Miller Mark VI Owner's manual

Miller

The

Power

fBlue.

OM2211B

July

1997

En.

w/Serial

Number

KH451

519

Processes

~

Shielded

Metal

Arc

(Stick)

Welding

~

DC-Gas

Tungsten

Arc

(DC-TIG)

Welding

~

Flux

Cored

Arc

Welding

and

Gas

Metal

Arc

Welding

(MIG)

Spray

Transfer

with

Voltage-

Sensing

Feeder

~

Air

Plasma

Cutting

and

Gouging

with

Spectrumﬁ

Plus

Air

Carbon

Arc

Cutting

and

Gouging

Description

Multiple

Operator

Arc

Welding

Power

Source

Mark

VI

p

Visit

our

website

at

www~mMerweMs.com

OWNERS

MANUAL

From

Miller

to

You

Thank

you

and

congratulations

on

choosing

Miller.

Now

you

can

get

the

job

done

and

get

it

done

right.

We

know

you

dont

have

time

to

do

it

any

other

way.

Thats

why

when

Niels

Miller

first

started

building

arc

welders

in

1929,

he

made

sure

his

products

offered

long-lasting

value

and.superior

quality.

Like

you,

his

customers

couldnt

afford

anything

less.

Miller

products

had

to

be

more

than

the

best

they

could

be.

They

had

to

be

the

best

you

could

buy.

Today,

the

people

that

build

and

sell

Miller

products

continue

the

tradition.

Theyre

just

as

committed

to

providing

equipment

and

service

that

meets

the

high

standards

of

quality

and

value

established

in

1929.

This

Owners

Manual

is

designed

to

help

you

get

the

most

out

of

your

Miller

products.

Please

take

time

to

read

the

Safety

precautions.

They

will

help

you

protect

yourself

against

potential

hazards

on

the

worksite.

Weve

made

installation

and

operation

quick

and

easy.

With

Miller

you

can

count

on

years

of

reliable

service

with

proper

maintenance.

And

if

for

______________

some

reason

the

unit

needs

repair,

theres

a

Troubleshooting

section

that

will

help

you

figure

out

what

the

problem

is.

The

parts

list

will

then

help

you

to

decide

which

exact

part

you

may

need

to

fix

the

problem.

Warranty

and

service

information

for

your

particular

model

are

also

provided.

Miller

Electric

manufactures

a

full

line

of

welders

and

welding

For

information

on

other

quality

Miller

products,

contact

your

local

Miller

distributor

to

receive

the

latest

full

line

catalog

or

individual

catalog

sheets.

To

locate

your

nearest

distributor

call

1-800-4-A-Miller.

.

iIE~iIiIiIiI

p

REGISTERED

QUALITY

SYSTEM

Miller

is

the

first

weldiNg

equipment

manufacturer

in

the

U.S.A.

to

he

registered

to

the

ISO

9001

Quality

System

Standard.

~ll~ftllh{?

Working

as

hard

as

you

do



every

power

source

from

Miller

is

backed

by

the

most

hassle-free

warranty

in

the

busiNess.

ri/A

Miller.

~

.

Call

1

-800-4-A-MILLER

for

your

local

Miller

distributor.

Your

distributor

gives

you

Service

You

always

get

the

fast,

reliable

response

you

need.

Most

replacement

parts

can

be

in

your

hands

in

24

hours.

Support

Need

fast

answers

to

the

tough

welding

questions?

Contact

your

distributor.

The

expertise

of

the

distributor

and

Miller

is

there

to

help

you,

every

step

of

the

way.

Miller

offers

a

Technical

Manual

which

provides

more

detailed

seivice

and

parts

information

for

your

unit.

To

obtain

a

Technical

Manual~

contact

your

local

distributor~

Your

distributor

can

also

supply

you

~wTh

Welding

Process

Manuals

suchasSMAW,

GTAW,

GMAW,

and

GMAW-P

For

practical

information

on

welding,

process

applica

tions,

and

Miller

products,

visit

our

website

at

www.millerwelds.com

The

following

terms

are

used

interchangeably

throughout

this

manual:

TIG

=

GTAW

Stick

=

SMAW

TABLE

OF

CONTENTS

SECTION

1



SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

1-1.

Symbol

Usage

1-2.

Arc

Welding

Hazards

1-3.

Additional

Symbols

for

Installation,

Operation,

and

Maintenance

1-4.

Principal

Safety

Standards

1-5.

EMF

Information

SECTION

1



CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTILISATION

1-1.

Signification

des

symboles

1-2.

Dangers

relatifs

au

soudage

a

Iarc

1-3.

Dangers

supplØmentaires

en

relation

avec

Iinstallation,

le

fonctionnement

et

Ia

maintenance

1-4.

Principales

normes

de

sØcuritØ

1-5.

Information

sur

les

champs

electromagnetiques

SECTION

2

INSTALLATION

2-2.

Volt-Ampere

Curves

2-3.

Duty

Cycle

And

Overheating

2-11.

Standard

Module

Weld

Output

Connections

Without

Common

Work

Terminal

2-12.

Standard

Module

Weld

Output

Connections

With

Common

Work

Terminal

2-13.

Parallel

Module

Weld

Output

Connections

Without

Common

Work

Terminal

2-14.

Parallel

Module

Weld

Output

Connections

With

Common

Work

Terminal

2-15.

Remote

14

Receptacle

Information

2-16.

Electrical

Service

Guide

SECTION

3

OPERATION

SECTiON

4MAINTENANCE

AND

TROUBLESHOOTING

4-1.

Routine

Maintenance

4-3.

Troubleshooting

SECTION

5

ELECTRICAL

DIAGRAM

SECTION

6

PARTS

LIST

OPTIONS

AND

ACCESSORIES

WARRANTY

1

3

4

5

7

8

9

10

15

16

17

18

19

21

22

24

26

28

.

SECTION

1

-

SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

som

_nd_5197

1-1.

Symbol

Usage

a

A

Marks

a

special

safety

message.

~

Means

Note;

not

safety

related.

1-2.

Arc

Welding

Hazards

I

A

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

seethe

symbol,

watch

out,

and

follow

the

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

NO

TAG.

Read

and

follow

all

Safety

Standards.

A

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

A

During

operation,

keep

everybody,

especially

children,

away.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

bums.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.



Do

not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact.

with

the

work

or

ground.



Do

not

use

AC

output

in

damp

areas,

if

movement

is

confined,

or

if

there

is

a

danger

of

falling.



Use

AC

output

ONLY

if

required

for

the

welding

process.



If

AC

output

is

required,

use

remote

output

control

if

present

on

unit.



Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

191

0.147

(see

Safety

Standards).



Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.



Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.



When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.



Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.



Turn

off

all

equipment

when

not

in

use.



Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.



Do

not

drape

cables

over

your

body.

This

group

of

symbols

means

Waming!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

actions

to

avoid

the

hazards.



If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.



Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.



Use

onlywell-maintained

equipment.

Repairor

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.



Wear

a

safety

harness

if

working

above

floor

level.



Keep

all

panels

and

covers

securely

in

place.



Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as near

the

weld

as

practical.



Insulate

work

clamp

when

not

connected

to

workpiece

to

prevent

contact

with

any

metal

object.



Do

not

connect

more

than

one

electrode

or

work

cable

to

any

single

weld

output

terminal.

SIGNIFICANT

DC

VOLTAGE

exists

after

removal

of

input

power

on

inverters.



Tum

Off

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

to

instructions

in

Maintenance

Section

before

touching

any

parts.

FUMES

AND

GASES

can

be

hazardous.

Welding

produces

fumes

and

gases.

Breathing

=9.

these

fumes

and

gases

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.



If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.



If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.



Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instructions

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.



Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watch-

person

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.



Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.



Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

OM-2211

Page

1

ARC

RAYS

can

burn

eyes

and

skin

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Sparks

fly

oft

from

the

weld.



Weara

welding

helmet

fitted

with

a

proper

shade

of

filterto

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).



Wear

approved

safety

glasses

with

side

shields

under

your

helmet.



Use

protective

screens

or

barners

to

protect

others

from

flash

and

glare;

wam

others

not

to

watch

the

arc.



Wear

protective

clothing

made

from

durable,

flame-resistant

matenal

(leather

and

wool)

and

foot

protection.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

oft

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

orfire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.



Protect

yourself

and

others

from

flying

sparks

and

hot

metal.



Do

not

weld

where

flying

sparks

can

strike

flammable

material.



Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.



Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.



Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.



Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.



Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).



Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.



Do

not

use

welder

to

thaw

frozen

pipes.



Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.



Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.



Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

FLYING

METAL

can

injure

eyes.



Welding,

chipping,

wire

brushing,

and

grinding

cause

sparks

and

flying

metal.

As

welds

cool,

they

can

throw

oft

slag.



Wear

approved

safety

glasses

with

side

shields

even

under

your

welding

helmet.

BUILDUP

OF

GAS

can

Injure

or

kill



Shutoff

shielding

gas

supply

when

not

in

use.



Always

ventilate

confined

spaces

or

use

approved

air-supplied

respirator.

HOT

PARTS

can

cause

severe

burns.:



Do

not

touch

hot

parts

bare

handed.



Allow

cooling

period

before

working

on

gun

or

torch.

MAGNETIC

FIELDS

can

affect

pacemakers.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

NOISE

can

damage

hearing.

Noise

from

some

processes

or

equipment

can

damage

hearing.



Wear

approved

ear

protection

if

noise

level

is

high.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.



Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.



Install

cylinders

in

an

upright

position

by

secunng

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on a

pressurized

cylinder



explosion

will

result.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.



Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.



Keep

protective

cap

in

place

overvalve

except

when

cylinder

is in

use

or

connected

for

use.



Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

CYLINDERS

can

explode

if

damaged.

.

S

OM-2211

Page

2



Do

not

install

or

place

unit

on,

over,

or

near

combustible

surfaces.



Do

not

install

unit

near

flammables.

Do

not

overload

building

winng



be

sure

power

supply

system

is

properly

sized,

rated,

and

protected

to

handle

this

unit.

I

FALLING

UNIT

can

cause

injury.



Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.



Use

equipment

of

adequate

capacity

to

lift

and

support

unit.



If

using

lift

forks

to

move

unit,

be

sure

forks

are

long

enough

to

extend

beyond

opposite

side

of

unit.

OVERUSE

can

cause

OVERHEATING



Allow

cooling

period;

follow

rated

duty

cycle.



Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.



Do

not

block

or

filter

airflow

to

unit.

STATIC

(ESD)

can

damage

PC

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.



Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

WELDING

WIRE

can

cause

injury



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

1-4.

Principal

Safety

Standards

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

American

Welding

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

HF.

RADIATION

can

cause

interference.



High-frequency

(H.F.)

can

interfere

with

radio

navigation,

safety

services,

computers,

and

communications

equipment.



Have

only

qualified

persons

familiar

with

electronic

equipment

perform

this

installation.



The

user

is

responsible

for

having

a

qualified

electrician

promptly

correct

any

interference

problem

resulting

from

the

installation.



If

notified

by

the

FCC

about

interference,

stop

using

the

equipment

at

once.



Have

the

installation

regularly

checked

and

maintained.



Keep

high-frequency

source

doors

and

panels

tightly

shut,

keep

spark

gaps

at

correct

setting,

and

use

grounding

and

shielding

to

minimize

the

possibility

of

interference.

ARC

WELDING

can

cause

interference.



Electromagnetic

energy

can

interfere

with

sensitive

electronic

equipment

such

as

computers

and

computer-driven

equipment

such

as

robots.



Be

sure

all

equipment

in

the

welding

area

is

electromagnetically

compatible.



To

reduce

possible

interference,

keep

weld

cables

as

short

as

possible,

close

together,

and

down

low,

such

as

on

the

floor.



Locate

welding

operation

100

meters

from

any

sensitive

elec

tronic

equipment.



Be

sure

this

welding

machine

is

installed

and

grounded

according

to

this

manual.



If

interference

still

occurs,

the

user

must

take

extra

measures

such

as

moving

the

welding

machine,

using

shielded

cables,

using

line

filters,

or

shielding

the

work

area.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

W117.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1-3

Additional

Symbols

for

Installation,

Operation,

and

Maintenance

I

FIRE

OR

EXPLOSION

hazard~

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts

such

as

fans.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

OM-2211

Page

3

1-5

EMF

Information

/

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

1.

Keep

cables

close

together

by

twisting

or

taping

them.

Electric

And

Magnetic

Fields

Welding

current,

as

it

flows

through

welding

cables,

will

cause

electro-

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

magnetic

fields.

There

has

been

and

still

is

some

concern

about

such

fields.

However,

after

examining

more

than

500

studies

spanning

17

3.

Do

not

coil

or

drape

cables

around

your

body.

years

of

research,

a

special

blue

ribbon

committee

of

the

National

Research

Council

concluded

that:

The

body

of

evidence,

in

the

4.

Keep

welding

power

source

and

cables

as

far

away

from

opera-

committees

judgment,

has

not

demonstrated

that

exposure

to

power-

tor

as

practical.

frequency

electric

and

magnetic

fields

is

a

human-health

hazard.

