Miller RAMROD Owner's manual

Miller
Brand
Miller
Model
RAMROD
Category
Welding System
Type
Owner's manual

This manual is also suitable for

July
1981
FORM:
OM-268C
Effective
With
Serial
No.
JB475790
MODEL
Ramrod
OWNERS
MANUAL
ITUIIIER
MILLER
ELECTRIC
MFG.
CO.
718
S;BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
l~;~p
~,
~
%~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(11
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
Ii)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX~
CLUDED
AND
DISCLAIMED
BY
MILLER.
1
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
llabor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
)
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
1301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
4
~,
~
j
~
....~
~
TABLE
OF
CONTENTS
Section
No~
Page
No.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1
-
3.
Arc
Welding
7
1
-
4.
Standards
Booklet
Index
10
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
12
2
-
2.
Receiving-Handling
12
2
-
3.
Description
12
SECTION
3
-
INSTALLATION
3
-
1.
Location
12
3
-
2.
Weld
Output
Connections
13
3
-
3.
Remote
Amperage
Control
Connection
13
3
-
4.
Electrical
Input
Connections
13
SECTION
4
-
OPERATOR
CONTROLS
4
-
1.
Power
Switch
15
4
-
2.
Amperage
Adjustment
Control
&
Switch
15
4-3.
Volt-Ampere
Curves
15
4-4.
DutyCycleChart
15
4
-
5.
Control
Circuit
Overload
Breaker
16
SECTION
5
-
SEQUENCE
OF
OPERATION
5
-
1.
Shielded
Metal-Arc
Welding
(SMAW)
16
5
-
2.
Shutting
Down
16
SECTION
6
-
MAINTENANCE
6-1.
Fan
Motor
16
6
-
2.
Internal
Cleaning
16
6
-
3.
Weld
Cables
16
SECTION
7
-
TROUBLESHOOTING
7-1.
General
17
7
-2.
Troubleshooting
Chart
17
-
.~
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
SECTION
1
-
REGLES
DE
SECURITE
POUR
LE
FONCTIONNEMENT
DU
POSTE
DE
SOUDAGE
A
LARC
1-1.
INTRODUCTION
-
We
learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise. Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Acidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
loal
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
A.
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
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled
without
gloves.
1-1.
INTRODUCTION
-
Contrairement
a
lappren
tissage
de
Ia
vie,
Iapprentissage
de
Ia
sØcuritØ
par
ex
pØrience
personnelle,
comme
lenfant
qui
touche
un
poŒlo
chaud,
est
dangereux,
imprudent
et
inutile.
Instruisez-vous
donc
de
IexpØrience
dautrui.
Des
mØthodes
de
sØcuritØ
issues
de
lexpØrience
du
soudage
et
du
coupage
sont
dØcrites
dans
le
manuel.
La
recherche,
le
progres
ot
IexpØrionce
dans
co
domaine
ont
dØvoloppØ
un
materiel
fiable
et
des
mØthodes
de
sØcuritØ
pour
Iinstallation,
le
fonctionnement
et
lentro
tien.
Des
accidents
se
produisent
Iorsquo
lo
materiel
est
inadØquatement
utilisØ
ou
ontreteflu.
La
raison
do
ces
mØthodes
do
sØcuritØ
pout
no
pas
Œtre
toujours
donnØe.
Certaines
sont
fondØos
sur
le
Sons
commun,
dautres
domandoront
a
Otre
expliquees
par
des
livres
techni
ques.
II
est
plus
sage
do
suivre
les
rŁgles.
Lisez
et
comprenoz
ces
mØthdes
do
sØcuritØ
avant
dessayor
dinstaller,
do
faire
fonctionner
ou
de
rØparer
Iappareil.
Pour
votre
sØcuritØ
personnelle
et
cello
dautrui,
conformez-vous
a
ces
rŁgles
et
aux
manuels
dinstructions.
Manquer
dobserver
cos
mØthodes
do
sØcuritØ
pourrait
entrainer
des
blessures
graves
ou
memo
Ia
mort.
Quand
Ia
sØcuritØ
devient
une
habitude,
le
materiel
pout
alors
Œtre
utilisØ
on
touto
confiance.
Ces
mØthodes
de
sØcuritØ
sont
divisØes
en
deux
sec
tions:
1
-
Precautions
gØnØrales,
communes
au
soudage
et
au
coupago
a
larc,
et
2
-
Soudage
a
larc
(ot
coupage)
(uniquement).
Normes
de
rØfØrenco:
Des
publications
dos
normes
amØricainos
do
sØcuritØ
sont
aussi
a
votro
disposition
pour
dautres
modes
opØratoires
plus
complets
quo
ceux
du
present
manuel.
ElIes
sont
donnØes
dans
Iln
dex
des
Normes
do
ces
rŁgles
do
sØcuritØ.
ANSI
Z49-1
est
Ia
plus
complete.
Les
codes
do
IACNOR,
los
codes
provinciaux
et
municipaux
donnent
aussi
los
oxigencos
pour
uno
in
stallation,
une
utilisation
et
un
entretien
sQrs.
1-2.
PRECAUTIONS
GENERALES
A.
Prevention
des
brUlures
Portez
des
vŒtements
do
protection,
des
gants
a
crispin
en
cuir
(ou
amianto),
un
casque
ot
des chaussures
de
sØcuritØ.
Boutonnez
le
col
do
votre
chemise
ot
los
pattes
do
vos
pochos,
ot
portez
des
pantalons
sans
rovers
pour
Øviter
que
des
Øtincelles
et
du
laitier
no
sy
introduisent.
Portez
un
masque
avec
lunottes
do
sØcuritØ
ou
avec
Øcrans
latØ-rux
do
protection,
des
lunettes
filtrantes
ou
des
couvre-lentilles
(protØgØs
par
un
verre
clair).
Pour
le
soudage
ou
le
coupago
(et
le
burinage),
il
est
OBLIGATOIRE
de
protØger
sos
yeux
contre
lenergie
de
rayonnement
01
los
Øclats
do
metal.
Romplacez
le
verre
protecteur
IorsquiI
est
brisØ,
piquØ
ou
quil
a
recu
des
projections.
Voir
1
.3A.2.
Evitez
do
porter
des
habits
imprØgnØs
dhuile
ou
de
graisse.
