Miller JK651490 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
August
1989
FORM:
OM-1540D
Effective
With
Serial
Number
JK651490
MODEL:
AUTOMATIC
2A
Shunt
Control
Hub
&
Spindle
Assembly
Spool
Support
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
o~3erating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.
Comparry
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PR
?~()
IN
U.S.A
J
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
~~1
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nished
by
Miller
is
free
from
defectin
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
..
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
or
any
other
dutywith
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repairor
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or
(4)
payment
of
or
credit
forthe
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacementwill
be
FOB.,
Factory
atAppleton,
Wisconsin,
or
FOB.
ata
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTy~
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH OF
CONTRACT
WHICH,
BUT
FORTHIS
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
l
ERRATA
SHEET
Replace
Warranty
with
the
following:
Li
MILLERS
TRUE
BLU
EIM
LIMITED
WARRANTY
Effective
January
1,1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
Conditions
below.
MILLER
Electric
Accessory
Kits
MIg
Co.
Appleton.
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
Replacement
Parts
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
01
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
MILLERS
True
Blue
Limited
Warranty
shall
not
apply
to:
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT.
NESS.
1..
Items
furnished
by
MILLER.
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
Items
are
covered
by
the
manufacturers
warranty,
if
Within
the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war-
any.
ranted
parts
or
components
that
Isil
due
to
such
defects
in
material
or
wortrmsnship.
MILLER
must
be
nofified
in
writing
within
thirty
(30)
days
01
such
defect
or
failure,
at
2..
Consumabte
components:
such
as
contact
tips,
cutting
nozzles.
contactors
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
and
relays.
tollowed.
3.
Equipmenf
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip-
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
ment
that
has
been
Improperly
installed,
improperly
operated
or misused
event
ot
such
a
lailure
within
the
warranty
time
periods.
All
warranty
time
periods
based
upon
industry
standards.
or
equipment
which
has
not
had
reasonable
start
on
the
date
that
the
equipment
was
delivered
10
the
original
retail
purchaser,
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
and
are
as
follows:
outside
of
the
specifications
for
the
equipment.
5
Years
Parts
-
3
Years
Labor
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAIJINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
Original
main
power
rectifiers
THE USE
AND
MAtNTENANCE
OF
WELDING
EQUIPMENT.
2.
3
Years
Parts
and
Labor
,
-
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
Transformer/Rectifier
Power
Sources
shall
be,
at
MILLERS
option:
(1
(repair:
or
(2(
replacement,
or,
where
authorized
in
Plasma
Arc
Cutting
Power
Sources
writing
by
MILLER
in
appropriate
cases,
(3(
the
reasonable
cost
of
repair
or
replace-
Semi.Automatic
and
Automatic
Wire
Feeders
went
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
*
Robots
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
01
the
goods
at
customers
risk
and
expense
MILLERS
Option
of
repair
or
replacement
3
2
Years
Parts
and
Labor
will
be
FOB..
Factory
at
Appleton.
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therelore
no
compensation
or
reimburse-
Engine
Driven
Welding
Generators
went
for
transportation
costs
of
any
kind
will
be
allowed.
(NOTE:
Engines
are
warranted
separatety
by
the
engine
manufacturer.)
4
t
Yea
Parts
and Labo
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
Motor
Driven
Guns
LIABLE
FOR
DIRECT.
INDIRECT.
SPECIAL.
INCIDENTAL
OR
CONSEQUENTIAL
Process
Controllers
DAMAGES
(INCLUDING
LOSS
OF
PROFIT(,
WHETHER
BASED
ON
CON-
Water
Coolant
Systems
TRACT.
TORT
OR
ANY
OTHER
LEGAL
THEORY.
HF
Units
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR-
Grids
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
Spot
Welders
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
Load
Banks
THEORY
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION,
SDX
Transformers
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
Running
Gear/Trailers
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
Field
Options
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER,
(NOTE:
Field
options
are
covered
under
True
BIue~
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
one
year
whichever
is
greater
(
lasts.
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
5..
