Miller JK651490 Owner's manual

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

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

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-

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

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

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

when

pressurized,

nor

returns

to

stop

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

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

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



Crater

(Jog)

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

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

//

CR50

2TL/2TM

I

II

CR5

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

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

Page

12

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Miller JK651490 Owner's manual

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