Miller | JC646118 | Owner Manual | Miller GPS-1500A User manual

Miller GPS-1500A User manual
December 1982
FORM: OM-267D
ec~t\1ł
Effective With Serial No. JC646118
MODEL
GPS-1000
G PS-i 500A
GPS-1 500V
OWNERS
fullER
MANUAL
C
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON
WI
54912 USA
NWSA CODE NO. 4579
PRINTED IN U.S.A.
...~
~
~.
t~~
~
LIMITED WARRANTY
EFFECTIVE: JUNE 1. 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
LIMITED
\d
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
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade acother items manufactured by others. Such
or
cessories
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase,
.
specified below, Millers warranty does not apply
to components having normal useful life of less than one Ill
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators wherefailure does
not result from defect in workmanship or material.
Except
as
Miller shall be
required to honor warranty claims on warEquipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equipment to the original user:
ranted
-
As
a
general policy only, Miller may honor claims
by the original user within the foregoing periods.
matter of
submitted
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option (11 repair or (2) replacement
writing by Miller in appropriatecases, (3)
repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price Iless reasonable depreciation based upon actual use) upon
return of the goods at Customers risk and expense. Upon receipt
or, where authorized in
the reasonable cost of
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
WARRANTY, GUARANTY OR REPRESENTAPERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED
TION
ANY
AS
~
TO
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
Arc welders, power sources and components
2. Original main power rectifiers
1.
(labor
3.
4.
.
.
3 years
1 year
only)
feeder/guns
-
5.
Replacement
Batteries
or
repair parts, exclusive
EXCEPT
AS
90
of labor
.
days
1 year
60 days
6 months
EXPRESSLY
MILLER
WRITING,
All welding guns and
All other Millermatic Feeders
6.
1 year
PURCHASE
ULTIMATE
BY
provided that Miller is notified
in
writing
within
thirty (30) days
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED
WELDING
IN
USE
THE
EQUIPMENT
AND
CONSUMER USE. MILLER
of the date of such failure.
PROVIDED
PRODUCTS
TO,
AND
MILLERS
~
NO
RESELLER
AND
NOT
MAINTENANCE
FOR
CONSUMERS
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
WARRANTIES TO, ANY CONSUMER.
..~
~
OF
OR
~
~
TO
EXTEND
~s
March 6, 1984
FORM: OM-267D
ERRATA SHEET
After this manual
was
printed,
refinements in
appearing
AMENDMENT TO SECTION 4
Amend
equipment design
occurred. This sheet lists
exceptions
to data
later in this manual.
Figure
-
OPERATION
4-1. Front Panel
Circuit
Ammeter A
Pilot
Light
meter
Voltmeter A
B
B
Start And
Stop Buttons
1000
Models Illustrated
DC PositIve
DC Negative
TB-079 824
Figure
AMENDMENT TO SECTION 5
-
4-1. Front Panel
MAINTENANCE
Amend Section 5-3. CONTROL CIRCUIT PROTECTION
welding power source is protected by a cartidge type fuse Fl. This fuse is located
beside contactor W. Should this fuse open, the welding power source would completely shut
The entire control circuit of the
under the top
down.
cover
Item
Dia.
Part
Replaced
No.
Mkgs.
No.
With
5
Pg4
Pg4
Fl
R2
34
Ti
34
Ti
34
Ti
Pg4
Pg4
Pg4
Pg 4
Pg 4
Pg 4
Ru
R12
TP1
Note: Be
604
083
601
079
070
044
030
604
026
079
070
259
640
837
718
897
147
691
288
181
529
724
045 971
088 384
083 640
Description
FUSE, cartridge 1 amp 600 volts
RESISTOR, grid (dia mkg chg)
NUT, brass-hex jam 3/8-16
TRANSFORMER, power-main
TRANSFORMER, power-main
TRANSFORMER, power-main
601 838
**See Note
**See Note
**See Note
Deleted
Deleted
092 624 THERMOSTAT, NC
**See Note COIL, pri/sec
**See Note COIL, pri/sec
**See Note
COIL, pri/sec
provide primary voltage of the unit when ordering these items.
Factory or Factory Authorized Service Station.
sure to
**Replace
at
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
42
1
1
1
6
6
6
6
TABLE OF CONTENTS
Page
Section No.
SECTION 1
1
1
-
-
1.
2.
1 -3.
1
4.
-
SECTION 2
2- 1.
2
2
-
2.
3.
2-4.
-
SECTION 3
3
3
3
-
-
-
4
-
-
Introduction
General Precautions
1
ArcWelding
7
Standards Booklet Index
10
-
1
INTRODUCTION
General
12
Receiving-Handling
Description
Safety
12
-
12
12
INSTALLATION
1.
Location
12
Electrical Input Connections
Weld Output Connections
13
SECTION 4
4
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
2.
3.
-
14
OPERATION
1.
Power Control Switch
16
2.
Overload Protection
16
PilotLight
16
Meters
16
Volt-Ampere Curve
DutyCycle
16
16
4-3.
4
4.
4 -5.
-
4-6.
SECTION 5
-
MAINTENANCE
5-1.
FanMotor
17
5
2.
Internal
Cleaning
17
3.
Control Circuit Protection
17
5
-
-
SECTION 6
No.
-
TROUBLESHOOTING
SECTION 1
SECTION 1
-
-
REGLES
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
learn by experience.
experience, like a
personal
Learning safety through
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
Contrairemont a lappren
1-1. INTRODUCTION
tissage de Ia vie, lapprentissage de Ia sØcuritØ par ex
pØrience personnelle, comme lenfant qui touche un
poŒle chaud, est dangeroux, imprudent et inutile.
I nstruisez-vous donc de lexpØrienco dautrui.
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
Des mØthodes de sØcuritØ issues de lexpØrience du
et du coupage sont dØcrites dans le manuel. La
recherche, le progrŁs et lexpØrience dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes de
sØcuritØ pour linstallation, le fonctionnement et lontre
tien. Des accidents se produisent lorsque le materiel est
inadØquatement utilisØ ou entretenu. La raison do ces
mØthodes do sØcuritØ peut no pas Œtro t~ujours donnØe.
Certaines sont fondØes sur le sons commun, dautres
demanderont a Œtre expliquØos par dos livros techni
ques. II est plus sage de suivre los rŁgles.
1-1. INTRODUCTION
-
We
rules.
-
soudage
mØthodes do sØcuritØ avant
Read and understand these safe practices before at
Lisez et comprenez
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.
dessayer dinstaller, do faire fonctionner ou do rØparer
lappareil. Pour votre sØcuritØ personnelle et celle
dautrui, conformez-vous a ces rØgles et aux manuels
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
These safe practices are divided into two Sections:
General Precautions, common to arc welding and
1
cutting; and 2 Arc Welding (and Cutting) (only).
-
ces
dinstructions.
Manquer dobserver ces mØthodes de sØcuritØ pourrait
entrainer des blessures graves ou mŁme Ia mort. Quand
Ia sØcuritØ devient une habitude, le materiel pout alors
Œtre utilisØ en toute confiance.
Ces mØthodes de sØcuritØ sont divisØes en deux sec
1
Precautions gØnØrales, communes au
tions:
soudage et au coupage a larc, et 2 Soudage a larc
-
-
-
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
ment
installation,
also
provide
a
basis for
equip
(et coupage) (uniquement).