6
Months
Batteries
cific
legal
rights,
and
other
righf
s
may
be
available,
but
may
vary
from
state
to
state,
6.
90
Days
Parts
and
Labor
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
MIG
Guns/TIG
To
ches
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
Out
above
may
not
apply.
This
Limited
*
Plasma
Cutting
Torches
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available.
but
may
Remote
Controls
vary
from
province
to
province.
~1
:1
U
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
t
AMENDMENT
TO
SECTION
4INSTALLATION
Amend
Figure
4-4.
Weld
Control
Cycle
as
follows:
Control
relay
CR51
contacts
are
available
at
terminal
strip
2T
terminals
J
and
K.
Amend
socket
information
portion
of
Section
4-4D.
WELD
CONTROL
INTERCONNECTIONS:
Electrical
I
nputlContactor
ControlNoltage
Control
Connections
Socket
C:
+10
volts
dc
with
respect
to
socket
D
required
from
an
external
source.
Socket
D:
Control
circuit
common
for
remote
control
device
from
an
external
source.
Socket
E:
Output
Signal;
0
volts
equals
machine
minimum;
+10
volts
equals
machine
maximum.
Socket
G:
115
volts
ac
circuit
common.
Socket
I:
Requires
115
volts
ac,
60
Hz,
with
respect
to
socket
G
(circuit
common).
Socket
J:
A
contact
closure
from
socket
Ito
socket
J
energizes
the
115
volt
contactor
control
circuit
in
the
welding
power
source.
Socket
K:
Chassis
ground.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
AMENDMENT
TO
SECTION
8
ELECTRICAL
DIAGRAMS
Amend
Diagram
8-3.
Circuit
Diagram
For
Dual
Timer
Board
PCi
And
PC2
Circuit
Diagram
No.
SB-084
442-B
Diagram
8-3.
Circuit
Diagram
For
Dual
Timer
Board
PCi
And
PC2
OM-1540D
Page
2
Dia.
Part
Replaced
Mkgs.
No.
With
27-29
27-47
27-48
27-50
28-58
30-
30-
31-
32-3
33-
34-5
34-
123
154
111
123
109
771
039
734
111
122
134327
+152
370
079
534
079
739
+141
162
134
731
079
739
152
492
134
731
091
861
092
648
144
240
134
464
083
772
135
205
134
464
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
+These
items
effective
with
KC274029
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
AMENDMENT
TO
SECTION
9
PARTS
LIST
Amend
Parts
List
as
follows:
Description
Quantity
109770
.RC1
.094480
079843
Added
Qi
.037824
047497
VR5O
..
081
832
085980
121316
LABEL,
warning
general
precautionary
1
CONNECTOR
w/SOCKETS,
(consisting
of)
1
CONNECTOR,
circ
skt
14-lBga
Amp
66358-6
14
CONNECTOR,
circ
clamp
str
rlf
sz
17-20
Amp
206322-2
.
1
CONNECTOR
&
PINS,
(consisting
of)
1
CONNECTOR,
circ
pin
14-lBga
Amp
213603-1
14
CONNECTOR,
circ
clamp
str
rlf
sz
17-20
Amp
206322-2
.
1
CONNECTOR
w/P~NS,
(consisting
of)
I
CONNECTOR,
circ
pin
14-l8ga
Amp
213603-1
14
SOCKET,
relay
l4skt
2
RESISTOR,
WW
fxd
zero
ohm
2
THYRISTOR,
SCR
16A
600V
1
LABEL,
warning
general
precautionary
1
IC,
linear
7815
1
NUT,
sti
slflkg
hex
reg
.625-11
1
LABEL,
warning
general
precautionary
1
OM-1540D
Page
3
OM-15400-
9/89
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
deliverIng
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_________________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
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.
ArcWelding
4
1-4.
Standards
Booklet
Index
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3
SPECIFICATIONS
3-1.
Description
7
SECTION
4
INSTALLATION
4-1.
Site
Selection
8
4-2.
Equipment
Installation
8
4-3.
Internal
Connections
10
4-4.
Weld
Control
Interconnections
11
4-5.
Shunt
Control
Interconnections
12
4-6.