Une
Øtincelle
pourrait
les
enflammer.
Ne
manipulez
jamais
sans
gants
un
metal
chaud
tel
quo
des
chutes
dØlectrode
et
des
piŁces
Ł
souder.
OM-268
Page
1
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along~
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of metallic
particles
that
can
causeshort
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
von
tilators.
If
the
work
cannot
be
moved,
move
com
bustibles
at
least
35
feet
away
out
of
reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(or
cut).
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time
after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35
feet
may
expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
thØt-held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
3
in
Standards
index.
Thisincludes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
com
bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment,
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
Should
be
cleaned
(see
paragraph
above).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if it
is
safe
to
weld
dr
cut.
emploi
des
gaz
comprimØs
et
des
boutoilles
ainsi
que
los
courts-circuits.
Sachez
que
les
Øclats
dØtincelles
ou
Ia
chute
du
laitier
peuvent
sinfiltrer
dans
las
fissures,
le
long
des
tuyauteries,
par
lea
fanŒtres
et
lea
portes
at
par
les
couvertures
des
murs
ou
du
aol,
sans
qua
Ia
soudeur
portent
des
lunottes
ne
los
voie.
Lee
Øtincelles
et
los
scones
peuvent
voler
jusqu
35
pieds.
Pour
prØvenir
las
incendies
at
los
explosions:
Veillez
a
ce
que
votre
appareil
soit
propre
et
en
Otat
do
marche,
dØnuØ
dhuile
at
do
graisso,
et
do
particules
do
metal
sur
los
piŁces
Ølectriques
qui
pourraient
entramnor
des
courts-circuits.
Si
des
combustibles
se
trouvent
a
proximitØ,
no
soudez
pea,
ne
coupez
pas.
Si
possible,
deplacez
votre
travail
loin
des
combustibles.
Evitez
lea
ateliers
do
peinture
au
pistolet,
los
cuves
dimmersion,
los
entrepts,
los
von
tilateurs.
Si
cola
nast
pas
possible,
placoz
los
com
bustibles
a
au
moms
35
piods
des
Øtincellos
et
do
Ia
chaleur
et
protegoz-Ies
des
Øtincellos
avec
des
couvor
tures
ou
des
Øcrans
protecteurs
adequate,
bien
ajustØs
at
ignifugØs.
On
ne
dolt
pea
souder
(ou
cou
per)
Ia
ctØ
oppose.
dos
murs
touchant
los
combustibles.
Los
murs,
plafonds
et
planchers
proches
du
travail
doivont
Øtre
protØgØs
par
dos
couvortures
ou
Øcrans
protecteurs
ignifuges.
Un
surveillant
dolt
so
tenir
a
proximitØ
avec
un
matØrial
do
lutte
contre
lincendie
adØquat,
pendant
at
quelque
temps
aprŁs
Ia
soudage
ou
le
coupage
Si:
a.
Des
quantitØs
apprØciables
do
combustibles
(y
compris
une
construction
en
chantier)
so
trouvont
a
moms
do
35
pieds.
b.
Des
quantitØs
apprØciables
do
combustibles
sont
a
plus
do
35
pieds
mais
peuvent
Łtro
onflammØes
par
des
Øtincelles.
c.
Des
ouvertures
(cachØes
ou
visibles)
sur
les
planchors
ou
los
murs
a
moms
de
35
pieds
peuvent
exposer
des
combustibles
aux
Øtincelles.
d.
Les
combustibles
adjaconts
aux
murs,
plafonds,
toits
ou
cloisons
mØtalliques
peu
vent
Œtre
enflammØs
par
une
chaleur
rayon
nante
ou
transmise.
Avant
do
commoncer,
avisoz
Ia
contremaltro
pour
quil
sassure
quo
los
precautions
adØquates
soient
prisos.
Une
fois
le
travail
terminØ,
vØrifiez
quil
ny
ait
pea
dOtincollos,
de
cendres
ardentes
ou
do
flammes
dana
Ia
local.
On
no
doit
jamais
souder
ni
couper
sur
un
recipient
ayant
contenu
dos
combustibles,
ou
pouvant
produire
des
vapeurs
inflammables
ou
toxiques
a
Ia
chauffe,
Ł
moms
que
le
recipient
nait
ØtØ
lavØ
au
prØalablo,
com
ma
dØcrit
dana
Ia
Norma
AWS
A6.O,
figurant
au
paragraphe
3
de
llndex
des
Normes.
Cola
comprend:
un
nettoyago
a
fond
a
Ia
vapeur.ou
au
caustique
(ou
un
lavage
avec
diasolvant
ou
eau
salon
Ia
solubilitØ
du
combustible)
suivi
dune
purge
at
dune
in
jection
dazote
ou
do
gaz
carbonique,
en
utilisant
un
equipement
do
protection
comma
recommandØ
dana
lA6-O.
LatmosphŁre
inerto
peut
Otre
remplacØe
par
un
niveau
deau
arrivant
au-dessous
du
travail
a
effectuer.
Vous
devez
lever
un
recipient
dont
Ia
nature
do
contenu
est
inconnue
(voir
paragraphe
ci-dessus).
NE
vous
fiez
PAS
a
Iodorat
ou
a
a
vue
pour
dire-
si
lon
pout
le
souder
ou
Ia
couper
en
toute
sØcuritØ.
OM-268
Page3
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
PRECAUTIONS
FOR
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
listed
6
in
Stan
dards
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is
not
intended
to
pro
tect
any
downstream
equipment.
Provide
such
protec
tion
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
whore
special
techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
ac
cident.
(See
1-3C.)
-
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Vous
devez
pratiquer
un
event
sur
los
piŁces
ou
rØci
pients
creux
avant
de
les
souder
ou
couper:
ils
peuvent
exploser.
Atmospheres
explosives:
Ne
soudez
ni
ne
coupez
jamais
dana
des
lioux
oCi
Iair
peut
contenir
des
poussiŁres,
gaz
ou
vapeurs
liquides
inflammablos
(tels
quo
Iessence).
D.