Normes de rØfØrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opOratoires plus complots quo
pour dautres
coux du present manuel. Elles sont donnØes dans lln
dex des Normes do cos regles do sØcuritØ. ANSI Z49-1
est (a plus complete.
los codes provinciaux et
Les codes de IACNOR,
municipaux donnent aussi les exigences pour une in
stallation, une utilisation et un entretien sOrs.
use, and service.
1-2.
1-2. GENERAL PRECAUTIONS
Different
arc
and fluxes
welding processes, electrode alloys,
produce different fumes, gases,
can
and radiation levels. In addition to the information
In this manual, be sure to consult flux and olec
trode manufacturers for specific technical data
and precautionary measures concerning their
material.
Plusiours procØdØs du soudago a larc, doe loc
trodes allis,
ot los flux peuvont produire des
de
nivoaux
et
rayonnemont
vapours,
gal,
diffØronts. Pour tout ronsoignoment supplmen
tairo a ce manuel, consultez aussi lee fabricants
doe loctrodes
et doe flux afin dobtenir
los
renseignoments techniques spØcifiques et lea
do
mesuras
precaution concernant leurs
matriaux.
A.
A.
PRECAUTIONS GENERALES
Prevention des brOlures
Burn Prevention
Portez des vºtements de
gauntlet gloves designed for
high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks. and slag.
Wear protective clothing
use in welding, hat, and
-
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filt~r lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
protection
-
des gants a
crispin
spØcialement dØsignes
pour le soudage, un casque et
des chaussures de sØcuritØ. Boutonnez le col de votre
chemise et les pattes de vos poches, et portez des pantalons sans revers pour Øviter quo des Øtincelles et du
laitier ne sy introduisent.
Portez un masque avoc lunettes de sØcuritØ ou avec
Øcrans latØ-raux do protection, des lunettes filtrantes ou
des couvre-lentilles (proteges par un verre clair). Pour le
soudage ou le coupage (et le burinage), ii est
OM-267
Page
1
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily
or
greasy
Hot metal such
should
never
clothing.
A
spark
may
electrode stubs and
as
be handled without
ignite
them.
workpieces
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 im
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working 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
intending to weld or cut.
Evitez de porter des habits imprØgnØs dhuile
graisse. Une Øtincelle pourrait les enflammer.
de
Premiers soins et traitement des yeux: Tout atelier
devrait avoir a sa disposition un poste de premiers soins
ainsi quune personne compØtente, a moms quur, ser
vice medical ne soit a proximitØ pour soigner immediate
ment les brlures des yeux et de Ia peau.
Portez des bouche-oreilles Iorsque vous travaillez au
ou dans un espace restreint. Portez un casque
lorsque dautres personnes travaillent au plafond.
plafond
ou
couper
ne
employer des preparations inflammables
Toxic Fume Prevention
ou
Ne manipulez jamais sans gants un metal chaud tel que
des chutes dØlectrode et des piŁces Ł souder.
Les personnes devant souder
Sons
B.
OBLIGATOIRE de protØger ses yeux contre lØnergie de
rayonnement et les Øclats de metal. Remplacez le verre
protecteur lorsquil est brisØ, piquØ ou quil a reu des
projections. Voir 1 .3A.2.
doivent pas
pour leurs
cheveux.
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
-
B.
Prevention des gax
toxiques
Les gaz, les vapeurs, Ia chaleur, un enrichissement ou
peuvent entralner un malaise,
manque doxygŁne
une maladie ou mØme Ia mort. Remediez-y par Ia ven
tilation dØcrite dans Ia Norme ANSI Z49.1 paragraphe 1
de llndex
des Normes. NE ventilez JAMAIS a lox
un
ygene.
Lead
cadmium -, zinc -, mercury -, and beryllium
bearing and similar materials, when welded (or cut) may
produce harmful concentrations of toxic fumes. Ade
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
-
-,
air-supplied respirator.
For
beryllium, both
must be us
ed.
En soudant
ou en
coupant, les plomb, cadmium, zinc,
ou autres matØriaux semblables
peuvent crØer des concentrations nocives de gaz toxi
ques. On doit avoir recours a une ventilation aspirante
adequate du local, ou alors toute personne sur les Iieux,
de mŒme que le soudeur, doit porter un masque a ad
On doit employer les deux pour le
duction d.air.
mercure
et
beryllium
beryllium.
Metals coated with
or
containing materials
that emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ven
tilated,
or
the operator
wears an
air-supplied respirator.
Work in a confined space only while it is being ven
tilated and, if necessary, while wearing an air-supplied
respirator.
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
Les mØtaux enrobØs ou composes de matØriaux Ømet
des gaz toxiques ne doivent pas etre chauffØs a
de Ia surface a
moms que lenrobage
ne soit tØ
travailler, que le local ne soit bien ventilØ, ou que le
soudeur ne porte un masque a adduction dair.
tant
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
Gas
a
confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
to
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 pro
ducts. The ultraviolet (radiant) energy of the arc can
also
decompose trichioroethylene and per
chloroethylene
WELD
the
Page2
or
vapors
to
form
phosgene. DO NOT
cut where solvent vapors can be drawn into
welding
or
cutting atmosphere
or
where the radiant
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en
grande quantitØ peuvent
transformer dangereusement Ia concentration dox
ygŁne. Namenez pas de bouteilles de gaz dans un
espace restreint.
En quittant un espace restreint, FERMEZ le robinet
dalimentation de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme si les
robinets aval
ont ete ouverts par accident, ou si on les
a laissØs ouverts.
Les vapeurs de dissolvants chlorØs peuvent Œtre dØcom
(ou de (a flamme) et
par Ia chaleur de larc
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant les poumons et les yeux. Lenergie
ultra-violette de (arc peut aussi dØcomposer les vapeurs
de trichloroØthylŁne et de perchloroØthylene pour
former du phosgŁne. NE SOUDEZ PAS ou ne coupez
pas dans des endroits ou les vapeurs de dissolvants peu
de soudage ou de
vent Œtre attirØes dans latmosphŁre
posees
energy carl penetrate to
minute amounts of
atmospheres containing
trichloroethylene or
even
per
chloroethylone.
coupage et oCi lenergie de rayonnement peut pØnØtrer
dans des atmospheres contenant des quantitØs memo
de
minuscules
trichloroØthylŁne ou de per
chloroØthylBne.
C.
Fire and
Explosion Prevention
Causes of fire and explosion
by the arc, flame,
material; misuse of
are:
combustibles reached
hot
Prevention des incendies et des
C.
heated
slag
flying sparks,
compressed gases and cylinders;
or
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.
sont les com
Les causes dincendie
et dexplosion
bustibles atteints par larc, Ia flamme, les Øtincelles, lo
laitier chaud ou les matØriaux chauffØs, le mauvais
emploi des gaz comprimØs et des bouteilles ainsi que les
courts-circuits.