However,

studies

are

still

going

forth

and

evidence

continues

to

be

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

examined.

Until

the

final

conclusions

of

the

research

are

reached,

you

possible.

may

wish

to

minimize

your

exposure

to

electromagnetic

fields

when

welding

or

cutting.

About

Pacemakers:

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

Pacemakerwearersconsultyourdoctorfirst.

If

cleared

byyourdoctor,

procedures:

then

following

the

above

procedures

is

recommended.

.

OM-2211

Page

4

SECTION

1



CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTILISATION

som

_nd_Fre

4/97

1-1.

:Signification

des

symboIes~.

a

Signifie

Mise

en

garde!

Soyez

vigilant!

Cette

procedure

presente

des

risques

de

danger!

Ceux-ci

sont

identifies

par

des

symboles

adjacents

aux

directives.

A

Identifie

un

message

de

sØcuritØ

particulier.

~

Signifie

NOTA

nest

pas

re/at/f

a

Ia

sØcuritØ.

1-2.

Dangers

relatifsau

soudage

a

Iarc

A

Les

symboles

prØsentØs

ci-aprŁs

sont

utilisØs

tout

au

long

du

present

manuel

pour

attirer

votre

attention

et

identifier

lea

riaquea

de

danger.

Loraque

vous

voyez

un

symbole,

soyez

vigilant

et

suivez

lea

directives

mentionnØes

atm

dØviter

tout

danger.

Les

consignes

de

sØcuritØ

presentØes

ci-aprŁs

ne

font

que

rØsumer

linformation

contenue

dans

lea

normes

desØcurite

enumerØes

a

Ia

section

1-5.

Veuillez

lire

et

respecter

toutes

ces

normes

de

sCcuritØ.

A

Linstallation,

lutiliaation,

lentretien

et

lea

reparations

ne

doi

vent

etre

confiØs

qu

des

person

nes

qualif

lees.

A

Au

cours

de

lutilisation,

tenirtoute

personne

a

lØcart

et

plus

par

ticuliŁrement

lea

enfants.

UN

CIIOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Łlectriques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

LŁlectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrŁe

et

les

circuits

intemes

de

lappareil

sont

Łgalement

sous

tension

ace

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

dŁvidoir,

le

logement

des

galets

dentraTnement

et

les

piŁces

mŁtalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matŁriels

ma!

installŁs

ou

ma!

mis

a

terre

prŁsentent

un

danger.



Ne

jamais

toucher

les

piŁces

Łlectriques

sous

tension.



Porter

des

gants

et

des

vŁtements

de

protection

secs

ne

comportant

pas

de

trous.



Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empecher

le

contact

phy

sique

Łventuel

avec

Ia

piŁce

ou

Ia

terre.



Ne

passe

servir

de

source

Ølectrique

courant

Łlectrique

dans

les

zones

humides,

dans

les

endroits

confines

ou

l

o

on

risque

de

tomber.



Se

servir

dune

source

Łlectrique

acourant

Łlectrique

UNIQUEMENT

si

le

procŁdŁ

de

soudage

le

demande.



Si

lutilisaton

dune

source

Łlectrique

acourant

Łlectrique

savŁre

nŁces

saire,

se

servir

de

Ia

fonction

de

tŁlŁcommande

Si

lappareil

en

est

ØquipŁ.



Couperlalimentation

ou

arrŁter

le

moteur

avant

de

procØdera

linstal

lation,

a

Ia

reparation

ou

a

lentretien

de

lappareil.

DŁverrouiller

lalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sŁcuritŁ).



Installeret

mettre

a

laterre

correctement

cet

appareil

conformŁment

a

son

manuel

dutilisation

et

aux

codes

nationaux,

provinciaux

et

municipaux.



Toujours

verifier

Ia

terre

du

cordon

dalimentation



VŁrtfier

et

sassu

rer

que

le

fil

de

terre

du

cordon

dalimentation

est

bien

raccordŁ

a

Ia

bome

de

terre

du

sectionneurou

que

Ia

fiche

du

cordon

est

raccordŁe

a

une

prise

correctement

mise

a

Ia

terre.



En

effectuant

les

raccordements

dentrŁe

fixer

dabord

le

conducteur

de

mise

a

Ia

terre

approprtŁ

et

contre-vŁrifier

les

connexions.



VŁrifierfrŁquemment

le

cordon

dalimentation

pour

voir

sil

nest

pas

endommagŁ

ou

dŁnudŁ



remplacer

le

cordon

immŁdiatement

sil

est

endommagŁ



un

cable

dŁnudŁ

peut

provoquer

une

electrocution.



Mettre

lapparei!

hors

tension

quand

on

ne

lutilise

pas.



Ne

pas

uti!iser

des

cables

uses,

endommagŁs,

de

grosseur

insuffi

sante

ou

mal

ŁpissŁs.



Ne

pas

enrouler

les

cables

afflour

du

corps.



Si

Ia

piŁce

soudŁe

dolt

Łtre

mise

a

laterre,

le

faire

directementavec

un

cable

distinct



ne

pas

utiliser

le

connecteur

de

piŁce

ou

le

cable

de

retour.



Ne

pas

toucher

lelectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

ri

~

wa

Ce

groupe

de

symboles

signifie

Mise

en

garde

l

Soyez

vigilant

II

y

a

des

rtsques

de

danger

relies

aux

CHOCS

ELECTRIQUES,

aux

PIECES

EN

MOUVEMENTet

aux

PIECES

CFIAUDES.

Reportez-vous

aux

symboles

et

aux

directives

ci-dessous

afin

de

connaltre

les

mesures

a

prendre

pour

Łviter

tout

danger.



Nutiliser

quun

materiel

en

bon

Łtat.

Reparer

ou

remplacer

sur-le

champ

les

piŁces

endommagŁes.

Entretenir

lappareil

conformement

ace

manuel.



Porter

un

hamais

de

securite

quand

on

travaille

en

hauteur.



Maintenir

solidement

en

place

tous

les

panneaux

et

capots.



Fixer

le

cable

de

retour

de

faon

a

obtenir

un

bon

contact

metal-metal

avec

Ia

piŁce

~

souderou

Ia

table

de

travail,

le

plus

pits

possible

de

Ia

soudure.



Isoler

Ia

pince

de

masse

quand

pas

mis

a

Ia

piŁce

pour

Łviter

le

contact

avec

tout

objet

mOtallique.

Ily

a

DU

COURANT

CONTINU

IMPORTANT

dans

les

convertisseurs

aprŁs

Ia

suppression

de

Ialimenta

tion

Ølectrique.