Gaz
comprlmØ
Precautions
genØrales:
Suivez
les
precautions
de
ce
manuel,
et
cellos
dØcrites
a
Ia
Norme
CGA
P-i
(PrØcau
tions
do
sØcuritØ
pour
Ia
manipulation
de
gaz
comprimØs
en
bouteilles),
paragraphe
6
do
llndex
des
Normes.
1.
DØtendeurs
do
pression
La
soupapo
do
sOrotØ
dun
dØtendeur
est
destinØe
a
pro
tØger
seulement
le
dØtendeur
de
Ia
surpression.
Ella
na
pas
pour
but
do
protØger
les
boyaux
et
le
chalumeau:
on
protege
ceux-ci
par
des
soupapes
do
retenue
concuos
spØcialement
pour
cette
fonction.
No
montez
jamais
un
dØtendeur
sur
une
boutoillo
canto
nant
un
gaz
different
de
celui
pour
lequel
le
dØtendeura
ØtØ
concu.
Enlovoz
immØdiatement
un
dØtendour
dØfectueux
pour
lo
faire
rØparer
(dabord,
formez
le
robinet
do
Ia
bouteille).
Los
symptmos
suivants
dØnotent
Ia
dØfec
tuositØ
du
dØtondeur:
Fuites
-
Si
le
gaz
fuit
extØrieuroment.
Ascension
excessive
-
si
Ia
pression
de
debit
continue
a
monter,
Ia
robinet
du
chalumoau
Øtant
fermØ.
ManomŁtro
dØfectueux
-
Si
laiguille
du
manomŁtre
no
sØcarte
pas
do
Ia
goupillo
do
butØo
Iors
do
Ia
mise
en
pression,
ou
no
roviont
pas
sur
Ia
goupille
aprŁs
lØchap
pement
do
Ia
prossion.
Reparation.
NESSAYEZ
PAS
do
reparor
vous-mØmos.
Envoyez
los
dØtendeurs
dØfectueux
a
rØparer
aux
ateliers
do
reparation
agrØØs
du
fabricant,
oCi
des
techni
ques
at
des
outils
spØciaux
sont
utilisØs
par
un
person
nel
formØ.
2.
Bouteilles
Los
boutoilles
doivent
Œtro
manipulees
avec
soin
pour
prØvenir
Ios.fuites
ou
degØts
a
louts
parois,
robinots
ou
systemos
do
sCiretØ.
Evitez
quun
circuit
eloctrique
soft
en
contact
avoc
los
boutoilles,
y
compris
los
rails
do
con
tact,
los
fils
electriquos
ou
los
circuits
do
soudago.
Cola
pourrait
crØor
dos
arcs
courts-circuits
pouvant
ontrainer
dos
accidents
graves
(Voir
1
.3C.).
Chaque
bouteille
doit
portor
los
inscriptions
ICC
ou
DOT.
Cest
un
gage
do
sØcuritO
pourvu
quo
Ia
bouteille
soit
bien
manipulØo.
Identification
du
gaz:
Nutilisez
quo
los
bouteillos
mdi
quant
Ia
naturo
du
gaz;
no
vous
fioz
pas
a
Ia
couleur
pour
reconnaItro
Ia
nature
du
gaz.
Adressoz-vous
a
votro
fournisseur
si
cola
nost
pas
indiquØ.
NEFFACEZ
ou
no
modifiez
JAMAIS
los
noms,
numØros
ou
autros
indications
sur
uno
bouteille.
Cela
est
illegal
at
dangoroux.
-~
Page4
Y
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
blaÆk
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
Vides:
Maintenez
les
robinets
fermØs,
replacez
bien
es
chapeaux;
inscrivez
Vides.;
sØparez-les
des
Pleines
et
retournez-les
rapidement.
Emploi
interdit:
Nutilisez
une
bouteille
ou
son
contenu
que
pour
ce
a
quoi
elle
est
destinØo,
mais
JAMAIS
corn-
me
support
ou
rou~eau.
Placez
les
bouteilles
pour
quelles
ne
tombent
pas.
Lors
quun
dØtendeur
(et
un
boyau)
est
monte
sur
elles,
placez
les
ou
attachez-les
debout.
Passages
et
lieux
de
travail.
Enlevez
es
bouteilles
dun
endroit
o
lon
pourrait
les
frapper.
Transport
des
bouteilles.
Avec
une
grue,
utilisez
un
sup
port
fiable
tel
quune
plate-forme
ou un
cadre.
NE
SOULEVEZ
PAS
des
bouteilles
du
sol
par
leur
robinet
ou
chapeau,
ou
avec
des
chalnes,
Ølingues
ou
aimants.
NEXPOSEZ
PAS
es
bouteilles
a
une
chaleur
excessive,
aux
Øtincelles,
au
laitier
et
aux
flammes,
etc.,
pouvant
causer
leur
rupture.
Le
contºnant
ne
doit
jamais
dØpasser
55C.
Refroidissez
en
pulvØrisant
de
leau
si
nOcessaire.
ProtØgez
les
bouteilles
et
particuliŁrement
les
soupapes
contre
los
chocs,
les
chutes,
les
chutes
dobjets
et
Ia
temperature.
Remettez
bien
les
chapeaux
lorsque
vous
dØplacez
es
bouteilles.
Robinet
coincØ.
NUTILISEZ
PAS
un
marteau
ou
une
clØ
mØtallique
pour
ouvrir
un
robinet
de
bouteille
que
Ion
ne
peut
pas
ouvrir
a
Ia
main.
Avisez
votre
four
nisseur.
MØlange
de
gaz.
Nessayez
jamais
do
mØlanger
des
gaz
dans
une
bouteille.
Ne
rechargez
jamais
une
bouteille.
Les
ØlØments
de
Ia
bouteille
ne
doivent
jamais
Œtre
modifies
ou
remplacØs.
3.
Boyau
Utilisation
interdite.
Nutilisez
jamais
un
boyau
autre
que
celui
appropriØ
au
gaz
indiquØ.
La
rŁgle
gØnØrale
didentification
est:
rouge
pour
les
gaz
combustibles,
vert
pour
IoxygŁne,
et
noir
pour
los
gaz
inertes.
Utilisez
des
bagues
ou
colliers
appropriØs
au
boyau
(et
non
du
fil
ordinaire
ou
autre
substitUtion)
pour
brancher
les
boyaux
a
lappareillage.