Sachez que tes Øclats dØtincelles ou Ia chute du laitier
sinfiltrer
dans les fissures, le long des
tuyauteries, par les fenŒtres et les portes et par les
peuvent
couvertures des murs ou du
portant des lunettes
ne
es
sol, sans que le soudeur
voie. Les Øtincelles et les
35 pieds.
peuvent voler jusqua
prevenir los incendies et les explosions: Veillez Ł co
que votre appareil soit propre et en Øtat do marche,
dØnuØ dhuile et de graisse, et de particules de metal sur
les piŁces Ølectriquos qui pourraiont entraInor des
scones
To prevent fires and explosion:
explosions
Pour
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
courts-circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, yen
tilators. If the work cannot be moved, move com
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire ex
tinguishing equipment during and for some time after
welding or cutting if:
Si des combustibles
a proximitØ, ne soudez
possible, dØplacez votre travail
loin des combustibles. Evitez los ateliers do peinture au
pistolet, los cuves dimmersion, les entrepts, les von
tilateurs. Si cola nest pas possible, placez les com
bustibles a au moms 35 pieds des Øtincelles et de Ia
chaleur et protØgez-les des Øtincelles avec des couver
turos ou des Øcrans protecteurs adØquats, bien ajustØs
et ignifuges.
On ne doit pas souder (ou couper) le ctØ oppose des
murs touchant les combustibles. Les murs, plafonds et
planchers proches du travail doivent Œtre protØgØs par
des couvertures ou Øcrans protecteurs ignifugØs.
Un surveillant doit so tonir a proximitØ avec un materiel
de lutte contre lincendie adØquat, pendant et quelque
temps aprŁs le soudage ou le coupage Si:
pas,
ne
a.
a.
b.
appreciable combustibles (including building
construction) are within 35 feet
appreciable combustibles are further than 35
can be ignited by sparks
openings (concealed or visible) in floors
b.
feet but
c.
walls
within
35
feet
may
expose
or
c.
com
bustibles to
d.
sparks
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant
or
d.
conducted heat.
Hot work
ensure
permit should be obtained before operation to
supervisors approval that adequate precautions
have been taken.
After work is done, check that
glowing embers, and flames.
area
is free of sparks,
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
so trouvent
coupez pas. Si
Des
quantites apprØciables de combustibles
(y compris une construction en chantier) so
trouvent a moms de 35 pieds.
Des quantites apprØciables do combustibles
sont a plus de 35 pieds mais peuvent Otre
enflammØes par des Øtincelles.
Des ouvertures (cachØes ou visibles) sur los
planchors ou les murs a moms do 35 pieds
peuvent exposer des combustibles aux
Øtincelles.
Les
combustibles adjacents aux murs,
plafonds, toits ou cloisons mØtalliques peu
vent Œtre enflammØs par une chaleur rayon
nante ou transmise.
Avant de commencer, avisez le contremaltre pour quil
sassure que les precautions adØquates soient prises.
Une fois le travail terminØ, vØrifiez quil ny ait pas
dØtincelles, de cendres ardentes ou de flammes dans le
local.
On no doit jamais souder ni couper sur un recipient
ayant contenu des combustibles, ou pouvant produire
des vapeurs inflammables ou toxiques a Ia chauffe, a
described in AWS Standard A6.O,
listed 3 in Standards index.
moms quo le recipient nait OtØ lavØ au prØalablo, cornme dØcrit dans Ia
Norme AWS A6.O, figurant au
paragraphe 3 de llndex des Normes.
This includes:
Cela comprend: un nettoyage a fond a Ia vapeur ou au
caustique (ou un lavage avec dissolvant ou eau solon Ia
been cleaned
a
solvent
or
as
thorough steam or caustic cleaning (or
water washing, depending on the corna
solubilitØ du combustible) suivi dune
purge et dune
in
OM-267
Page
3
bustibles solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.O. Waterfilling just
below working level may substitute for inerting.
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell
sight
or
to determine if it is safe to weld or cut.
jection dazote ou de gaz carbonique, en utilisant un
Øquipement de protection comme recommandØ dans
lA6-O. LatmosphŁre inerte peut Łtre remplacØo par un
arrivant au-dessous du travail a effectuer.
niveau deau
Vous devez layer un recipient dont Ia nature de contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS a lodorat ou a Ia vue pour dire si lon pout le
souder ou le couper en toute sØcuritØ.
Vous devez
Hollow
welding
castings or containers must be
or cutting. They can explode.
Explosive atmospheres.
may contain flammable
as
Never weld
dust,
gas,
vented before
or cut
where the air
liquid
vapors (such
or
gasoline).
D.
pients
exploser.
Atmospheres explosives: Ne soudez ni ne coupez
jamais dans des lieux oCi Iair peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
quo Iessence).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i,
PRECAUTIONS FOR SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, listed 6 in Stan
dards index.
1.
un event sur les piŁces ou rØci~
do les souder ou couper: ils peuvent
pratiquer
creux avant
0.
Precautions genØrales: Suivez les precautions de ce
at celles dØcrites a Ia Normo CGA P-i (PrØcau
tions de sØcuritØ pour Ia manipulation do gaz comprimØs
des Normes.
en bouteilles), paragraphe 6 de Ilndex
manuel,
1.
Pressure
Regulators
comprimØ
Gaz
DØtendeurs de pression
La soupape de sQretØ dun dØtendeur est destinØe a pro
le dØtendeur de Ia surpression. Ello na
pas pour but de protØger los boyaux et Ia chalumoau: on
protege coux-ci par des soupapos do retenue concues
tØger seuloment
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream equipment. Provide such protec
tion with
one or more
spØcialement
Ne montez
Never connect
a
regulator
cylinder containing gas
regulator was designed.
to a
other than that for which the
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
Leaks
if gas leaks externally.
Excessive Creep
if delivery pressure continues to rise
with downstream valve closed.
-
-
Faulty Gauge if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after
-
pressure release.
Repair. Do NOT attempt repair. Send faulty regulators
for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
2.
pour cette fonction.
relief devices.
Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious ac
cident. (See 1-3C.)
un dØtendeur sur une bouteille conte
different de celui pour lequel le dØtendeur a
jamais
nant un gaz
ØtØ concu.
Enlevez immØdiatement un dØtendeur dØfectueux pour
Ia faire rØparer (dabord,
fermez le robinot de Ia
bouteilte). Les symptmes suivants dØnotent Ia dØfec
tuositØ du dØtendeur:
Fuites Si Ie gaz fuit extØrieurement.
Ascension excessive si Ia pression do debit continue Ł
monter, le robinet du chalumeau Øtant fermØ.
ManomŁtre dØfoctueux
Si laiguille du manomŁtre no
sØcarte pas do Ia goupille de butØe lors do Ia mise en
pression, ou no revient pas sur Ia goupille aprŁs IØchap
pement do Ia pression.
-
-
-
Reparation. NESSAYEZ PAS de rØparer vous-mØmes.
Envoyoz es dØtendeurs dØfectueux a rØparer aux
ateliers de reparation agrees du fabricant, o dos techni
ques et des outils spØciaux sont utilisØs par un person
nel formØ.
2.
Bouteilles
Los boutoilles doivent Œtre manipulØos avec soin pour
prØvenir les. fuites ou dØgªts a leurs parois, robinets ou
systŁmes de sOretØ. Evitez quun circuit Ølectrique soit
en contact avoc les bouteilles, y compris es rails de con
tact, les fils Ølectriques ou les circuits do soudage. Cola
pourrait crØer des arcs courts-circuits pouvant entralner
des accidents graves (Voir 1 .3C.).
ICC
DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
handled.
Page 4
or
Chaque bouteille doit porter
es inscriptions ICC ou
DOT. Cest un gage do sØcuritØ pourvu que Ia bouteille
soit bien manipulØe.