Welding
Wire
Installation
14
SECTION
5OPERATOR
CONTROLS
5-1.
Power/Emergency
Stop
Switch
And
Pilot
Light
15
5-2.
Jog
Up
And
Jog
Down
Switches
15
5-3.
Preflux
Switch
15
5-4.
Start
Switch
15
5-5.
Stop
Switch
15
5-6.
Meters
15
5-7.
Preflux
Time
Control
15
Section
No
Page
No.
5-8.
Run
In
Speed
Control
15
5-9.
Weld
Wire
Speed
Control
15
5-10.
Weld
Voltage
Control
15
5-il.
Crater&JogSpeedControl
15
5-12.
Crater
Voltage
Control
15
5-13.
CraterTime
Control
15
5-14.
Burnback
Control
15
5-15.
Optional
Postf
low
Time
Control
16
5-16.
Optional
Run
in
Controls
16
SECTION
6SEQUENCE
OF
OPERATION
6-1.
Submerged
Arc
Welding
(SAW)
16
6-2.
Gas
Metal
Arc
Welding
(GMAW)
17
6-3.
Shutting
Down
17
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine
Maintenance
17
7-2.
Overload
Protection
18
7-3.
Hub
Reinstallation
18
7-4.
Circuit
Board
Handling
Precautions
18
7-5.
Troubleshooting
19
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
21
Diagram
8-2.
Wiring
Diagram
22
Diagram
8-3.
Circuit
Diagram
For
Dual
Timer
Board
PCi
And
PC2
24
Diagram
8-4.
Circuit
Diagram
For
Meter
Converter
Board
PC3
24
Diagram
8-5.
Circuit
Diagram
For
Motor
Control
Board
PC4
25
SECTION
9
PARTS
LIST
Figure
9-1.
Control
Box
26
Figure
9-2.
Panel,
Mounting
-
W/Components
29
Figure
9-3.
Circuit
Card,
Timer
PCi
,2
30
Figure
9-4.
Circuit
Card,
Control
Motor
PC4
31
Figure
9-5.
Shunt
Control
32
Figure
9-6.
Hub
&
Spindle
Assembly
34
Figure
9-7.
Reel,
Wire
34
LIST
OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Table
3-2.
Weld
Parameters
7
Table
7-1.
Troubleshooting
19
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
arid
unwise.
Let
the
experience
of
oth
ers
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Re
search,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
rea
son
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
seri
ous
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
cut
ting;
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
local
inspection
requirements
also
provide
a
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.
In
addition
to
the
information
in
this
manual,
be
sure
to
consult
flux
and
electrode
manu
facturers
Material
Safety
Data
Sheets
(MSDSs)
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A.
Burn
Prevention
Wear
protective
clothing-gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuff
less
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
and
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.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
workin9
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(orcutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Standard
Z49.1
listed
in
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
of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-sup
plied
respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
orcontaining
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
to
r.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
prod
ucts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
perchloroethyle
ne
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
OM-1540
Page
1
to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloroethylene.
C.
Fire
and
Explosion
PreventIon
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
nal;
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
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free
of
combustibles.
Avoid
pal
nt
spray
rooms,
dip
tanks,
storage
areas,
venti
lators.
If
the
work
cannot
be
moved,
move
combustibles
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
extin
guishing
equipmentduring
andfor
sometime
afterweld
ing
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
orwalls
within
35
feet
may
expose
combustibles
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
that
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
7
in
Standards
Index.
This
includes:
athorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective
equip-
ment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should
be
cleaned
(see
preceding
paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if it
is
safe
to
weld
or
cut.
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,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
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
regulatorfrom
service
immediately
for
re
pair
(first
close
cylinder
valve).
The
following
symptoms
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
to
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
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
acci
dent.
(See
i-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
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.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MI;
keep
them
separate
from
FULLS
and
return
promptly.
OM-1540
Page
2
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
orcradle.
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
al
low
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.
Cylindertittings
should
never
be
modified
or
exchanged.
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
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
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
tape.