ArrŁter

les

convertisseurs,

dŁbrancher

le

courant

electrique,

et

de

charger

les

condensateurs

dalimentation

selon

les

instructions

indiquŁes

dans

Ia

partie

entretien

avant

de

toucher

les

piŁces.

LES

FUMEES

ET

LES

GAZ

peuvent

J~~

Œtre

dangereux.

Le

soudage

genŁre

des

fumŁes

et

des

gaz.

Leur

V

inhalation

peut

Łtre

dangereux

pour

votre

sante.

-.



Eloigner

votre

tŒte

des

fumŁes.

Ne

pas

respirer

les

fumees.



A

lintŁrieur,

ventiler

Ia

zone

et/ou

utiliser

un

echappement

au

ni

veau

de

arc

pour

lŁvacuation

des

fumŁes

et

des

gaz

de

soudage.



Si

Ia

ventilation

est

insuffisante,

utiliser

un

respirateur

a

alimenta

tion

dair

homologue.



Lire les

specifications

de

sŁcuritŁ

des

materiaux

(MSDSs)

et

les

ins

tructions

du

fabricant

concemant

les

mŁtaux,

les

consommables,

les

revŁtements,

les

nettoyants

et

les

degraisseurs.



Travailler

dans

un

espace

fermŁ

seulement

siI

est

bien

ventilŁ

ou

en

portant

un

respirateura

alimentation

dair.

Demander

toujours

a

un

surveillant

dment

forme

de

se

tenir

a

proximitŁ.

Des

fumØes

et

des

gaz

de

soudage

peuvent

dŁplacer

lair

et

abaisser

le

niveau

doxygŁne

provoquant

des

blessures

ou

des

accidents

models.

Sassurer

que

Iair

de

respiration

ne

presente

aucun

danger.



Ne

pas

souderdans

des

endroits

situes

a

proximite

dopŁrations

de

degraissage,

de

nettoyage

ou

de

pulvŁrisation.

La

chaleur

et

les

rayons

de

Iarc

peuvent

rŁagir

en

presence

de

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.



Ne

pas

souder

des

mŁtaux

munis

dun

revŒtement,

tels

que

lacier

galvanisØ,

plaque

en

plomb

ou au

cadmium

a

moms

que

le

revŁte

ment

nail

ŁtŁ

enlevŁ

dans

Ia

zone

de

soudure,

que

lendroit

soit

bien

ventilØ,

et

si

necessaire,

en

portant

un

respirateur

a

alimenta

tion

dair.

Les

revŁtements

et

tous

les

metaux

renfermant

ces

ele

ments

peuvent

dŁgager

des

tumees

toxiques

en

cas

de

soudage.

OM-2211

Page

5

LESRAYONSDEL!ARC

peuvent

pro~

voquer

desbrlures:danŁ

les

yeux

et

sur

Ia

peau

Le

rayonnement

de

larc

du

procedØ

de

soudage

genOre

des

rayons

visibles

et

invisibles

intenses

(ultraviolets

et

infrarouges)

susceptibles

de

provoquer

des

bri~Iures

dans

les

yeux

et

sur

Ia

peau.

Des

etincelles

sont

projetees

pendant

0

soudage.



Porter

un

casque

de

soudage

muni

dun

Øcran

de

filtre

appropnØ

pour

proteger

votre

visage

et

vos

yeux

pendant

le

soudage

ou

pour

regar

der

(voir

ANSI

Z49.

1

et

Z87.1

ØnumØrØ

dans

les

normes

de

sØcuntØ).



Porter

des

protections

approuves

pour

les

oreilles

Si

le

niveau

sondre

est

trop

ØlevØ.



Utiliser

des

Øcrans

ou

des

barnŁres

pour

protegerdes

tiers

de

IØclair

et

de

IØblouissement;

demander

aux

autres

personnes

done

pas

re

garder

arc.



Porter

des

vØtements

do

protection

constituØ

dans

une

matiŁre

dura

ble,

resistant

au

feu

(cuir

ou

lame)

et

une

protection

des

pieds.

m

E~I

LESOUDAGE

peutprovoquØr

(~

m~

incendie

ou

ne

explOsion.

Le

soudage

effectuØ

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours

ou

des

conduites

peut

provoquerleureclatement.

Des

etincellespeuventŒtre

projetØes

de

arc

de

soudure.

La

projection

dØtincel

es,

des

piŁces

chaudes

et

des

equipements

chauds

peut

provoquerdes

incendies

et

des

brOlures.

Le

contact

accidentel

de

lØlectrode

avec

des

objets

metalliques

peut

provoquer

des

Øtincelles,

une

explosion,

un

surchauffement

ou

un

incendie.

Avant

de

commencer

le

soudage,

vØnfier

et

sassurer

que

lendroit

ne

prØsente

pas

de

danger.



Se

proteger

et

dautres

personnes

de

Ia

projection

dØtincelles

et

de

metal

chaud.



No

pas

souder

dans

un

endroit

l

o

des

Øtincelles

peuvent

tomber

sur

des

substances

inflammables.



DØplacertoutes

les

substances

inflammables

a

une

distance

de

10,7

m

de

larc

do

soudage.

En

cas

dimpossibilitØ

les

recouvrirsoigneuse

ment

avec

des

protections

homologues.



Des

Øtincelles

et

des

matØnaux

chauds

du

soudage

peuvent

facile

ment

passer

dans

dautres

zones

en

traversant

de

petites

fissures

et

des

ouvertures.



Surveillertout

dØclenchement

dincendie

et

tenir

un

extincteur

proxi

mite.



Le

soudage

effectuØ

sur

un

plafond,

plancher,

paroi

ou

separation

peut

dŁclencher

un

incendie

de

lautre

cOtØ.



Ne

pas

effectuer

le

soudage

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours,

ou

conduites,

a

moms

quils

naient

ØtØ

prØpa

res

correctement

conforrnØment

a

AWS

F4.1

(voir

es

norrnes

de

securite).



Brancher

le

cable

sur

Ia

piŁce

le

plus

prŁs

possible

do

Ia

zone

de

sou

dage

pour

Oviter

le

transport

du

courant

sur

une

longue

distance

par

des

chemins

inconnus

eventuels

en

provoquant

des

nsques

dØlec

trocution

et

dincendie.



Ne

pas

utiliser

le

poste

de

soudage

pour

degeler

des

conduites

go

lees.



En

cas

de

non

utilisation,

enlever

Ia

baguette

dØlectrode

du

porte

electrode

ou

couper

le

fil

a

Ia

pointe

de

contact.



Porter

dos

vŒtements

de

protection

dØpourvus

dhuile

tels

que

des

gants

en

cuir,

une

chemise

en

matØnau

lourd,

des

pantalons

sans

re

vers,

des

chaussures

hautes

et

un

couvre

chef.