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 MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Identification du gaz: Nutilisez que les bouteilles mdi
nature du gaz; no vous fiez pas a Ia couleur
Ia nature du gaz. Adressez-vous a
reconnaItre
pour
votre fournisseur si cela nest pas indiquØ.
quant Ia
modifiez
NEFFACEZ
no
ou
numØros ou autres indications
est
illegal
or secure
cylinders
so
they
cannot be knocked
dangereux.
et
Vides: Maintenez los robinets fermØs, replacez bien los
sØparez-les dos Pleines
chapeaux; inscrivez Vides;
et retournez-les rapidement.
une bouteille ou son contenu
elle est destinØe, mais JAMAIS cornrouleau.
Emploi interdit: Nutilisez
que pour
Locate
me
ce
support
a
quoi
ou
Placez los bouteilles pour
over.
Passageways and work areas. Keep cylinders clear
areas where they may be struck.
of
Do NOT expose cylinders to excessive heat, sparks,
and flame, etc. that may cause rupture. Do not
allow contents to exceed 130F. Cool with water spray
where such exposure exists.
slag,
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
quelles
no
tombent p85. Lors
quun dØtendeur (ot un boyau) est monte
placez los ou attachez-les debout.
sur
ellos,
-
travail. Enlevez los bouteilles dun
pourrait los frapper.
et lieux de
Passages
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
JAMAIS los noms,
bouteille. Cela
sur une
lon
endroit o
des bouteillos. Avec une grue, utilisez un sup
plate-forme ou un cadre. NE
port fiable tel quuno
SOULEVEZ PAS des boutoilles du sol par leur robinet
ou chapeau, ou avec des chaInes, Ølingues ou aimants.
Transport
PAS los bouteilles a une chaleur excessive,
au laitier et aux flammes, etc., pouvant
leur rupture. Le contenant ne doit jamais
causer
dØpasser 55C. Refroidissez en pulvØrisant do leau si
nØcessaire.
NEXPOSEZ
aux
Øtincelles,
les boutoillos et particuliŁroment los SOUP8P~S
chocs, los chutes, les chutes dobjets et Ia
temperature. Rernettez bien los chapeaux lorsque vous
deplacez los bouteilles.
ProtØgez
contro los
Stuck valve. Do NOT use a hammer or wrench to open
cylinder valve that can not be opened by hand. Notify
a
supplier.
your
Mixing
gases. Never try to mix any gases in
Never refill any
a
cylinder.
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
Robinet coincØ. NUTILISEZ PAS un martoau ou une
clØ metallique pour ouvrir un robinet do boutoille quo
lon ne peut pas ouvrir a Ia main. Avisez votre four
nisseur.
MØlange
dans
3.
hose other than that designed
hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Prohibited
use.
Never
specified
general
tubing splices.
splice hose.
No copper
to
Use
only
standard brass f it
3.
Boyau
Utilisation interdite. Nutilisez
que celui
excess
hose to prevent kinks and
tangles.
approprie
jarnais
un
boyau
autre
gaz indiquØ. La rŁgle gØnØrale
didentification est: rouge pour los gaz combustibles,
vert pour loxygŁne, et noir pour los gaz inertes.
au
Utilisez des bagues ou colliers appropriØs au boyau (et
non du fil ordinaire ou autro substitution) pour brancher
les boyaux a lappareillage.
Nutilisez
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
jamais do mØlanger des gaz
use
gas. A
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
tings
do gaz. Nessayez
bouteille.
Ne rechargez jamais une bouteille. Los ØlØments de Ia
bouteille no doivent jarnais Œtro modifies ou romplacØs.
Hose
for the
une
pas des raccords en cuivre. Nutilisez quo des
en laiton pour raccorder un boyau.
accessoires standard
Utilisez une petite longuour do boyau. Cola Øvitera los
noeuds et lusure prOmaturØe. Suspendez le boyau au
dessus du sol pour Øviter quil no soit ØcrasØ, piØtinØ ou
endommagØ.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con
pressured hose in water; bubbles indicate leaks.
Enroulez le surplus do boyau pour Øviter los noeuds et
emrnºlements. Evitez que le boyau no soit endommage
par dos tranchants, Øtincelles, laitier et flamme nue.
nections. Immerse
OM-267
Page
5
Repair leaky
ing (1-2D3).
4.
or worn
hose by
Do NOT
cutting
area out
and splic
tape.
use
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
a clean lintless cloth.
sources
of
ignition. Wipe
with
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten
connections. When
assembling threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
a CGA adapter (available from your sup
between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Adapters. Use
plier)
VØrifiez rØguliŁrement les fuites, lusure et les rac
cordements lches.
Plongez le boyau sous pression
dans de leau; les bulbs indiqueront les fuites.
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØsif.
4.
Branchements corrects
Avant de brancher be dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteilbe des impuretØs qui peuvent
obstruer los orifices et endommager les sieges. Sauf
pour lhydrogene, ouvrez momentanØment be robinet,
Øloignant Ia sortie des personnes et des sources in
Essuyez avec un tissu propre at non
graisseux.
en
flammables.
Appareiblez be dØtendeur a Ia bouteible. Avant de bran
cher, vØrifiez qua Ia marque du dØtendeur et Ia descrip
tion de Ia bouteibbe concordant, et que lorif ice dentrØe
du dØtendeur et borifice de sortie de Ia bouteille ailbent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
concu pour un gaz special (ou des gaz spØciaux) a une
bouteille contenant dautres gaz.
Serrez les branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges oCi
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-Ies, nettoyez et resserez avec une clef adØ
quate.
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5.
Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw
engaged slightly
on
single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
When gauge is pressurized (gauge
creases slowly.
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E.
User
Responsibilities
Remove leaky
or defective equipment from service im
mediately for repair. See User Responsibility statement
in
equipment manual.
*Trademark of Proctor & Gamble
Page 6
un adaptateur CGA
chez votre fournisseur) entre Ia bouteille et le
dØtendeur. Avec deux clefs, serrez ladaptateur filetØ A
DROITE et A GAUCHE.
Adaptateurs. Pbacez, si besoin est,
(en
yenta
On peut reconnaItre las branchements de sortie du
dØtendeur (ou boyau) a laide du filetage a droite pour
loxygŁne et a gauche (identifiØ par un Øcrou cannelØ)
pour bes gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur de rØsidu do gaz avant douvrir Ia
bouteible (ou be robinet do canalisation) en serrant Ia vis
de reglage (dans le sans des aiguilles dune mbntre).
Cette operation permet au siege de haute pression de
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez Ia vis de reglage
des dØtendeurs a simple dØtente lØgerement engagØe.
Avant douvrir le robinet de Ia bouteille, assurez-vous
que les boyaux sont branches et quo los soupapes avab
sont fermØes.
Tenez-vous latØrabement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-le lentement pour que Ia
pression du dØtendeur monte progressivement. Lorsque
le manomŁtre est mis sous pression (indique le max
imum) be robinet do Ia bouteilbe do gaz inerte ou dox
ygene devra Łtre ouvert a fond pour assurer IØtanchØitØ
at celui de Ia bouteible de gaz combustible ouvert de
moms dun tour pour pouvoir be reformer rapidement en
cas
durgence.
RØfØrez-vous aux tableaux do pression (distribuØs par
fournisseur) pour un rØglage recommandØ de
pression sOr et efficace sur los dØtendeurs. VØrifiex los
fuites a Ia premiere mise en pression puis rØguliŁrement,
brossez avec une solution savonneuse (un bouchon
dIvory Liquid* ou semblable par gallon deau). Los
bulles indiquent une fuite. Enlevez Ieau savonneuse
aprŁs examen; le savon sec est inflammable.
votre
*Marque
de Commerce de Proctor & Gamble
F.