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
area,
and
thatthe
regulator
inlet
and
cylinderoutlet
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
identified
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
be
fore
opening
cylinder
(or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise).
Draining
prevents
exces
sive
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
fol
lowing
position:
Foroxygen,
and
inert
gases,
open
fLtlly
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.
Brushwith
soap
solution
(capfull
of
Ivory
Liq
uid~
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
E.
User
ResponsIbilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
weldtng
or
cutting
operation;
rope
may
burn.
*Trademark
of
Proctor
&
Gamble.
OM.1540
Pa~)
3
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
in
frared
energy
radiates,
weldments
are
hot,
and
com
pressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
stan
dards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
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
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1
-2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-re
sistant
leggings.
Avoid
outer
garments
of
untreated
cot
ton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pock
ets
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.
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
sepa
rate
room
or
enclosed
bay
is
best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow
for
free
air
circulation,
par
ticularly
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
arcwelding
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
ves
sel.
It
creates
a
brittle
area
that
can
cause
a
violent
nip
ture
or
lead
to
such
a
rupture
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
weld
ing
circuit,
or
in
ungrounded,
electrically-HOT
equip
ment
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.
To
protect
against
shock:
Wear
dry
insulating
gloves
and
body
protection.
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
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces
the
electrical
resistance,
and
could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between
the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
conduct
ing
objects
include,
but
are
not
limited
to,
buildings,
elec
trical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
1.
Grounding
the
Equipment
Arc
welding
equipment
must
be
grounded
according
to
the
National
Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,control,
work
table,
and
water
cir
culator
to
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-1540
Page
4
electrically
HOT
by
stray
Cu
rrent
may
shock,
possiblyfa
tally.
Do
NOTGROUNDto
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
or
flammable
liquid
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
re
ceptacle,
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
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
ott
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.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
a.
Equipment
with
output
on/ott
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
of
the
welding
power
output.
When
so
equipped
the
electrode
wire
becomes
electri
cally
HOT
when
the
power
source
switch
is
ON
and
the
welding
gun
switch
is
closed.
Never
touch
the
electrode
wire
or
any
conducting
ob
ject
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is
off.
b.
Equipment
without
output
on/oft
control
(no
contactor)
Welding
power
sources
used
with
shielded
metal
arc
welding
(SMAW)
and
similar
proc
esses
may
not
be
equipped
with
welding
power
output
on-ott
control
devices.
With
such
equip
ment
the
electrode
is
electrically
HOT
when
the
power
switch
is
turned
ON.
Never
touch
the
electrode
unless
the
welding
power
source
is
off.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equipment,
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
weld
ing.
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.
F.
Protection
For
Wearers
of
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
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
referto
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,
550
N.W.
LeJeune
Rd, Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Gov
ernment
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
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
Broad
way,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PROCESSES
OM-1540
Pagis
5
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from
the
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
fromthe
Compressed
Gas
Association,
1235
Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
CSA
Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Ca
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,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE
PRACTICES
FOR
THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT
HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI
Standard
Z88.2,
PRACTICE
FOR
RESPIRA
TORY
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
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
equipment.
B
.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
OM-1540
Page
6
SECTION
3-
SPECIFICATIONS
Table
3-1.
SpecIfications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Weld
Control
20-1/2
in.
(521
mm)
17
in.
(432
mm)
8-1/4
in.
(210
mm),
43
lbs.
(19.5
kg)
Total
118
lbs.
(54
kg)*
-
Shunt
Control
4in.
(102
mm)
8-3/4
in.
(222
mm)
14
in.
(356
mm)
11
lbs.
(5.0
kg)
Spool
Support
Assembly
13-3/4
in.
(349
mm)
8-3/4
in.
(222
mm)
9-1/4
in.
(235
mm)
6
lbs.
(2.7
kg)
Add
1-1/2
in.
(38
mm)
for
control
knobs.
+Spool
Support
without
optional
wire
reel.
lncludes
weight
of
wire
drive
assembly.