Avant

de

souder,

retirer

toute

substance

combustible

de

vos

poches

telles

quun

allumeur

au

butane

ou

des

allumettes.



Le

soudage,

lØcaillement,

le

passage

de

Ia

piŁce

a

Ia

brosso

en

fil

de

for,

et

le

meulage

generent

desŁtincelles

et

des

particules

metalliques

volan

tes.

Pendant

Ia

penode

do

refroidissement

dos

soudures,

elles

nsquent

de

projeter

du

laitier.



Porter

des

lunettes

do

sØcuritØ

avec

ecrans

latØraux

ou

un

Øcran

facial.

LES

ACCUMULATIONS

DE

GAZ

ris

quent

de

provoquer

des

blessures

ou

mŒmeIafl~orL::.

(

)

U

L~



Fermer

Ialimentation

du

gaz

protecteur

en

cas

do

non

utilisation.



Veillertoujours

a

bien

aØrer

los

espacesconfinØs

ou

so

servir

dun

respi

rateur

dadduction

dair

homologue.

DES

PIECESCHAUDES

peuvent

pro

voquer

des~bru1ures

graves.



No

pas

toucher

des

parties

chaudes

a

mains

flues



PrØvoir

une

periode

de

refroidissement

avant

dutiliser

le

pistolet

ou

Ia

torche.

LES

CHAMPS

MAGNETIQUES

peuvent

affecter

les

stimulateurs

cardiaques.



Los

porteurs

dun

stimulateur

cardiaque

doivent

dabord

consultor

leur

medecin

avant

de

sapprocher

des

operations

do

soudage

a

larc,

do

gougeago

ou

do

soudago

par

points.

LE

BRUIT

peut

affecter

louIe.

Le

bruit

dos

procossus

ot

dos

equipements

pout

affecter

louie.



Porter

des

protections

approuves

pour

los

oreilles

Si

10

nivoau

sondro

ost

trop

ØlevØ.

Si

des

BOUTEILLES

sont

endomma

gees,

elles

pourront

exploser.

Des

bouteilles

do

gaz

protecteur

contiennent

du

gaz

sous

haute

pression.

Si

une

bouteille

est

endomma

____________

gee,ellopoutexplosor.

Dufaitquelesbouteillesdegaz

font

normalement

partie

du

procede

do

soudago,

es

manipuler

avec

precaution.



Proteger

les

bouteillos

do

gaz

compnme

dune

chaleur

excessive,

des

chocs

mecaniques,

du

laitier,

des

flammes

ouvertes,

des

Øtin

cellos

et

des

arcs.



Placer

les

bouteilles

debout

en

les

fixant

dans

un

support

station

nairo

ou

dans

un

porte-bouteilles

pour

los

ompŒchor

do tombor

ou

do

so

renverser.



Tenir

los

bouteilles

eloignees

des

circuits

de

soudago

ou

autros

cir

cuits

electriques.



Ne

jamais

placer

une

torcho

do

soudage

sur

uno

bouteille

a

gaz.



Une

electrode

do

soudage

no

dolt

jamais

entrer

en

contact

avec

une

boutoillo.



No

jamais

souder

uno

bouteille

pressurisee



risque

dexplosion.



Utiliser

seulement

des

bouteilles

do

gaz

protectour,

regulateurs,

tuyaux

et

raccords

convenables

pour

cello

application

specifique;

los

maintenir

ainsi

quo

les

elements

associØs

en

bon

Øtat.



Ne

pas

tonir

Ia

tŒte

en

face

do

Ia

sortie

en

ouvrant

Ia

soupape

do

Ia

bouteillo.



Maintenir

10

chapeau

de

protection

sur

Ia

soupape,

sauf

en

cas

dutilisation

ou

do

branchoment

do

Ia

boutoille.



Lire

et

suivre

los

instructions

concemant

les

bouteilles

de

gaz

corn

prime,

los

equipements

associØs

et

los

publications

P-i

CGA

Ønu

mØrØos

dans

los

nomios

do

sØcuntØ.

.



Porteurs

do

stimulateurcardiaque,

rostez

a

distance.

DES

PARTICULES

VOLANTES

peuvent

blesser

les

yeux.

OM-2211

Page

6

et

Ia

maintenance

Risque

DINCENDIE

OU

DEXPLOSION.

LA

CHUTE

DE

LAPPAREIL

petit

blessØr.



Utiliserlanneau

de

levage

uniquement

pour

sou

lever

lappareil,

NON

PAS

les

chariot,

les

bouteil

es

de

gaz

ou

tout

autre

accessoire.



Utiliser

un

engin

dune

capacite

approp

nØe

pour

soulever

lappareil.



En

utilisant

des

fourchØs

de

levage

pour

dØplacer

lunitØ,

sassurer

que

les

fourches

sont

suffisamment

longues

pourdØpasserdu

ctØ

oppose

de

Iappareil.

LEMPLOI

EXCESSIF

peut

SURCHAUFFER

LEQU!PEMENT.



PrØvoir

une

penode

de

refroidissement,

respec

ter

le

cycle

opØratoire

nominal.



Reduire

le

courantou

le

cycle

opØratoire

avant

de

recommancer

le

soudage.



Ne

pas

obstruer

les

passages

dair

du

poste.

LES

CHARGES

ELECTROSTATIQUES

peuvent

endommager

les

circUits

im~

primes.



Etablir

Ia

connexion

avec

Ia

barrette

de

terre

avant

de

manipuler

des

caries

ou

des

piŁces.



Utiliser

des

pochettes

et

des

boites

antistatiques

pour

stocker,

deplacer

ou

expedier

des

caries

de

circuits

impnmes.

DES

ORGANES

MOBILES

peuvent

provoquerdes

blessures.



Ne

pas

sapprocher

des

organes

mobiles.



Ne

pas

sapprocher

des

points

de

coincement

tels

que

des

rouleaux

de

commande.

LES

FILS

DE

SOUDAGE

peuvent

pro

voquer

des

blessures.



Ne

pas

appuyer

sur

Ia

gachette

avant

den

avoir

recu

linstruction.



Ne

pas

dinger

le

pistolet

vers

soi,

dautres

per

sonnes ou

toute

piŁce

mecanique

en

engagearri

le

fil

de

soudage.

DES

ORGANES

MOBILES:

peuvent

provoquer

des

blessures.



Rester

a

lecart

des

organes

mobiles

comme

le

ventilateur.



Maintenirfermes

et

fixement

en

place

es

portes,

panneaux,

recouvrements

et

dispositifs

de

protection.