Leaving Equipment Unattended
Close gas supply at
source
E.
Otez
and drain gas.
ResponsabilitØs
do
lusager
immØdiatement les parties percØes
Voir les ResponsabilitØs de lUsager
tueuses.
G.
de
Rope Staging-Support
Rope staging-support should not be
cutting operation; rope may burn.
used for
welding
Appareil
laissØ
Fermez lalimentation
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
G.
-
-
lappareil.
F.
or
dØfec
ou
du manuel
sans
surveillance
de gaz a Ia
Liens et supports
source et
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
voltages. The
--
arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents.
are
Precautions
described here and in standards referenced in index.
A.
Burn Protection
Comply
with precautions in 1-2.
The welding arc is intense and visibly bright, Its radia
tion can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DONT
GET BURNED; COMPLY WITH PRECAU
TIONS.
1.
Protective Clothing
Wear
long-sleeve clothing (particularly for gas-shielded
A LARC
Conformez-vous aux
1-3. SOUDAGE
precautions des paragraphes 1.1 et 1.2 de cette section.
bien exØcutØ est sQr, mais un
Le soudage a Iarc
soudeur negligent est un danger. Le poste do soudage
-
sous do fortes tensions.
Les Øtincelles volent, Ies
vapeurs montent, lØnergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrui contre
los accidents. Los precautions sont dØcrites ici et dans
los normes donnØes dans IIndex.
transporte des courants ØlevØs
Larc
A.
est trØs vif et chaud.
Protection contre los brOlures
Conformez-vous aux precautions du paragraphe 1 .2.
Larc de soudage est intense et visiblement vif. Son
rayonnement peut blesser los yeux, traverser los habits
legers, se rØflØchir sur los surfaces claires, et brQler Ia
peau et les yeux. Les brlures de Ia peau ressemblent a
un gros coup de soleil. CeHes darcs sous gaz protecteur
sont plus graves et plus douloureuses. NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fireresistant leggings. Avoid outergarments of untreated
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets
2.
to
VŒtements do
protection
Portez des vŒtements a manches longues (surtout pour
Iarc en atmosphere inerte) avec gants, masque et
chaussures (1.2A.).
Si nØcessaire portez en plus une veste ou des manches
cuir, un tablier et des guŒtres ignifugØs. Do
prØfØrence ne portez pas do vŒtemonts en coton non
en
prevent entry of sparks.
traitØ.
Eye and Head Protection
Protect eyes from exposure to
electric arc without protection.
1.
arc.
NEVER look at
an
Protection de Ia peau. Portez des vŒtements Øpais
foncØs. Boutonnez le col pour protØger Ia poitrine et le
cou, et boutonnez les poches pour prØvenir lirifiltration
dØtincelles.
Welding
no.
over
helmet
or
shield
containing
a
filter
plate shade
12
or denser must be used when welding. Place
face before striking arc.
Protect filter
Cracked
or
plate .with
a
clear
broken helmet
worn; radiation
can
Cracked, broken,
or
pass
plate.
shield should NOT be
through
to cause burns.
loose filter plates must be replaced
clear cover plate when
IMMEDIATELY.
Replace
broken, pitted,
spattered.
or
or
cover
2.
Protection des yeux et do Ia tŒte
Evitez que vos yeux soient exposØs a arc. NE regardez
JAMAIS un arc Ølectrique sans protection.
vous soudez, portez un Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-le sur le
visage avant damorcer larc.
Lorsque
verre
ProtØgez le
verre filtrant dun
couvre-vorre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ment peut sinfiltrer et causer des brlures.
Les verres filtrants fendus, brisØs ou lØches doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez un couvre
verre brisØ, piquØ ou tachØ par des projections.
OM-26lPage7
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.
eyes
Looking at an arc momentarily with unprotected
(particularly a high intensity gas-shielded arc) can
retinal burn that may leave
in the field of vision.
cause a
area
3.
permanent dark
welding
For
area.
Local de
production welding,
a
enclosed bay is best. In open areas,
the operation with low-reflective, noncombustible screens or panels. Allow for free air circula
separate
room or
surround
tion, particularly
floor level.
at
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in
flash goggles.
area.
Before
weld, make
bay
starting
doors
B.
are
to
See that all persons
sure
that
Protection du
3.
Protection of Nearby Personnel
Enclosed
-
a
Vous devez portez des lunettes a Øcrans latØraux sous le
masque pour proteger les yeux dans le cas o le masque
de
ne serait pas abaissØ sur le visage avant Iamorage
larc. Regarder momentanØment un arc sans protection
(principalement un arc en atmosphere inerte a haute in
tensitØ) peut brler Ia rØtine et laisser un point sombre
permanent dans le champ de vision.
are
screen
wearing
flaps
tion, il
soudage
personnel
a
proximitØ
fermØ. Pour le
vaut mieux utiliser une salle
soudage de produc
sØparØe ou une baie
fermØe. Dans les locaux ouverts, entourez les travaux
dØcrans ou panneaux peu rØflØchissants et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
Donnez des masques aux personnes qui regarderont
directement Ia soudure.
Autres personnes travaillant sur les lieux. Veillez a ce
que toutes les personnes portent les lunettes de protec
tion.
or
closed.
Avant dattaquer
Ia soudure, assurez-vous
rebords dØcran ou es portes soient fermØs.
que
Ies
Toxic Fume Prevention
B.
Comply
with
Generator engine exhaust must be vented
air. Carbon monoxide can kill.
C.
Fire and
Comply
with
Prevention des gaz toxiques
precautions in 1-2B.
to
the outside
Suivez les precautions du paragraphe 1.26. LØchappe
gØneratrice doit Otre ventilØ a lair
extØrieur. Loxyde de carbone peut tuer.
ment du moteur de Ia
Explosion Prevention
precautions
C.
Prevention des incendies at des explosions
in 1-2G.
Suivez les precautions 1.2G.
rated capacity. Do not overload arc
Equipments
welding equipment. It may overheat cables and cause a
fire.
Loose cable connections may overheat
fire.
or
flash and
rupture
or
arc
a
on
brittle
lead to such
a
cylinder
area
a
that
or
other pressure
can cause a
violent
rupture later under rough
handling.
D.
Compressed Gas Equipment
Comply
E.
with precautions in 1-2D.
Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
Page 8
Ne
surchargez
Les branchements lªches de cØble peuvent surchauffer
faire des Øtincelles et causer un incendie.
ou
cause a
Never strike an
vessel. It creates
Puissance nominale de
pas le poste de soudage a
larc. Cela peut surchauffer les cables et causer un in
cendie.
lappareil.
Namorcez
jamais un arc sur une bouteille ou autre rØci
pression. Gela crØerait un point de rupture
entraInant a plus ou moms longue ØchØance lexplosion
pient
sous
du reservoir.
D.
Gaz
comprimØ
Suivez les precautions 1 .2D.
E.