Wire
Feed
Speed
Range
A2
Low
Speed
Models
12-288
1pm
(.30
to
7.32
mpm)
A2
High
Speed
Models
46-1125
ipm(1.l7to
28.58
mpm)
Al
Standard
Speed
Models
70-750
ipm
(1.78
to
19.05
mpm)
Al
Low
Speed
Models
20-190
ipm
(51
to
4.83
mpm)
Weld
Voltage
And
Amperage
Capacity
(AC
or
DC)
0
to
100
Volts
0
to
1500
Amperes
3-1.
DESCRIPTION
This
weld
control
is
designed
to
automatically
cycle
welding
events
while
maintaining
constant
wire
feed
speed.
This
unit
is
to
be
used
with
a
constant
voltage
(CV)
AC
or
DC
welding
power
source
having
remote
contactor
and
voltage
control
capabilities
for
Sub
merged
Arc
Welding
(SAW)
or
Gas
Metal
Arc
Welding
(GMAW).
The
standard
weld
control
has
provisions
to
set
weld
parameters
according
to
Table
3-2.
Normally-open
relay
contacts
that
work
in
conjunction
with
the
weld
cycle
are
available
to
interface
with
other
equipment
(Such
as
fixtures).
Optional
controls
include
run
in
voltage
and
time,
shield
ing
gas
valve
with
postllow
timer,
and
water
valve.
An
op
tional
pendant
control
provides
remote
control
of
start,
stop,
jog
up,
jog
down,
and
preflux.
Table
3-2.
Weld
Parameters
Weld
Cycle
Controls
Wire
Speed
Voltage
Time
Preflux/
X
Pref
low
Run-In
X
Weld
X
X
Crater
(Jog)
X
X
X
Burnback
X
Postf
low
.
X
=
Standard
+
=
Optional
For
information
on
the
wire
drive
assembly,
see
Owners
Manual
supplied
with
the
wire
drive
assembly.
A
current
sensing
shunt
control,
wire
spool
hub,
and
spindle
support
are
provided
with
the
weld
control.
The
wire
reel
is
optional.
OM-1540
Page
7
inches
Millimeters
A
21-7/8
556
B
13-3/4
349
3
76
0
2-1/2
63.5
E
3-1/2
88.9
F
4-1/2
114
C
10-11/16
275
4-1.
SITE
SELECTION
(Figure
3-1
And
Figure
4-1)
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No
flammables
6.
A
clean
and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around
unit
OM-1540
Page
8
9.
Adequate
space
to
open
and
remove
cover
and
wrapper
for
installation,
maintenance,
and
repair
functions.
Mounting
holes
provide
the
capability
to
install
and
se
cure
the
system
components
in
a
permanent
location.
Figure
3-1
gives
overall
dimensions
and
mounting
hole
layout.
4-2.
EQUIPMENT
INSTALLATION
A.
Supplied
EquIpment
The
following
equipment
is
supplied
as
standard
and
re
quires
installation
or
assembly:
1.
Weld
Control
2.
Shunt
Control
3.
Hub
and
Spindle
Assembly
2
in.
(50.8mm).
9/32
in.
(7.1
mm)
Die.
4
Holes
3/8
In.
4
in.
(101.6
mm)
Add
1-1/2
In.
(38.1
mm)
For
Front
Panel
Knobs
(7.9
mm)
Dia.
4
Holes
Overall
Dimensions
And
Mounting
Hole
Layout
Figure
3-1.
Dimensional
Views
TC-083
441-B
TA-083
354-A
18-080
486-C
SECTION
4-INSTALLATION
Control
4.
Spindle
Support
5.
10
ft.
(3
m)
Weld
Control
Shunt
Control
Intercon
necting
Cord
6.
25
ft.
(8
m)
Weld
Control
Welding
Power
Source
Interconnecting
Cord
7.
5ft.(1.5
m)
Motor
Cord
8.
25
ft.
(8
m)
Voltage
Sensing
Cord
B.
Equipment
Location
(Figure
4-1)
When
deciding
on
equipment
location,
consider
the
fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
ca
pable
of
supporting
the
weight
of
the
equipment.
2.
The
lead
lengths
of
the
cords
supplied
with
the
equipment
will
limit
the
area
in
which
the
equipment
can
be
located.