Nutilisez
pas
des
raccords
en
cuivre.
Nutilisez
que
des
accessoires
standard
en
laiton
pour
raccorder
un
boyau.
Utilisez
une
petite
longueur
do
boyau.
Cola
Øvitera
les
noeuds
et
lusure
prØmaturØe.
Suspendez
le
boyau
au-.
dessus
du
sol
pour
Øviter
quil
no
soit
ØcrasØ,
piØtinØ
ou
endommage.
Enroulez
le
surplus
do
boyau
pour
Øviter
los
noeuds
et
emmŁlements.
Evitez
que
le
boyau
ne
soit
endommagØ
par
des
tranchants,
Øtincelles,
laitier
et
flamme
nue.
VØrifiez
rØgulierement
los
fuites,
Iusure
et
es
rac
cordements
lches.
Plongez
le
boyau
sous
pression
dans
de
leau;
los
bulbs
indiqueront
los
fuites.
Reparation.
Coupez
Ia
partie
percØe
ou
usØe,
et
rac
cordez
(1-2D3).
NUTILISEZ
JAMAIS
de
ruban
adhØsif.
OM-268
Page
5
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that,
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
Service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
*Trademark
of
Proctor
&
Gamble
4.
Branchements
corrects
Avant
de
brancher
lo
dØtendeur,
nettoyez
Ia
sortie
du
robinet
de
Ia
bouteille
des
impuretes
qui
peuvent
obstruer
los
orifices
et
endommagor
es
sieges.
Sauf
pour
lhydrogŁne,
ouvrez
momentanØment
le
robinet,
en
eloignant
Ia
sortie
des
personnes
et
des
sources
in
flammables.
Essuyez
avec
un
tissu
propre
et
non
graisseux.
Appareillez
le
dØtendeur
a
Ia
bouteille.
Avant
de
bran
cher,
vØrifioz
que
Ia
marque
du
dØtendeur
et
Ia
descrip
tion
de
Ia
bouteillo
concordent,
et
que
lorifice
dentrØe
du
dØtendeur
et
Iorifice
de
sortie
do
Ia
bouteille
aillent
ensemble.
NE
BRANCHEZ
JAMAIS
un
dOtondour
concu
pour
un
gaz
special
(ou
des
gaz
spØciaux)
a
une
bouteillo
contenant
dautres
gaz.
Serrez
los
branchements.
Lorsque
vous
assemblez
des
branchements
filetØs,
nettoyez
et
polissez
les
sieges
oU
cest
nØcessaire.
Serrez.
Si
los
branchements
perdent,
dØmontez-les,
nettoyez
et
resserez
avec
une
clef
adØ
quate.
Adaptateurs.
Placez,
si
besoin
est,
un
adaptateur
CGA
(en
vonte
chez
votre
fournisseur)
entre
Ia
bouteille
et
le
dØtendeur.
Avec
deux
clefs,
serrez
ladaptateur
filetØA
DROITE
et
A
GAUCHE.
On
pout
reconnaltro
los
branchements
do
sortie
du
dØtondeur
(ou
boyau)
a
laide
du
filetage
a droite
pour
loxygŁne
et
a
gauche
(idontifiØ
par
un
Øcrou
cannelØ)
pour
los
gaz
combustibles.
5.
DØmarches
do
mise
en
pression
Purgez
le
dØtendour
de
rØsidu
de
gaz
avant
douvrir
Ia
bouteille
(ou
le
robinet
do
canalisation)
en
serrant
Ia
vis
do
reglage
(dans
le
sons
des
aiguilles
dune
montro).
Cette
operation
permet
au
siege
de
haute
pression
de
souvrir
a
Ia
miso
on
pression,
supprimant
ainsi
toute
surchaufte
do
compression.
Maintenoz
Ia
vis
do
rØglage
des
dØtondeurs
a
simple
dØtente
lØgŁrement
ongagØe.
Avant
douvrir
le
robinet
do
Ia
bouteille,
assuroz-vous
quo
los
boyaux
sont
branches
et
quo
les
soupapes
aval
sont
fermØos.
Tenez-vous
latØralement
au
dØtendeur
on
ouvrant
lo
robinot
de
Ia
bouteille.
Ouvrez-le
lentoment
pour
quo
Ia
pression
du
dØtendeur
monte
progiessivoment.
Lorsquo
le
manomŁtre
est
mis
sous
pression
(indique
le
max
imum)
le
robinet
do
Ia
bouteille
do
gaz
inerte
ou
dox
ygŁne
devra
Otre
ouvort
a
fond
pour
assurer
IØtanchØitØ
et
celui
do
Ia
boutoille
do
gaz
combustible
ouvert
de
moms
dun
tour
pour
pouvoir
le
reformer
rapidement
en
cas
durgence.
RØfØrez-vous
aux
tableaux
de
pression
(distribuØs
par
votre
fournisseur)
pour
un
rØglage
recommandØ
de
prossion
sOr
et
efficace
sur
los
dØtondeurs.
VØrifiez
los
fuites
a
Ia
premiere
miso
on
pression
puis
rØguliŁrement,
brossez
avoc
une
solution
savonneuse
(un
bouchon
dlvory
Liquid*
ou
semblable
par
gallon
doau).
Los
bulles
indiquont
une
fuito.
Enlevez
loau
savonneuse
aprŁs
oxamen;
lo
savon
sec
ost
inflammable.
E.
ResponsabilitØs
de
lusager
Otez
immØdiatoment
les
parties
percØes
ou
dØfec
tueuses.
Voir
les
ResponsabilitØs
do
lUsager
du
manuel
do
lappareil.
Page
6
*Marque
de
Commerce
do
Proctor
&
Gamble
F.
Leaving
Equipment
Unattended
F.
Appareil
laissØ
sans
surveillance
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3.
ARC
WELDING
-
Comply
with
precautions
in
1-1,
1-2,
and
this
section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weidments
are
hot,
and
compressed
gases
may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
standards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
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
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAU
TION
S.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
f
ire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pockets
to
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Fermez
lalimentation
de
gaz
a
Ia
source
et
purgez.
G.
Liens
et
supports
temporalres
Pour
vos
travaux
de
soudage
ou
de
coupage,
nutilisez
pas
de
Ia
corde
comme
soutien,
elle
est
inflammable.