LE

RAVONNEMENT

HAUTE

FRE

QUENCE(H.F.)

risque

de

provoquer

des

iliterfØrences.



Le

rayonnement

haute

frequence

peut

provoquer

des

interferences

avec

les

equipements

de

ra

dionavigation

et

de

communication,

les

services

de

sØcuritØ

et

les

ordinateurs.



Demander

seulement

a

des

personnes

qualifiees

familiansØes

avec

des

Øquipements

electroniques

de

faire

fonctionner

installa

tion.



Lutilisateur

est

tenu

de

faire

cornger

rapidement

par

un

Ølectncien

qualifie

les

interferences

resultant

de

linstallation.



Si

le

FCC

signale

des

interferences,

arrØter

immØdiatement

lappa

reil.



Effectuer

regulierement

le

contrOle

et

lerrtretien

de

linstallation.



Maintenir

soigneusement

fermØs

les

portes

et

les

panneaux

des

sources

de

haute

frequence,

maintenir

les

Øclateurs

a

une

distance

correcte

et

utiliser

une

terre

et et

un

blindage

pour

rØduire

les

inter

fØrences

Oventuelles.

LE

SOUDAGE

A

L~ARC

risqUe

de

provoquer

des

interferences.



LØnergie

electromagnetique

risque

de

provoquer

des

interferences

pour

lØquipement

electronique

sensible

tel

que

les

ordinateurs

et

lequipement

commandØ

par

ordinateur

tel

que

les

robots.



Veiller

ace

que

tout

lequipement

de

Ia

zone

de

soudage

soit

com

patible

electromagnØtiquement.



Pour

rØduire

Ia

possibilitØ

dinterfØrence,

maintenir

les

cables

de

soudage

aussi

courts

que

possible,

les

grouper,

et

les

poser

aussi

bas

que

possible

(ex.

par

terre).



Veiller

a

souder

a

une

distance

de

100

metres

de

tout

equipement

electronique

sensible.



Veiller

a

ce

que

ce

poste

de

soudage

soit

pose

et

mis a

Ia

terre

conformement

a

ce

mode

demploi.



En

cas

dinterfØrences

aprŁs

avoir

pns

es

mesures

prØcØdentes,

il

incombe

a

lutilisateur

de

prendre

des

mesures

supplØmentaires

telles

que

le

deplacement

du

poste,

lutilisation

de

cables

blindØs,

lutilisation

de

filtres

de

ligne

ou

Ia

pose

de

protecteurs

dans

Ia

zone

de

travail.

1-3.

Dangers

supplØmentaires

en

relation

avec

linstallatiofl;

le

fonctionnement



Ne

pas

placer

appareil

sur,

au-dessus

ou

a

proximite

de

surfaces

infllammables.



Ne

pas

installer

lappareil

a

proximitØ

de

produits

inflammables



Ne

pas

surcharger

linstallation

electnque



sassurer

que

lalimen

tation

est

correctement

dimensionnØ

et

protØgØ

avant

de

mettre

lappareil

en

service.

LES

CHAMPS

MAGNETIQUES

peuvent

affecterles

stimulateurs

cardiaques.



Porteurs

de

stimulateur

cardiaque,

restez

a

dis

tance.



Les

porteurs

dun stimulateur

cardiaque

doivent

dabord

consutter

leur

mØdecin

avant

de

sapprv

cher

des

operations

de

soudage

a

larc,

de

gou

geage

ou

de

soudage

par

points.

OM-2211

Page

7

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Documents,

U.S.

Govemment

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cut

ting

of

Containers

That

Have

Held

Hazardous

Substances,

nomie

AWS

F4.1,

de

American

Welding

Society,

550

N.W.

Lejeune

Rd,

Mia

mi

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

de

Ia

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Lextrait

tire

des

conclusions

gØnØrales

du

document

intitu

lØ

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper;

OTABPE53

(Washington

DC:

U.S.

Govern

ment

Printing

Office,

mai

1989), publie

par

le

Office

of

Technology

Assessment

du

Congres

amØricain

:

i...

ii

existe

maintenant

dabon

dantes

donnØes

scientifiques

compilØes

a

Ia

suite

dexpØnences

sur

Ia

cellule

ou

dØtudes

sur

des

animaux

et

des

humains,

qui

montrent

clairementqueleschampselectromagnetiques

bassefrequence

peu

vent

avoir

des

effets

sur

lorganisme

et

mŒme

y

produire

des

transformations.

MŒme

sil

sagit

de

travaux

de

trŁs

grande

qualite,

les

rØsultats

sont

complexes.

Cette

dØmarche

scientifique

ne

nous

per-

met

pas

dØtablir

un

tableau

densemble

coherent.

Pire

encore,

elle

ne

nous

permet

pas

de

tirer

des

conclusions

finales

concemant

les

ns

ques

Øventuels,

ni

doffrir

des

conseils

sur

les

mesures

a

prendre

pour

rØduire

sinon

Øliminer

les

risques

Øventuels.

(Traduction

libre)

Regles

de

sØcuntØ

en

soudage,

coupage

etprocØdes

connexes,

nor-

me

CSA

Wi

17.2,

de

Association

canadienne de

normalisation,

vente

de

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

norme

ANSI

Z87.1,

de

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cuffing

and

Welding

Processes,

nomie

NFPA

51

B,

de

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1

Garder

les

cables

ensembles

en

les

torsadant

ou

en

les

attachant

avec

du

ruban

adhØsif.

2

Mettre

tous

les

cables

du

ctØ

oppose

de

lopØrateur.

3

Ne

pas

courber

pas

et

ne

pas

entourer

pas

les

cables

autour

de

vous.

4

Garder

le

poste

de

soudage

et

les

cables

le

plus

loin

possible

de

vous.

5

Relier

Ia

pince

de

masse

le

plus

pres

possible

de

Ia

zone

de

soudure.

Consignes

relatives

aux

stimulateurs

cardiaques

Les

consignes

mentionnØes

prØcedemment

font

parlie

de

celles

desti

nØes

aux

personnes

ayant

recours

a

un

stimulateur

cardiaque.

Veuillez

consulter

votre

mØdecin

pour

obtenir

plus

de

details.

1-4

Principales

normes

de

sØcuritØ

Safety

in

Weldingand

Cuffing,

norme

ANSI

Z49.i,

delAmencan

Wel-

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

ding

Society,

550

N.W.

Lejeune

Rd,

Miami

FL 33126

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

.