Some
cords
can
be
extended
by
us
ing
optional
extension
cords
(check
with
welding
equipment
distributor).
3.
The
interconnecting
cords
must
be
routed
so
that
they
are
not
caught,
pinched,
or
strained
during
welding
operations.
4.
One
weld
output
cable
must
be
routed
to
the
shunt
control.
5.
Welding
wire
must
be
routed
so
that
it
does
not
con
tact
the
weld
control
or
any
other
grounded
equip
ment.
C.
Equipment
Installation
Obtain
appropriate
mounting
brackets
or
adapter
plates
as
necessary
and
mounting
hardware.
Prepare
struc
ture
for
equipment
installation.
Secure
weld
control,
shunt
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
D.
Hub
And
Spindle
Installation
To
Spindle
Sup
port
(Figure
4-2)
1.
Remove
hex
nut
from
spindle
support
shaft,
align
keyway,
and
insert
shaft
through
one
of
the
sets
of
holes
in
the
spindle
support.
Hole
selection
depends
on
wire
spool
size.
Be
sure
the
brake
washers
are
properly
seated
in
the
hub.
2.
Replace
hex
nut
and
tighten
until
a
slight
drag
is
felt
while
turning
hub.
3.
Install
welding
wire
according
to
Section
4-6.
Control
4
Drive
Typical
Side
Beam
Application
L~~J
Welding
Power
Source
~I
t~
Welding
Power
Source
Figure
4-1.
Equipment
Location
Diagram
TC~131
138
Retaining
Ring
Retalner*
Reel
*
Support
Shaft
Fiber
Washer
Washer
Hex
Nut
/
Optlonai
Washer
Figure
4-2.
Hub
And
Spindle
installation
OM-1540
Page
9
4-3.
INTERNAL
CONNECTIONS
There
are
two
terminal
strips
in
the
weld
control
to
which
external
equipment
can
be
connected
or
at
which
inter
nal
reconnections
can
be
made.
The
use
of
these
termi
nal
strips
depends
on
the
welding
system
set-up
and
welding
application.
External
optional
pendant
or
customer
supplied
remote
start/stop
devices
can
be
connected
to
the
weld
control.
External
customer
supplied
devices
(such
as
fixtures)
can
access
relay
contacts
that
change
state
in
conjunc
tion
with
the
weld
cycle.
An
automatic
flux
valve
can
be
connected
to
the
weld
control
for
Submerged
Arc
Weld
ing
(SAW).
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
at
rap
BEFORE
working
near
circuit
boards.
Perform
work
only
at
a
static
safe
work
area.
To
access
the
terminal
strips,
open
control
panel
door.
Loosen
screws
from
cabinet
door
on
the
weld
control,
and
open
door.
Route
incoming
cables
through
strain
re
lief
provided
on
right
side
of
weld
control.
Close
and
se
cure
control
door,
and
tighten
strain
relief
when
installa
tion
is
complete.
A.
Auxiliary
Relay
Contact
(Figure
4-3
And
Figure
4-4)
Connections
Three
sets
of
normally-open
relay
contacts
are
provided
to
work
in
conjunction
with
the
weld
cycle.
The
connec
tion
points
for
the
relay
contacts
are
terminals
J
through
P
on
terminal
strip
2T.
These
terminals
provide
on/ott
control
only.
The
terminals
and
functions
available
are
as
follows:
Terminals
J
and
K
(CR51)
close
at
the
end
of
Preflux
(Pref
low)
Time
and
open
at
the
end
of
Burnback.
Terminals
L
and
M
(CR50)
close
at
the
end
of
Preflux
(Pref
low)
Time
and
open
when
the
STOP
switch
is
pressed
or
an
external
signal
is
received.
Terminals
N
and
P
(CR5)
close
at
arc
initiation
and
open
at
the
end
of
Crater
Time.
Various
combinations
of
these
contacts
allow
a
variety
of
fixture
start
and
stop
points.
For
example,
if
a
fixture
needs
to
start
moving
at
arc
initiation
and
stop
when
the
STOP
switch
is
pressed,
proceed
as
follows:
1.