1-3.
SOUDAGE
A
LARC
-
Conformez-vous
aux
precautions
des
paragraphes
1.1
et
1.2
de
cette
section.
Le
soudage
a
larc
bien
exØcutØ
est
sOr,
mais
un
soudeur
negligent
est
un
danger.
Le
poste
de
soudage
transporte
des
courants
ØlevØs
sous
de
fortes
tensions.
Larc
est
trŁs
vif
et
chaud.
Les
Øtincelles
volent,
les
vapeurs
montent,
lØnergie
ultra-violette
et
infrarouge
rayonnent,
les
soudures
sont
chaudes,
et
des
gaz
corn
primes
peuvent
Œtre
utilisØs.
Le
soudeur
prudent
Øvite
les
risques
inutiles,
se
protege
et
protege
autrui
contre
las
accidents.
Les
precautions
sont
dØcrites
ici
et
dans
las
normes
donnØes
dans
llndex.
A.
Protection
contre
lee
brOlures
Conformez-vous
aux
precautions
du
paragraphe
1.2.
Larc
de
soudage
est
intense
et
visiblernent
vif.
Son
rayonnernent
peut
blesser
les
yeux,
traverser
les
habits
lØgers,
se
rØflØchir
sur
les
surfaces
claires,
et
brOler
Ia
peau
et
les
yeux.
Les
brQlures
de
Ia
peau
ressemblent
a
un
gros
coup
de
soleil.
Celles
darcs
sous
gaz
protecteur
sont
plus
graves
et
plus
douloureuses.
NE
VOUS
BRULEZ
PAS
-
SUIVEZ
LES
PRECAUTIONS.
1.
VØtements
de
protection
Portez
des
vŒtements
a
manches
longues
(surtout
pour
larc
en
atmosphere
inerte)
avec
gants,
masque
et
chaussures
(1.2A.).
Si
nØcessaire
portez
en
plus
une
veste
ou
des
manches
en
cuir,
un
tablier
et
des
guŒtres
ignifugØs.
De
prØfØrence
ne
portez
pas
de
vŒtements
en
coton
non
traitØ.
Protection
de
Ia
peau.
Portez
des
vOtements
Øpais
foncØs.
Boutonnez
Ie
col
pour
protØger
Ia
poitrine
et
le
cou,
et
boutonnez
les
poches
pourprØvenir
linfiltration
dØtincelles.
2.
Protection
des
yeux
et
de
Ia
tŒte
Evitez
que
vos
yeux
soient
exposØs
a
larc.
NE
regardez
JAMAIS
un
arc
Ølectrique
sans
protection.
Lorsque
vous
soudez,
portez
un
Øcran
ou
masque
avec
verre
filtrantteintØ
N
12
ou
plus
foncØ.
Mettez-Ie
sur
le
visage
avant
damorcer
larc.
ProtØgez
le
verre
filtrant
dun
couvre-verre
clair.
NE
PORTEZ
PAS
un
masque
fendu
ou
brisØ;
le
rayonne
mont
peut
sinfiltrer
et
causer
des
brOlures.
Los
verres~filtrants
fendus,
brisØs
ou
lŒches
doivent
Œtre
remplacØs
IMMEDIATEMENT.
Remplacez
un
couvre
verre
brisØ,
piquØ
ou
tachØ
par
des
projections.
OM-268
Page
7
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
Iow-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for
all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat
cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on
a
cylinder
or
other
pressure
vessel.
It
creates
a
brittle
area
that
can
cause
a
violent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other
bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface
when
welding,
without
suitable
protection.
Vous
devez
portez
des
lunettes
a
Øcrans
latØraux
sous
Ia
masque
pour
protØger
les
yeux
dans
le
cas
o
le
masque
ne
serait
pas
abaissØ
sur
le
visage
avant
lamorage
de
larc.
Regarder
momentanØment
un
arc
sans
protection
(pnincipalement
un
arc
en
atmosphere
inerte
a
haute
in
tensitØ)
peut
brQler
Ia
rØtine
et
laisser
un
point
sombre
permanent
dans
Ia
champ
de
vision.
3.
Protection
du
personnel
a
proximitØ
Local
de
soudage
fermØ.
Pour
Ia
soudage
de
produc
tion,
il
vaut
mieux
utiliser
une
salle
sØparØe
ou
une
baie
fermØe.
Dans
les
locaux
ouverts,
entourez
les
travaux
dØcrans
ou
panneaux
peu
rØflØchissants
et
ininflam
mables.
Laissez
lair
circular
librement,
particuliŁrement
au
niveau
du
sol.
Donnez
des
masques
aux
personnes
qui
regarderont
directement
Ia
soudure.
Autres
personnes
travaillant
sur
les
lieux.
VeillØz
a
ce
que
toutes
les
personnes
portent
les
lunettes
de
protec
tion.
Avant
dattaquer
Ia
soudure,
assurez-vous
que
les
rebords
dØcran
ou
les
portes
soient
fermØs.
B.
Prevention
des
gaz
toxiques
Suivez
las
precautions
du
paragraphe
1.2B.
LØchappe
ment
du
moteur
de
Ia
gØnØratrice
doit Otre
ventilØ
a
lair
extØrieur.
Loxyde
de
carbone
peut
tuer.
C.
Prevention
des
incendies
et
des
explosions
Suivez
las
precautions
1.2C.
Puissance
nominale
de
lappareil.
Na
surchargez
pas
le
poste
de
soudage
a
Iarc.
Cela
peut
surchauffer
las
cables
et
causer
un
in
cendie.
Les
branchements
lches
de
cable
peuvent
surchauffer
ou
faire
des
Øtincelles
et
causer
un
incendie.
Namorcez
jamais
un
arc
sur
une
buteille
ou
autre
rØci
pient
sous
pression.
Cela
crØerait
un
point
de
rupture
entralnant
a
plus
ou
moms
longue
ØchØance
lexplosion
du
reservoir.
D.
Gaz
comprimØ
Suivez
las
precautions
1.2D.
E.
Prevention
des
dØcharges
Ølectriques
Des
conducteurs
charges
ou
metal
nu
incorporØs
au
cir
cuit
de
soudage
ou
a
un
appareil
chargØ
sans
mise
a
Ia
terre
peuvent
donner
une
dØcharge
fatale
a
Ia
personne
dont
le
corps
devient
conducteur.
