Pro 15W User manual

Miller

Miller PipePro 304 User manual

Miller

Miller Legend 301 G User manual

Miller

Miller MigMatic S400i User manual

Miller

Miller Spectrum 3080 User manual

Miller

Miller Auto-Line XMT 350 CC User manual

Miller

Miller Maxstar 300 User manual

Miller

Miller Gold Seal GS-250 User manual

Miller

Miller Spectrum 300 User manual

Miller

Miller CST 250 User manual

Miller

Miller DIALARC 400 AC/DC User manual

Miller

Miller Gold Seal 160 i User manual

Miller

Miller Spoolmate 3035 User manual

Miller

Miller Dynasty 210 DX User manual

Miller

Miller MTT-2012HR User manual

Miller

Miller FieldPro Smart Feeder CE User manual

Miller

Miller AMD-4G User manual

Miller

Miller Trailblazer 330 Diesel User manual

Miller

Miller BOC Migmatic 250 User manual

Miller

Miller Gold Seal 442 User manual

Miller

Miller Gold Star 300SS User manual

Miller

Miller CP-302 User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual

Lincoln Electric

Lincoln Electric POWER WAVE I400 Operator's manual