Prevention des
dØcharges Ølectriques
Des conducteurs charges ou metal nu incorporØs au cir
cuit de soudage ou a un appareil chargØ sans mise a Ia
terre peuvent donner une dØcharge fatale a Ia
personne
dont le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE
humide ni en contact
tion appropriØe.
avec une
sur une
telle surface
sans
surface
protec
To protect
against shock:
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
on
a dry duckboard, or rubber mat when damp
Stay
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
reduces the body surface
or grounded metal
part
electrical resistance, enabling dangerous and possibly
without
-
-
lethal currents to flow
through
the
Pour vous proteger contre los dØcharges Ølectriques,
maintenez votre corps et vŒtements secs. Ne travaillez
jamais daris un endroit humide sans isolation adequate
les dØcharges
pouvez Øviter lhumiditØ
contre
Grounding
the
ou
Ia sueur,
Lorsque vous
placez-vous sur
ne
un
un tapis en caoutchouc. La sueur,
lhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal a Ia masse, rØduisent
Ia rØsistance Ølectrique de Ia surface du corps, permet
tant lentrØe de courants dangereux, voire mortels.
caillebotis
leau
sec
de mer,
ou
ou
body.
1.
1.
Ølectriques.
Mise a Ia terre de
lappareil
Equipment
Lorsque lappareil de soudage a larc
est mise a Ia terre
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
National Electrical Code, et Ia masse
est mise a Ia terre suivant Ia norme ANSI Z49.1 Safety
in Welding and Cutting, une tension pout exister entre
lØlectrode et un objet conducteur. Certaines de ces ob
jets sont par exemple (mais pas seulement), des
des outils Ølectriques, des Øtablis, des
btiments,
tools, work benches, welding power
chassis de postes de soudure, des piŁces douvrage,
etc. Ne jamais touchez IØlectrode ou des objets en
metal avant davoir mis Ia poste de soudure a larrŁt.
source
cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
suivant Ia
norme
off.
When
installing,
connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
must
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
quid such
as
oil
or
fuel.
par les courants vagabonds peut donner une decharge
risquant dŒtre mortelle. NE BRANCHEZ PAS VOTRE
PRISE DE TERRE a une conduite Ølectrique, ou a un
tuyau de gaz ou de liquide inflammable tel que lhuile
un combustible.
ou
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
a dangerous condi
ment will become electrically HOT
tion that can shock, possibly fatally.
vØrifiez Ia
Connexion triphasØe. Avant linstallation
phase nØcessaire a Iappareil. Si seul le triphasØ est
disponible, ne branchez lappareil monophasØ qu deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur de terre de lappareil au troisiŁme fil (sous
tension), autrement Iappareil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
Avant le soudage, vØrifiez si Ia prise do terre est
uniforme. En branchant, assurez-vous quo los con
ducteurs touchent le metal nu du chassis do lappareil.
-
ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a threeprong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
If
=
branchez les chassis de chaque ØlØment
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sØcuritØ. Lappareil chargØ
A linstallation,
a
line cord with
2.
a
Electrode Holders
appareil doit Œtre alimentØ a partir dun
cof
le conducteur de terre doit Otre reliØ
Si vous avez en plus une fiche a trois broches pour Ia
Ia broche
terre, ne branchez le conducteur de terre qu
de terre. Si le cordon dalimentation a une fiche a trois
broches, reliez-le a une prise femelle tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
2.
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3.
Lorsquun
fret dalimentation,
a celui-ci.
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pirice-electrodes avec vis saillantes.
Connectors
3.
Fully insulated lock-type connectors should be used
join welding cable lengths.
Connecteurs
to
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler de longs cables.
OM-267
Page 9
4.
Cables
4.
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 cabe dry, free of oil and grease, and protected
from hot metal and sparks.
-
5.
Terminals And Other Exposed Parts.
6.
VØrifiez frequemment lusure, Ies fissures et laltØration
des cables. REMPLACEZ IMMEDIATEMENT ceux dont
Iisolation serait trop usØe ou altØrØe pour prØvenir les
dØcharges mortelles provoquØes par un cØble dØnudØ.
Vous pouvez enrouler les parties endommagØes de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez les cØbles secs,
dØpourvus dhuile et de graisse et mettez-Ies a Iabri du
metal chaud et des Øtincelles.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
TŒtes de cables et autres parties dØnudØes
Avant Ia mise en marche, les tŒtes de cØbles et autres
parties dØnudØes dun appareil Ølectrique doivent Œtre
munies de leurs couvrefils isolants.
Electrode Wire
6.
Electrode wire becomes electrically HOT when the
power switch of gas metal-arc welding equipment is ON
and welding gun trigger is pressed. Keep hands and
body
CØbles
clear of wire and other HOT parts.
7.
Safety Devices
Safety devices
such
interlocks and circuit breakers
should not be disconnected or shunted out.
Before
or
service, of equip
ment, shut OFF all power and remove line fuses (or lock
red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
or
source, and
Le fil-Ølectrode est chargØ Iorsque Iorsque linterrupteur
dalimentation du poste a souder au MIG est sur MAR
CHE et que lon appuie sur Ia gØchette du pistolet.
Evitez que Ies mains et le corps soient en contact avec le
fit et autres ØlØments charges.
7.
as
installation, inspection,
pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Fils-Ølectrodes
Dispositif de
sØcuritØ
Le dispositif de sØcurite-verroulllage et
doit pas Œtre dØbranchØ ou dØshuntØ.
coupe-circuit
ne
(a reparation de lap
ARRET et enlevez les
fusibles generaux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez tous ~es cables de (a source de courant ainsi que les
prises des cordons dalimentation en 115 volts.
Avant
pareil,
linstallation, Iinspection
mettez lalimentation
ou
sur
et ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia polaritØ. Sil est dØbranchØ au
cours
dune
Lors du
Leaving equipment
unattended.
disconnect all power
to
Always shut OFF
equipment.
and
dØcharge
Power disconnect switch must be available
welding
power
1-4. STANDARDS BOOKLET INDEX
Appareil laissØ
sans surveillance. Mettez
ARRET et dØbranchez Iappareil.
-
For
or
more
Page
10
brOlures de
toujours
sur
in
their latest
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
Linterrupteur
imitØ de Ia
1-4.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from
the
Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
darrŒt doit toujours
de courant.
se
trouver a prox
source
INDEX
DES
NORMES
Pour
plus de
de IACNOR
amØricaines suivantes:
renseignements, rØfØrez-vous
ou aux normes
1.
2.
aux
jaillissements dØtincelles.
the
source.
formation, refer to the following standards
revisions and comply as applicable:
1.
near
urgence, faites attention
ou aux
-
aux normes
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par IAmerican Welding
Society, 550 Le Jeune Rd, P.O. Box 351040
Miami, FL 33135
2.
3.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
OSHA, SAFETY AND HEALTH STANDARDS,
1910, distribuØ par U.S. Government
Printing Office, Washington, D.C. 20402.
29CFR
PROTECTION obtainable from the
National Standards Institute, 1430
Broadway, New York, NY 10018.
FACE
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018.
5.
ANS1 Standard Z41.1, STANDARD FOR MENS
TOE FOOTWEAR distribuØ par lad
SAFETY
dresse donnee en 4.
American
5.
ANSI Standard Z41.i, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
6.
7.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par Iaddresse donnee en 4.
7.
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par laddresse donnee en
8.
FUEL GAS
NFPA Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING
distribuØ par Ia National Fire Protection Associa
tion, 470 Atlantic Avenue, Boston, MA 02210
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE distribuØ par Iaddresse donnØe
en 8
10.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
8
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS distribuØ par
500 Fifth
Ia Compressed Gas Association,
Avenue, New York, NY 10036.