NE
SOUDEZ
PAS
DEBOUT,
ASSIS,
COUCHE,
PENCHE
sur
une
surface
humide
ni
en
contact
avec
une
telle
surface
sans
protec
tion
appropriØe.
Page
8
To
protect
against
shock:
Keep body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
damp
ness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1.
Grounding
the
Equipment
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
lead
to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal
of
equipment
frames
at
connections.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-
prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2.
Electrode
Holders
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot metal
and
sparks.
Pour
vous
protØger
contre
les
dØcharges
Ølectriques,
maintenez
votre
corps
et
vOtements
secs.
Ne
travaillez
jamais
dans
un
endroit
humido
sans
isolation
adequate
contre
les
dØcharges
Ølectriques.
Lorsque
vous
no
pouvez
Øviter
lhumiditØ
ou
Ia
sueur,
placez-vous
sur
un
caillebotis
sec
ou
un
tapis
en
caoutchouc.
La
sueur,
Ieau
de
mer,
ou
lhumiditØ
entre
le
corps
et
une
piŁce
CHARGEE,
ou une
piŁce
de
metal
a
a
masse,
rØduisent
Ia
rØsistance
Ølectrique
de
Ia
surface
du
corps,
permet
tant
lentrØe
de
courants
dangereux,
voire
mortels.
1.
Mise
a
Ia
terre
de
lappareil
-
A
Iinstallation,
branchez
los
chassis
de
chaque
ØlØment
(source
de
courant,
commande,
Øtabli
et
circuit
deau)
a
Ia
terre.
Les
conducteurs
doivent
pouvoir
conduire
los
courants
telluriques
en
toute
sØcuritØ.
Lappareil
chargØ
par
les
courants
vagabonds
peut
donner
une
dØcharge
risquant
dŒtre mortelle.
NE
BRANCHEZ
PAS
VOTRE
PRISE
DE
TERRE
a
une
conduite
Øloctrique,
ou
a
un
tuyau
de
gaz
ou
de
liquide
inflammable
tel
quo
lhuile
ou
un
combustible.
Connexion
triphasØe.
Avant
linstallation
vØrifiez
Ia
phase
nØcessaire
a
lappareil.
Si
soul
le
triphasØ
est
disponible,
no
branchez
lappareil
monophasØ
qua
deux
des
fils
de
Ia
ligno
triphasØe.
NE
BRANCHEZ
PAS
le
conducteur
do
terre
de
Iappareil
au
troisiŁme
fil
(sous
tension),
autrement
lappareil
serait
chargØ:
condition
dangereuse
pouvant
donner
une
dØcharge
fatale.
Avant
le
soudage,
vØrifiez
si
Ia
prise
do
terre
est
uniforme.
En
branchant,
assurez-vous
que
los
con
ducteurs
touchent
Ia
metal
flu
du
chØssis
do
lappareil.
Lorsquun
appareil
doit
Œtre
alimentØ
Ł
partir
dun
cof
fret
dalimentation,
le
conductour
do
terre
doit
Œtre
reliØ
a
celui-ci.
Si
vous
avez
en
plus
une
fiche
a
trois
broches
pour
Ia
terre,
no
branchez
le
conducteur
de
terre
qu
Ia
broche
de
terre.
Si
le
cordon
dalimontation
a
une
fiche
a
trois
broches,
roliez-lo
a
uno
prise
femello
tripolaire
reliØe
a
Ia
terre.
Nenlevez
jamais
Ia
broche
de
terre
dune
fiche
ou
nutilisez
jamais
une
fiche
dont
Ia
broche
de
terre
sorait
brisØe.
2.
Pince-Ølectrodes
Utilisez
des
pince-Ølectrodes
bien
isolØes.
NUTILISEZ
PAS
des
pinco-Ølectrodes
avec
vis
saillantes.
3.
Connoctours
Utilisez
des
connecteurs
a
verrouillage
bien
isolØs
pour
assembler
do
longs
cØbles.
4.
Cables
VØrifiez
frØquemment
Iusure,
los
fissures
et
laltØration
des
cables.
REMPLACEZ
IMMEDIATEMENT
ceux
dont
Iisolation
sorait
trop
usØe
ou
altØrØe
pour
prØvenir
los
dØcharges
mortelles
provoquØes
par
un
cable
dØnudØ.
Vous
pouvoz
enrouler
los
parties
ondommagØes
do
ruban
adhØsif
on
Øpaissour
suffisante
pour
donner
une
rØsistance
do
cable
neuf.
Maintenez
les
cables
secs,
dØpourvus
dhuile
et
de
graisse
at
mettoz-Ies
a
labri
du
metal
chaud
et
des
Øtincelles.
OM-268
Page
9
5.
Terminals
And
Other
Exposed
Parts.
5.
TŒtes
de
cables
et
autres
parties
dØnudØes
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
Wire
Electrode
wire
becomes
electrically
HOT
when
the
power
switch
of
gas
metal-arc
welding
equipment
is
ON
and
welding
gun
trigger
is
pressed.
Keep
hands
and
body
clear
of
wire
and
other
HOT
parts.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
-
For
more
in
formation,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
2501
NW
7th
St.,
Miami,
FL
33125.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
ment
Printing
Office,
Washington,
D.C.
20402.
4.
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,
NY
10018.
5.
ANSI
Standard
Z41
.1,
STANDARD
FOR
MENS
SAFETY
-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018
Avant
Ia
mise
en
marche,
les
tŒtes
de
cables
et
autres
parties
dOnudØes
dun
appareil
Ølectrique
doivent
Otre
munies
de
leurs
couvrefils
isolants.
6.
Fils-Ølectrodes
Le
fil-Ølectrode
est
chargØ
lorsque
lorsque
linterrupteur
dalimentation
du
poste
a
souder
au
MIG
est
sur
MAR
CHE
et
que
lon
appuie
sur
Ia
gchette
du
pistolet.
Evitez
que
les
mains
et
le
corps
soient
en
contact
avec
le
fil
et
autres
ØlØments
charges.
7.
Dispositif
de
sØcuritØ
Le
dispositif
de
sØcuritØ-verroulllage
et
coupe-circuit
ne
doit
pas
Œtre
dØbranchØ
ou
dØshuntØ.