1-5

Information

sur

tes

champs

ØtectromagnØtiques

DonnØes

sur

le

soudage

electnque

et

sur

les

effets,

pour

lorganisme,

Afin

de

rØduire

les

champs

electromagnetiques

dans

environnement

des

champs

magnetiques

basse

frequence

de

travail,

respecter

les

consignes

suivantes

OM-2211

Page

8

2-1.

Specifications

80

60

(I)

I

!

40

20

0

SECTION

2-INSTALLATION

Rated

Output

at

44

Volts

DC

Welding

Current

Range,

Single

Module

Max.

Open

Circuit

Voltage

Amp

s

Input

at

Rated

Output

of

750

A,

60

Hz,

Three-Phase

230

V

460

V

575

V

KVA

KW

Single

Module

I

Main

Transformer

250

A

at

60%

1500

A

at

25%

I

750

A

at

100%

35315

75

164

12.5*

I

82.5

I

6.2*

I

66.1

5~

65.2

5*

41.9

3.2*

Duty

Cycle

Duty

Cycle

Duty

Cycle

*

While

idling

2-2.

Volt-Ampere

Curves

The

volt-ampere

curves

show

the

normal

minimum

and

maximum

voltage

and

amperage

output

ca

pabilities

of

the

welding

power

source.

Curves

of

other

settings

fall

between

the

curves

shown.

0

100

200

300

400

500

DC

AMPERES

SB-184

158

OM-2211

Page

9

And

Overheatii

2000

1500

1400

1200

~

1100

1000

700

~

500

~

400

250

200

150

Single

Module



60%

Duty

Cycle

at

250

Amperes

Duty

Cycle

is

percentage

of

10

minutes

that

unit

can

weld

at

rated

load

without

overheating.

If

unit

overheats,

thermostat(s)

opens,

output

stops,

and

cooling

fan

runs.

Wait

fifteen

minutes

for

unit

to

cool.

Reduce

amperage

or

voltage,

or

duty

cycle

before

welding.

A

Exceeding

duty

cycle

can

damage

unit

and

void

warranty.

The

main

transformer

of

the

poly

weld

system

has

dual

duty

cycle

ratings,

each

for

a

specific

amper

age

output

range.

If

the

unit

is

oper

ated

in

the

750

ampere

range,

the

unit

is

rated

at

100%

duty

cycle.

This

means

the

polyweld

system

can

be

operated

at

750

amperes

continuously.

When

the

unit

is

op

erated

in

the

1500

ampere

range,

it

is

rated

at

25%

duty

cycle.

The

sum

of

the

outputs

of

each

module

should

not

exceed

the

rated

duty

cycle

of

the

main

trans

former.

For

example,

the

polyweld

system

can

be

safely

operated

at

a

load

of

1000

amperes

at

80

per

cent

duty

cycle.

This

value

could

be

obtained

by

operating

four

mod

ules

at

a

load

of

250

amperes

at

80

percent

duty

cycle,

or

by

operating

six

modules

at

a

load

of

167

amperes

at

80

percent

duty

cycle.

.

10

15

20 25

30

X

DUTY

CYCLE

40

50

60708090100

Main

Transformer



100%

Duty

Cycle

at

750

Amperes

Continuous

Welding

Main

Transformer



25%

Duty

Cycle

at

1500

Amperes

2-1/2

Minutes

Welding

7-1/2

Minutes

Resting

6

Minutes

Welding

4

Minutes

Resting

Overheating

Minutes

OM-2211

Page

10

High

center

of

gravity



always

securelytie

down

unit

with

ade

quate

chains

or

other

proper

re

straints

when

moving

to

pre

vent

tipping.

Do

not

place

unit

where

it

could

tip.

1

Lifting

Eye

2

Lifting

Forks

Use

lifting

eye

or

lifting

forks

to

move

unit.

If

using

lifting

forks,

extend

forks

beyond

opposite

side

of

unit.

3

Rating

Label

Use

rating

label

to

determine

input

power

needs.

4

Line

Disconnect

Device

Locate

unit

near

correct

input

pow

er

supply.

Movement

A

Location

Special

installation

may

be

required

where

gasoline

or

volatile

liquids

are

present



see

NEC

Article

511

orCEC

Section

20.

36

in

(920mm)

AirOut

IMPORTANT!

This

unit

contains

fan

blades

with

different

airflow

directions

to

provide

proper

cooling

of

components.

Consult

Owners

Manual

for

correct

Part

No.

and

location.

S-i83

992

Do

not

block

airflow

to

sides

of

unit.

bc_i

3/96

Ret.

ST-801

OM-2211

Page

11

2-5.

Dimensions

And

Weights

Dimensions

F.Ieight*

I

65

in

(1651

mm)

Width

I

56-3/4

in

(1442

mm)

Depth

34-1/4

in

(870

mm)

*72

in

(1829

mm)

with

lifting

eye

Weight

Single

Module

I

Unit

125

lb

(57

kg)

1825

lb

(828

kg)

2-6.

115

Volts

AC

GFCI

Receptacles

And

Circuit

Breakers

!1~H

1

115V15AACGFCI

Receptacles

RC9

And

RC1O

These

receptacles

supply

up

to

15

amperes

of

115

volts

ac

power.

If

a

ground

fault

is

detected,

the

GFCI

Reset

button

pops

out

and

the

circuit

opens

to

disconnect

the

faulty

equipment.

Check

for

dam

aged

tools,

cords,

plugs,

etc.

con

nected

to

the

receptacle.

Press

button

to

reset

receptacle

and

resume

operation.

-

~

At

least

onceamonth,

test

but

ton

to

verify

GFCI

is

working

H

~

H

~



H

properly

,

0

2

Circuit

Breaker

CB1

protects

RC9

from

overload.

If

0

~

0

~

CB1

opens,

no

output

is

available

from

RC9.

3

Circuit

Breaker

CB2

~

CB2

protects

RC1O

from

overload.

If

CB2

opens,

no

output

is

available

from

RC1O.

4

Circuit

Breaker

CB3

protects

the

115

volts

ac

portion

of

Remote

14

receptacle

~~/

RC8

from

overload.

5

CB4

protects

the

24

volts

ac

2

3

4

5

portion

of

Remote

14

receptacle

RC8

from

overload.

Press

button

to

reset

breaker.

Ref.

ST-801

627

OM-2211

Page

12

2-7.