12.
CSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
Rexdale
178
Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
13.
NWSA
SAFETY
WELDING
booklet,
BIBLIOGRAPHY distribuØ par Ia
National
Street
1900
Arch
Association,
Welding Supply
Philadelphia, PA 19103.
14.
American
15.
ANSI Standard Z88.2 Practice
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society,
351040,
8.
-
550 Le Jeune Rd., P.O. Box
FL 33135.
FUEL GAS
NFPA Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
-
02210.
9.
10.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
CSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
14.
American
Welding Society Standard AWSF4.i
Safe Practices for the Prepara
Recommended
tion for
Welding
and
of Containers and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding Society,
Cutting
-
Welding Societe Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
distribuØ par lAmerican Welding Societe, 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33135
For Respiratory
Protection
distribuØ par lAmerican
National
Standards Institute, 1430 Broadway, New York,
NY 10018.
550 LeJeuneRd., P.O. Box 351040, Miami, FL
33135.
15.
ANSI StandardZ88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards
Institute, 1430 Broadway, New
York, NY 10018.
OM-267 Page 11
SECTION 2
INTRODUCTION
-
Input At Rated
Load Output
Max.
Rated
Model
Welding
Current Amperes
100% Duty Cycle
60 Hz. Three-Phase
OpenAmperes
Circuit
230V
Voltage
460V
Weight
At
575V
kva
41-1/8 in. (1045 mml
Width
27-1/4 in. (692 mm)
Depth -46 in. (1168 mm)
Height
1000
1000
@76
Volts
85
224
112
89
90
85
1500
@76 Volts
85
330
165
132
131
Ship
896 lbs.
986 lbs.
(406 kg)
(447 kg)
1068 lbs.
1158 lbs.
(484 kg)
(525 kg)
-
-
Height
1500
Net
Dimensions
kw
-
Width
123
-
Depth
41-1/8 in. (1045 mm)
27-1/4 in. (692 mm)
-46 in. (1168 mm)
Figure 2-1. Specifications
2-1. GENERAL
This manual has been prepared
especially for use in familiarizing personnel with the
-
design, installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein and on various labels, tags, and plates
on the unit should be given careful consideration to
2-4. SAFETY
-
Before
the
operation, the safety section
should be read completely.
equipment is put into
at
the front of this manual
This will help avoid
proper
possible injury
welding applications.
due to misuse
or
im
optimum performance of this equipment.
assure
2-2. RECEIVING-HANDLING
Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
The
following definitions apply
to
CAUTION, IMPOR
-
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re
quest if occasion to file claim arises.
When requesting information concerning this equip
ment, it is essential that Model Description and/or
Stock Number and Serial (or Style) Numbers of the
equipment be supplied.
TANT,
-
This
welding
NOTE
blocks
found
throughout
this
manual:
CAUTION Under
this
heading,
___________
operating,
and maintenance procedures
be found that if not
or
carefully followed
installation,
practices will
may create
a
hazard to personnel.
IMPORTANT
Under
this
heading,
______________
operating,
and maintenance procedures
be found that if not
damage
2-3. DESCRIPTION
and
to
or
carefully followed
installation,
practices will
may result in
equipment.
power source in
corporates a three phase Delta connected, constant
potential (CP) type main power transformer to provide
the constant voltage output required to operate the
I~s~l~ Under this
heading, explanato,y statements
special emphasis to obtain the
efficient operation of the equipment.
will be found that need
most
resistance grid welding stations connected to the unit.
SECTION 3
3-1. LOCATION
-
(Figure 3-1) A proper installation
site should be selected for the welding power source if
the unit is to provide dependable service, and remain
relatively maintenance free.
-
INSTALLATION
tions. The installation site should also permit easy
removal of the welding power source outer enclosure
for maintenance functions.
IMPORTANT Do not p/ace any filtering device over
the intake air passages of the welding power source as
this would restrict the volume of intake air and thereby
subject the welding power source internal components
__________
A proper installation site permits freedom of air move
ment into and out of the welding power source, and
also east subjects the unit to dust, dirt, moisture, and
corrosive vapors. A minimum of 18 inches (457 mm) of
unrestricted space must be maintained between the
welding
power
power
Page 12
source
front and rear panels and the
Also, the underside of the welding
be kept completely free of obstruc
source
nearest obstruction.
must
overheating condition and subsequent failure.
Warranty is void if any type of filtering device is used.
to an
Holes
are
mounting
provided in the welding power source base for
purposes. Figure 3-1 gives overall dimensions
and the base
mounting
hole
layout.
1.
It is recommended that the
welding cables be
kept as short as possible, be placed close
together, and be of adequate current carrying
capacity. The resistance of the welding cables
and connections causes a voltage drop which is
added to the voltage of the arc. Excessive cable
resistance may result in overloading as well as
reducing the maximum current output capability
of this unit. Proper operation is to a great extent
dependent on the use of welding cables and con
nections that are in good condition and of ade
quate size.
2.
Use Table 3-2 as a guide for selecting cable size
for the anticipated maximum weld current which
will be used. Table 3-2 shows total cable length
from the
welding power source
grid welding station. Select the
to the
resistance
size cable that is
recommended for the maximum weld current
that is to be used.
CAUTION
Do not
4.
Use correct lugs on the weld cables to connect
them to the weld output terminals.
damaged
use
or
frayed cables.
can
kill.
Do not touch live electrical parts.
Shut down the we/ding power source and discon
nect
input power before making weld output
con
nections.
Do not make connections to weld output ter
minals of the different sections (A and B) unless
the bus bars
are in p/ace.
positive output terminal of one section (A, for ex
ample) is connected to the negative output terminal of
the other section (B, for example), two times the normal
output voltage will exist between the remaining two
output terminals. Consult applicable safety codes.
If the
~ Select
the desired polarity before
making weld output connections. Choose either dc
straight polarity (electrode negative) or reverse polarity
(electrode positive).
1.
Ampere Models
For 1000
weld output terminals are not bused
500
together,
amperes of weld output is available bet
ween the A Positive and A Negative output terminals.
Simultaneously, 500 amperes of weld output is
When
3.
ELECTRIC SHOCK
_________
the
available between the B Positive and B
Negative output
terminals.
5.
Ensure that all connections
DC Po,~ti~.
DC
N.~oti~.
clean and
are
DC Po,itiv.
tight.
DC ~
When the weld output terminals are bused together,
1000 amperes of weld output is available between the A
Positive and A Negative or B Positive and B Negative
output terminals.
'
'
'
'
'
'
'
'
A
B
A
B
A
B
A
B
3-4).
2.
1000 AMP POSITION
500 AMP POSITION
This unit was shipped with the weld output terminals
bused together (in the 1000 ampere position; see Figure
For 1500
Ampere Models
079 746
1000
Ampere Models
When
'
'
'
'
'
'
ween
'
'
'
'
'
A
B
A
B
A
500-1000 AMP POSITION
1500
Figure
C.
Weld
'
'
'
B
A
B
the
weld
output
terminals
are
not
bused
together, 500
amperes of weld output is available bet
the A Positive and A Negative output terminals.
Simultaneously, 1000 amperes of weld output is
available between the B Positive and B Negative output
terminals.
1500 AMP POSITION
Ampere Models
TA-084 430
3-4. Weld Output Connections
Output Connections (Figure 3-4)
These units have two separate weld output sections, A
and B, that must be considered when making connec
tions.