Avant
linstallation,
linspection
ou
Ia
reparation
de
Iap
pareil,
mettez
lalimentation
sur
ARRET
et
enlevez
les
fusibles
generaux
(ou
verrouillez
les
interrupteurs)
pour
Øviter
une
remise
en
MARCHE
accidentelle.
DØbran
chez
tous
les
cables
de
Ia
source
de
cou
rant
ainsi
que
les
prises
des
cordons
dalimentation
en
115
volts.
Lors
du
soudage,
nouvrez
pas
le
circuitdalimentation
et
ne
changez
pas
Ia
polaritØ.
Sil
est
dØbranchØ
au
cours
dune
urgence,
faites
attention
aux
brOlures
de
dØcharge
ou
aux
jaillissements
dØtincelles.
Appareil
laissØ
sans
surveillance.
Mettez
toujours
sur
ARRET
et
dØbranchez
lappareil.
Linterrupteur
darrŒt
doit
toujours
se
trouver
a
prox
imitØ
de
Ia
source
de
courant.
1-4.
INDEX
DES
NORMES
-
Pour
plus
de
renseignements,
rØfØrez-vous
aux
normes
de
IACNOR
ou
aux
normes
amØricaines
suivantes:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
distribuØ
par
lAmerican
Welding
Society,
2501
N.W.
7th
Street,
Miami,
FL
33125
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
distribuØ
par
le
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington
D.C.
20402
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
distribuØ
par
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
distribuØ
par
lAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY
-
TOE
FOOTWEAR
distribuØ
par
lad
dresse
donnee
en
4.
Page
10
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
2501
NW
7th
Street,
Miami,
FL
33125.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10.
NFPA
Standard
SiB,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
ii.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
GSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.i
Recommended
Safe
Practices
for
the
PrØpara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the
American
Welding
Society,
2501
NW
7th
Street,
Miami,
FL
33125.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
distribuØ
par
laddresse
~onnee
en
4.
7.
AWS
Standard
A6.O,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
COM
BUSTIBLES
distribuØ
par
Iaddresse
donnee
en
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
distribuØ
par
Ia
National
Fire
Protection
Associa
tiOn,
470
Atlantic
Avenue,
Boston,
MA
02210
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
distribuØ
par
laddresse
donnØe
en
8
10.
NFPA
Standard
518,
CUTTING
AND
WELDING
PROCESSES
distribuØ
par
Iaddresse
donnØe
en
8
ii.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
distribuØ
par
Ia
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wii7.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
distribuØ
par
Ia
Cana
dian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
iR3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
distribuØ
par
Ia
National
Welding
Supply
Association,
1900
Arch
Street
Philadelphia,
PA
19103.
14.
American
Welding
Societe
Standard
AWSF4.i
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
distribuØ
par
lAmerican
Welding
Societe,
2501
NW
7th
Street,
Miami,
FL
33125.
15.
ANSI
Standard
Z88.2
Practice
For
Respiratory
Protection
distribuØ
par
lAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-268
Page
11
SECTION
2
-
INTRODUCTION
Input
At
Rated
Rated
Welding
Current
Amperes
200
@
28
Volts,
40%
Duty
Cycle
Welding
Current
Range
Amperes
dc
35-250
Max.
Open-
Circuit
Voltage
80
Load
Output
60
Hz.
Three-Phase
Amperes
At
kva
16.32
kw
9.1
Overall
Dimensions
Height
-
28-3/4
in.
(730
mm)
Width
-
16
in.
(406
mm)
Depth
-
26
in.
(660
mm)
Weight
Net
Ship
~
295
lb.
1305
lb.
(134
kg)j(138
kg)
200(208)V
230V
460V
L
45
41
20.5
Figure
2-1.
Specifications
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
provided
on
this
unit
pertains
to
equipment
design,
installation,
operation,
maintenance
and
troubleshooting
which
should
be
read,
understood
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated
and
maintained
only
by
qualified.
persons
in
accordance
with
this
manual and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
___________
which
identify
different
levels
of
hazard.
I~.tU1I.]~I
statements
include
installation,
operating
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
_______________
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
2-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
2-3.
DESCRIPTION
-
This
unit
is
welding
power
source
that
produces
Shielded
Metal-Arc
Welding
(SMAW).
SECTION
3
-
INSTALLATION
3-1.
LOCATION
t.~1I1l.T~r
IMPROPER
LIFTING
OF
EQUIPMENT
can
result
in
personal
injury
and
equipment
damage.
Use
equipment
of
adequate
capacity
to
lift
the
unit.
If
using
lift
forks
to
handle
this
unit,
be
sure
the
lift
forks
are
long
enough
to
extend
out
of
the
op
posite
side
of
the
base.
Using
lift
forks
too
short
will
expose
internal
com
ponents
to
damage
should
the
tips
of
the
lift
forks
penetrate
the
bottom
of
the
unit.
RESTRICTED
AIR
FLOW
causes
overheating
and
possible
damage
to
internal
parts.
Maintain
at
least
18
inches
(457
mm)
of
unrestricted
space
on
all
sides
of
unit
and
keep
underside
free
of
obstructions.
Do
not
place
any
filtering
device
over
the
intake
air
passages
of
this
welding
power
source.
Warranty
is
void
if
any
type
of
filtering
device
is
used.
This
welding
power
source
has
a
lifting
device
for
mov
ing
the
unit
and
holes
in
the
base
for
mounting
pur
poses.
Figure
3-1
gives
unit
dimensions.
The
location
should
allow
room
to
remove
cover
and
panels
for
maintenance
and
repair.
The
service
life
and
efficiency
of
this
unit
are
reduced
when
the
unit
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
WARNING
____________
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
serious
personal
injury
or
loss
of
life.
WARNING
and
CAUTION
a
three-phase
dc
current
for
Page
12
Control
Circuit
Overload
Breaker
Remote
Amperage_
Control
Switch
Remote
Amperage
Control
Receptacle~~
SECTION
.4
-
OPERATOR
CONTROLS
Figure
4-1.
Front
Panel
View
4-1.
POWER
SWITCH
(Figure
4-1)
-
Placing
the
POWER
switch
in
the
ON
position
energizes
the
welding
power
source,
making
the
unit
operational.