Weld

Cable

Sizes

Welding

Amperes

Total

Cable

(Copper)

Length

In

Weld

Circuit

Not

Exceeding

100

ft

(30

m)

Or

LeSS

150ft

(45

m)

200

ft

(60

m)

250ft

(70

m)

300ft

(90

m)

350ft

(105

m)

400ft

(120

m)

10

60%

Duty

Cycle

60

100%

Duty

Cycle

10100%

Duty

Cycle

100

4

4 4

3

2

1

1/0

150

3

2

1

1/0

2/0

3/0

200

3

2

1

1/0

2/0

3/0

4/0

250

2

1

1/0

2/0

3/0

4/0

2-210

2-2/0

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

350

1/0

2/0 3/0

4/0

2-2/0

2-3/0

2-4/0

400

1/0

2/0 3/0

4/0

2-2/0

2-3/0

2-4/0

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

600

3/0

4/0 2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

700

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

800

4/0

2-210

2-3/0

2-4/0

3-4/0

4-4/0

900

2-210

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

1000

2-2/0

2-3/0

2-4/0

3-3/0

4-3/0

4-4/0

1250

2-3/0

2-4/0

3-3/0

4-3/0

4-4/0

1500

2-4/0

3-3/0

3-4/0

4-4/0

1750

750

1000

2-750

2-1

000

2-1

000

Weld

cable

size

(AWG)

is

based

on

either

a

4

volts

or

less

drop

or

a

current

density

of

at

least

300

circular

mils

per

ampere.

Contact

your

distributor

for

the

mm2

equivalent

weld

cable

sizes.

2-8.

Common

Work

Cable

Sizes

Common

Work

Cable

Sizes

At

Main

Transformer

Rated

Welding

Current

Cable

Length

Cable

Size

50ft(15m)

2No.3/0

lOOft(30.5m)

2No.4/0

150ft(46m)

3No.3/0

200ft(61

m)

3

No.4/0

OM-2211

Page

13

2-9.

Safety

Information

For

Connecting

To

Weld

Output

Terminals

2-10.

Weld

Output

Terminals

.

V

A

Read

and

understand

safety

information

in

Section

2-9

before

proceeding.

1

Handle

2

Positive

(+)

Weld

Output

Terminal

3

Negative

()

Weld

Output

Terminal

4

Weld

Output

Terminal

Cover

(Typical

For

All

Weld

Output

Terminals)

Cover

all

weld

output

terminals

with

weld

output

terminal

covers.

Go

to

Section

2-11

and/or

2-12

for

standard

module

weld

output

con

nections,

or

Section

2-13

and/or

2-14

for

parallel

module

weld

output

connections.

Ref.

ST-801

627

ri~

A

ELECTRIC

SHOCK

can

kill;

ARCING

can

burn

skin

or

damage

electrical

connections.

Turn

Oft

welding

power

source

before

making

any

weld

output

connections.

Do

not

connect

welding

output

of

difterent

polarities

to

the

same

structure.

See

ANSI

Z49.1

and

OSHA

Title

29,

Chapter

XVII,

Part

1910,

Subpart

0

(addresses

at

beginning

of

manual).

When

Positive

or

Negative

weld

output

terminal

is

jumper

linked

to

the

Common

Work

terminal

and

the

work

cable

is

connected

to

the

Common

Work

Connection

panel,

do

not

connect

a

cable

between

the

remaining

weld

output

terminal

and

the

work.

Remove

jumper

link

from

any

module

where

work

and

electrode

connections

are

made

directly

to

the

Positive

and

Negative

output

terminals.

Do

not

handle

or

come

in

contact

with

two

live

electrodes

at

the

same

time.

Connect

all

paralleled

modules

for

the

same

polarity.

ELECTRIC

SHOCK

can

kill;

TWO

TIMES

NORMAL

OPEN-CIRCUIT

VOLTS

exist

between

electrode

holders

of

opposite

polarity.

Do

not

touch

electrode

holders

of

opposite

polarity

at

the

same

time.

Separate

electrode

holders

of

opposite

polarity

to

prevent

contact.

Consult

ANSI

Z49.1

for

common

grounding

safe

practices.

OM-2211

Page

14

A

Read

and

understand

safety

information

in

Section

2-9

before

proceeding.

See

Section

2-7

for

proper

cable

size.

1

Electrode

Holder

Cable

2

Work

Cable

For

Electrode

Positive

(Reverse

Polarity/DCEP),

connect

work

cable

to

Negative

()

terminal

and

electrode

holder

cable

to

Positive

(+)tem,inal (see

Section

2-10).

For

Electrode

Negative

(Straight

Polarity/DCEN),

reverse

cable

connections.

3

Weld

Output

Terminal

Cover

(Typical

For

All

Weld

Output

Terminals)

Cover

all

weld

output

terminals

with

weld

output

terminal

covers.

2-11.

Standard

Module

Weld

Output

Connections

Without

Common

Work

Terminal

2

Tools

Needed:

~

3/4,7/8

in

Ret.

ST-801

641

OM-2211

Page

15

2-12.

Standard

Module

Weld

Output

Connections

With

Common

Work

Terminal

A

INADEQUATE

WORK

CABLE

CONNECTIONS

can

cause

serious

damage

to

input

power

service

and

create

a

hazardous

condition.

Connect

a

weld

cable

of

adequate

size

between

the

Com

mon

Work

Connection

and

the

workpiece

whenever

any

module(s)

is

connected

to

use

the

Common

Work

terminal.

Do

not

exceed

duty

cycle

of

machine.

A

Read

and

understand

safety

information

in

Section

2-9

before

proceeding.

See

Section

2-7

for

proper

cable

size.

1

Electrode

Holder

Cable

2

Work

Jumper

Cable

3

Common

Work

Terminal

4

Common

Work

Cable

For

Electrode

Positive

(Reverse

Polarity/DCEP),

connect

work

jumper

cables

from

Negative

()

terminals

to

Common

Work

termi

nal,

and

connect

electrode

holder

cables

to

Positive

(+)

terminals

(see

Section

2-10).

For

Electrode

Negative

(Straight

Polanty/DCEN),

connect

work

jumper

cables

from

Positive

(+)

ter

minals

to

Common

Work

terminal,

and

connect

electrode

holder

cables

to

Negative

()

terminals

(see

Section

2-10).

Connect

as

many

modules

as

re

quired.

Do

not

exceed

duty

cycle

of

machine.

5

Cable

Restraint

Route

cables

through

restraints

as

shown.

6

Weld

Output

Terminal

Cover

(Typical

For

All

Weld

Output

Terminals)

Cover

all

weld

output

terminals

with

weld

output

terminal

covers.

.

For

common

work

connection,

work

cable

must

be

able

to

carry

combined

weld

outputof

all

modules

using

the

Common

Work

Terminal

(see

Section

2-8

for

prop

er

cable

size).

The

Common

Work

Terminal

is

isolated

from

the

unit

frame.

Ref.

ST-801

641

Tools

Needed:

-r

3/4,7/8

in

OM-2211

Page

16

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