Make
a
jumper
lead
and
connect
it
between
terrni
nals
2TM
and
2TN.
2.
Connect
fixture
leads
to
terminals
2TL
and
2TP
(polarity
is
not
important).
Determine
the
need
for
external
fixture
control,
and
con
nect
equipment
as
necessary.
B.
Automatic
Flux
Valve
Connections
(Figure
4-3)
1.
Mount
the
flux
hopper
and
automatic
flux
valve
in
desired
location
according
to
equipment
Owners
Manual.
2.
Connect
flux
valve
leads
to
terminals
1TB
and
1TE.
Polarity
is
not
important.
The
flux
valve
energizes
when
the
PREFLUX
or
START
switches
are
pressed.
C.
Optional
Pendant
Control
Connections
(Figure
4-3)
To
install
the
pendant
control,
connect
plug
from
pend
ant
control
cord
to
matching
receptacle
on
weld
control
as
follows:
align
keyways,
insert
plug
into
receptacle,
and
rotate
threaded
collar
fully
clockwise.
Remove
and
retain
jumper
links
connected
between
ter
minals
1TK,
1TL,
and
1TM.
Determine
the
need
for
these
connections
based
on
the
welding
application,
and
proceed
as
follows:
Strip
iT
Terminal
Strip
2T
Ref.
TD-083
381-C
Mounting
Panel
inside
unit
Figure
4-3.
Connection
Strip
Location
OM-1540
Page
10
CR5
CR50
2TPf~
~
2TN
2TM~1
2TL
~rLead
Fixture
Leads
4
CR51
2TG/2TK
II
IL-
I
II
II
//
CR50
2TL/2TM
I
II
CR5
II
II
2TNI2TP
I
+.
~
I
II
S0271
Figure
4-4.
Weld
Control
Cycle
IMPORTANT:
If
the
remote
pendant
control
is
discon
nected,
reinstall
jumper
links
to
terminals
I
TK,
1
TL,
and
1
TM.
The
weld
co
ntrol
does
not
work
if
the
pendant
con-
trolls
removed
and
the
jumpers
are
not
reinstalled.
4-4.
WELD
CONTROL
INTERCONNECTIONS
(Figure
4-5)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
lockin9
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
This
unit
is
supplied
with
the
necessary
interconnecting
cords.
Examine
and
select
the
proper
cord
for
each
of
the
following
connections.
A.
Drive
Motor
Connections
The
5
ft
(1.5
m)
motor
cord
has
a
9-pin
free-hanging
re
ceptacle
and
9-socket
plug.
The
9-pin
receptacle
con
nects
to
the
weld
control.
The
9-socket
plug
connects
to
the
cord
coming
from
the
wire
drive
motor.
To
make
con-
nections,
align
keyways,
insert
plugs
into
receptacles,
and
rotate
threaded
collars
fully
clockwise.
B.
Shunt
Control
Connections
The
lOft.
(3
m)
interconnecting
cord
has
a
14-pin
plug
and
16-socket
plug.
The
14-pin
plug
connects
to
the
weld
control.
The
16-socket
plug
connects
to
the
shunt
control.
To
make
connections,
align
keyways,
insert
plugs
into
receptacles,
and
rotate
threaded
collars
fully
clockwise.
C.
Voltage
Sensing
Connection
Connect
the
4-socket
plug
from
the
voltage
sensing
cord
to
the
matching
receptacle
on
the
weld
control
as
tot-
lows:
align
keyway,
insert
plug
into
receptacle,
and
ro
tate
threaded
collar
fully
clockwise.
Connect
the
voltage
sensing
lead
with
ring
terminal
to
the
workpiece.
D.
Electrical
Input/Contactor
Control/Voltage
Con
trol
Connections
The
25
ft.
(8
m)
interconnecting
cord
has
14-socket
and
14-pin
plugs.
The
14-socket
plug
connects
to
the
weld
control.
The
14-pin
plug
connects
to
the
welding
power
source.
To
make
connections,
align
keyway,
insert
plugs
into
receptacles,
and
rotate
threaded
collars
fully
clock
wise.