Placing
the
POWER
switch
in
the
OFF
position
shuts
the
unit
down.
4-2.
AMPERAGE
ADJUSTMENT
CONTROL
&
SWITCH
(Figure
4-1)
A.
Amperage
Adjustment
Control
The
AMPERAGE ADJUSTMENT
control
provides
fine
amperage
adjustment.
Rotating
the
control
clockwise
increases
amperage
output.
The
scale
surrounding
the
control
is
calibrated
in
percent
and
should
not
be
read
as
an
amperage
value.
Il~l~1;lf..t~I~
The
AMPERAGE ADJUSTMENT
control
may
be
adjusted
while
we/ding.
B.
Remote
Amperage
Control
Switch
If
a
Remote
Amperage
Control
is
used,
place
the
REMOTE
AMPERAGE
CONTROL
switch
in
the
REMOTE
position.
When
a
remote
control
is
used,
it
has
complete
control
of
weld
output.
If
a
remote
control
is
not
used,
place
the
REMOTE
AMPERAGE
CONTROL
switch
is
in
the
STANDARD
position.
When
this
switch
is
in
the
STANDARD
posi
tion,
only
the
AMPERAGE
ADJUSTMENT
control
varies
the
amperage.
4-3.
VOLT-AMPERE
CURVES
(Figure
4-2)
-
The
volt-ampere
curves
show
the
voltage
and
amperage
output
capabilities
of
the
welding
power
source
at
mm.
and
max.
of
each
coarse
range.
Voltage
and
amperage
adjustment
within
each
range
is
provided
by
the
AMPERAGE ADJUSTMENT
control.
With
the
use
of
the
volt-ampere
curves
it
is
possible
to
determine
the
load
voltage
at
any
particular
weld
cur-
rent.
80
70
60
550
v
40
a
30
20
0
0
Figure
4-2.
Volt-Ampere
Curve
8002
510
4-4.
DUTY
CYCLE
CHART
(Figure
4-3)
-
The
duty
cycle
of
a
welding
power
source
is
the
percentage
of
a
ten
minute
period
that
a
welding
power
source
can
safe
ly
be
operated
at
a
given
output.
This
welding
power
source
is
rated
at
40
percent
duty
cycle.
This
means
that
the
welding
power
source
can
be
safely
operated
at
rated
load
for
four
minutes
out
of
every
ten.
During
the
remaining
six
minutes,
the
unit
should
idle
to
permit
proper
cooling.
If
the
welding
amperes
are
decreased,
the
duty
cycle
will
increase.
Figure
4-3
enables
the
operator
to
determine
the
safe
output
of
the
welding
power
source
at
various
duty
cycles.
CAUTION:
EXCEEDING
DUTY
CYCLE
RATINGS
will.damage
the
welding
power
source.
Do
not
exceed
duty
cycles
indicated.
ro1
Amperage
Adjustment
Control
:
2
Power
Switch
Front
Access
Door
Negative
Weld
Output
Terminal
Positive
Weld
Output
Terminal
J
TB901
903.4
SO
100
50
200
250
300
DC
AMPERIS
OM-268
Page
15
00
RATED
OUTPUT
~~
~
~
-
h-..
-.
~.,
25
30
35
40
50
60
70
80
90
100
%
DUTY
CYCLE
B-002
523
Figure
4-3.
Duty
Cycle
Chart
SECTION
5
-
SEQUENCE
OF
OPERATION
WARNING:
____
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.
Keep
all
covers
and
pane/s
in
place
while
operating.
Warranty
is
void
if
the
welding
power
source
is
operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for
basic
welding
safety
infor
mation.
5-1.
SHIELDED
METAL-ARC
WELDING
(SMAW)
2.
Place
REMOTE
AMPERAGE
CONTROL
switch
in
desired
position
(see
Section
4-2).
3.
Rotate
AMPERAGE
ADJUSTMENT
control
or
remote
amperage
adjustment
control
to
desired
position.
4.
Place
POWER
switch
in
ON
position.
5.
Begin
welding.
5-2.
SHUTTiNG
DOWN
1.
Stop
welding.
2.
Allow
unit
to
idle
for
a
cooling
period
with
no
load
applied.
1.
Make
all
necessary
connections
as
instructed
in
Section
3.
3.
Place
POWER
switch
in
OFF
position.
SECTION
6
-
MAINTENANCE
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Disconnect
input
power
and
employ
lockout!
tagging
procedures
before
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
tagging
circuit
breaker
or
other
disconnecting
device.
IMPORTANT
______________
Periodically
inspect
the
labels
on
the
unit
for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
labels.
6-1.
FAN
MOTOR
-
This
unit
is
equipped
with
an
ex
haust
fan
and
relies
on
forced
draft
for
adequate
cool-
ing.
The
fan
motor
is
manufactured
with
lifetime
sealed
bearings
and
requires
no
maintenance.
6-2.
INTERNAL
CLEANING
-
Occasional
blowing
out
or
vacuuming
of
the
dust
and
dirt
from
around
the
internal
components
is
recommended.
This
should
be
done
periodically
depending
on
the
location
of
the
unit
and
the
amount
of
dust
and
dirt
in
the
atmosphere.
The
welding
power
source
outer
enclosure
should
be
remov
ed
and
a
clean,
dry
airstream
or
vacuum
suction
should
be
used
for
this
cleaning
operation.
6-3.
WELD
CABLES
-
Periodically
inspect
cables
for
breaks
in
insulation
and
ensure
that
all
connections
are
clean
and
tight.
Repair
or
replace
cables
as
necessary.
Clean
and
tighten
connections
periodically.
300
250
n~
200
4
(5
z
ISO
4-5.
CONTROL
CIRCUIT
OVERLOAD
BREAKER
(Figure
4-1)
-
The
amperage
control
circuit
is
pro
tected
against
overload
by
a
circuit
breaker.
Should
an
overload
occur,
the
circuit
breaker
would
open
and
weld
output
would
go
to
minimum.
Manually
depress
the
circuit
breaker
to
reset
it.
Page
16
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Miller RAMROD Owner's manual

Miller
Brand
Miller
Model
RAMROD
Category
Welding System
Type
Owner's manual
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