Be
sure
remote
contactor
and
voltage
control
switches
on
the
welding
power
source
are
in
the
correct
position
to
allow
use
of
a
remote
control
device.
Wetd
Time
0-Infinity
Stop
Start
Switch
Switch
Pressed
Pressed
lime
OM-1540
Page
11
Shunt
Control
Receptacle
TC-083
4428
Figure
4-5.
Cord
Connections
IMPORTANT:
If
the
supplied
electrical
input/contactor
control/voltage
control
cord
does
not
match
the
welding
power
source
remote
control
receptacle,
obtain
the
nec
essary
adapter
cord
from
your
welding
equipment
dis
tributor.
The
following
socket
information
is
inctuded
in
case
the
supplied
cord
is
not
suitable,
and
it
is
necessary
to
wire
a
plug
or
cord
to
interface
with
the
welding
power
source
REMOTE
14
receptacle.
Socket
C:
+10
volts
dc
with
respect
to
Socket
D.
Socket
D:
Control
circuit
common
for
remote
control
device.
Socket
E:
Input
command
signalfrom
wiperof
remote
control
potentiometer;
0
volts
equals
ma
chine
minimum;
+10
volts
equals
machine
maximum.
SocketG:
115
volts
ac
circuit
common;
also
connected
to
welding
power
source
chas
sis.
Socket
I:
Up
to
15
amperes
of
115
volts
ac,
60
Hz,
with
respect
to
socket
G
(circuit
common).
Socket
J:
Input
control
to
energize
weld
contactor
for
115
volts
ac
weld
control.
A
contact
closure
from
socket
Ito
socket
J
completes
the
115
volt
circuit.
Socket
K:
Weld
control
chassis.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
4-5.
SHUNT
CONTROL
INTERCONNECTIONS
(FIgure
4-6)
A.
Weld
Output
Connections
4A
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Select
and
prepare
proper
size
and
length
weld
cables
according
to
the
welding
power
source
Owners
Manual.
Remove
cover
from
shunt
control.
1.
Electrode
Positive/Reverse
Polarity
Connections
a.
Connect
a
weld
cable
to
the
positive
weld
output
terminal
on
the
welding
power
source.
b.
Route
cable
through
weld
cable
opening
on
shunt
control
IN
panel,
and
connect
weld
cable
to
bus
bar
on
shunt.
c.
Route
a
weld
cable
through
the
weld
cable
opening
on
the
opposite
end
of
the
shunt
con
trol,
and
connect
to
bus
bar
on
shunt.
d.
Connect
end
of
cable
coming
from
shunt
control
to
weld
cable
terminal
on
wire
drive
assembly.
See
wire
drive
assembly
Owners
Manual
for
terminal
location.
e.
Connect
a
weld
cable
from
the
negative
weld
output
terminal
on
the
welding
power
source
to
the
workpiece.
f.
Reinstall
and
secure
shunt
control
cover.
2.
Electrode
Negative/Straight
Polarity
Connections
Follow
directions
for
Electrode
Positive/Reverse
Polarity
with
the
following
exceptions:
a.
Route
weld
cable
from
welding
power
source
negative
weld
output
terminal
to
bus
bar
on
shunt
in
the
shunt
control.
b.
Connect
weld
cable
from
welding
power
source
positive
weld
output
terminal
to
workpiece.
B.
Optional
ShieldIng
Gas
Connections
The
shielding
gas
fittings
at
the
shunt
control
have
5/8-18
right-hand
threads.
IMPORTANT:
The
gas
flow
must
be
accurately
con-
(rolled
by
a
regulator/f
lowmeter
at
the
source.
1.
Select
and
obtain
shielding
gas
hose
of
suitable
length
and
type
for
connection
between
the
shield
ing
gas
source
and
the
shunt
control.
~Electrlcal
Inputl
Con
tactor
Con
troll
Voltage
Control
Receptacle
Pendant
Control
Receptacle
OM-1540
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12
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Miller JK651490 Owner's manual

Category
Welding System
Type
Owner's manual
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