When the weld output terminals are bused together,
1500 amperes of weld output is available between the A
Positive and A Negative
output terminals.
or
B Positive and B
Negative
This unit
bused
was shipped with the weld output terminals
together (in the 1500 ampere position; see Figure
3-4).
OM-267 Page 15
SECTION 4- OPERATION
To
Circuit
Breaker
Pilot
Ammeter A
Light
~
~~~-~Voltmeter
B
4-3. PILOT LIGHT
The pilot light PL1 indicates
when the welding power source is in a ready-to-weld
-
Start And
______
in
a ready-to-weld
trip, the circuit breaker
source
power
should be manually reset. Should the circuit breaker
continue to trip after each reset, an internal problem in
the circuitry is most probably present. Do not attempt
any further welding until the trouble has been remedied.
Ammeter B
Voltmeter A
place the welding
status should this circuit breaker
______
status.
Stop Buttons
_____________________
4-4.
METERS
The meters are provided to monitor
welding operation. They are not intended for exact
current or voltage measurements. These meters are in
ternally connected to the output terminals. The
voltmeters will indicate the voltage at the output ter
minals, but not necessarily the actual voltage at the
welding arc (due to cable resistance, poor connections,
-
the
~f~~iiL~
B
A
DC Positive
A
etc.). The
output of
4-5. VOLT-AMPERE
B
DC
ammeters will indicate the current
the unit.
CURVE (Figure 4-2)
The
shows the maximum voltage and
amperage output capabilities of the welding power
volt-ampere
Negative
TB-079 824
1000 Models Illustrated
-
curve
source.
100
Figure 4-1. Front Panel
90
4-1. POWER CONTROL SWITCH
(Figure 4-1)
80
CAUTION:
Depressing
STOP button does
the
POWER
CONTROL
the
not remove power from all of
welding power source internal circuitry. Completely ter
minate all electrical power to the welding power source
by employing machinery lockout procedures before
attempting
any
inspection
or
work
on
the inside of the
unit. If the welding power source is connected to a
disconnect switch, padlock the switch in an open posi
don. If connected to a fuse box, remove the fuses and
padlock the cover in a closed position. If the unit is con
nected to a circuit breaker, or other disconnecting
device without locking facilities, attach a red tag to the
device to warn others that the circuit is being worked
70
~
60
-a
0
>
50
0
o
40
30
20
10
0
200
400
600
I
I
800
1000
I
I
1200
1400
1600
DC AMPERES
B-047 999
Figure 4-2. Volt-Ampere Curve
on.
RATED
Depressing the POWER CONTROL START button will
energize the welding power source placing the unit in a
ready-to-weld status. Depressing the POWER CON
TROL STOP button will shut the welding power source
down.
OUTPUT,
2000
MODEL
w
~
~
<
-s
1500
GPS-1500
0
4-2. OVERLOAD PROTECTION
Thermostat TP1,
located in the main transformer, is wired into the con
tactor W coil circuit. Should overheating occur, TP1
would open causing the contactor to drop out thereby
-
suspending
all
to cool before
operations. If TP1 opens,
resuming operations.
allow the unit
z
~
0
-a
uJ
GPS -10 00
1000
40
50
60
70
80
90 100
% DUTY CYCLE
Circuit breaker CB protects the welding power source
from excessive secondary current draw. Current
transformer Cli and CT2, located in the secondary of
the main transformer, sense the secondary current
draw. Should
ing
overloading occur, CB would open caus
drop out thereby suspending all
the contactor to
operations.
4-6.
DUTY
16
CYCLE
-
The
duty cycle of
a
welding
power source is the percentage of a ten minute period
that a welding power source can safely be operated at a
given output. This welding power source is rated at 100
percent duty cycle. This
source can
Page
8-079809
Figure 4-3. Duty Cycle Chart
be
means
safely operated
that the
at rated
welding
power
load continuous-
input conductors
the
CAUTION: Connect
the
to
_____
welding power
the three-phase
source
before
power
supply.
making connections
to
input conductors should be covered with an in
sulating material which conforms to local electrical stan
dards. Table 3-1 is provided only as a guide for selecting
the proper size input conductors and fuses.
The
Table 3-1. Input Conductor And Fuse Sizes
Input Conductor Size
L
-
AWG
Fuse Size In
Amperes
Model
230V
460V
575V
230V
460V
1000 Amperes
4/0 (2)
2 (8)
4 (8)
350
175
125
2/0 (4)
1/0 (6)
500
250
225
1500 Amperes 400 MCM (1/0)
575V
are based on National Electrical Code specifications
ompacities of insulated copper conductors, having a
with not more than three conductors in a
temperature rating of 75C,
input conductor sizes
for
lncluding
raceway
2-7/8 in. (73 mm) Lifting Eye
Figure 3-1. Overall Dimensions And
Mounting Hole Layout
ductor
of lift forks too short to ex
of the base will expose in
side
opposite
ternal components to damage should the tips of the lift
forks penetrate the bottom of the unit.
The
use
tend out of the
3-2. ELECTRICAL INPUT CONNECTIONS
A.
or
cable. Numbers in I I
Electrical Input Requirements
welding power source is designed to be operated
a three-phase, 60 Hertz, ac power supply which
has a line voltage rating that corresponds with one of
the electrical input voltages shown on the nameplate.
Consult the local electric utility if there is any question
This
from
are
equipment ground conductor sizes.
ground con
panel. This
accept standard conduit fittings. See Figure
Insert the three
Base
On most welding power sources a lifting device is pro
vided for moving the unit. However, if a fork lift vehicle
is used for lifting the unit, be sure that the lift forks are
long enough to extend completely under the base.
IMPORTANT
allowable
through
input conductors plus
the
access
hole
on
one
the
rear
hole will
3-2 for hole location and size.
Connect the three input conductors to the line terminals
the contactor. Connect the ground conductor to the
terminal labeled GROUND on the frame near the con
tactor. The remaining end of the ground conductor
should be connected to a proper ground. Use a groun
ding method that is acceptable to the local electrical in
on
spection authority.
CAUTION The ground terminal is connected to the
welding power source chassis and is for grounding pur
poses only. Do not connect a conductor from the
ground terminal to any one of the line terminals as this
will result in an electrically energized welding power
source
chassis.
2-5/8 In. (66.7 mm)
Die. Access Hole
Line Terminals
about the type of electrical system available at the in
stallation site or how proper connections to the welding
power
B.
source are
to be made.
Input Conductor Connections
1~LsIl~ It is
recommended that
a
line
disconnect
switch be installed in the input circuit to the welding
-
power source. This would
nient means to completely
from the
to
provide
a
safe and
conve
all electrical power
whenever it is necessary
remove
welding power source
perform any internal function
on
the unit.
making electrical input connec
we/ding power source, machinery lockout
procedures should be employed. If the connection is
CAUTION Before
TB-079 826
*1000 Model Illustrated
tions to the
to
be made from
a
line disconnect
switch, the switch
the open position. If the connec
tion is made from a fuse box, remove the fuses from the
box and padlock the cover in the closed position. If the
unit is connected to a circuit breaker;, or other discon
should be
necting
tag
C.
padlocked in
device without
locking facilities, attach
to the device to warn others that the circuit is
worked
Figure 3-2. Input Conductor Connections
on.
a
red
being
Matching
The
The Available
1.
Welding Power Source To
Input Voltage
For 1000 And 1500 Models
This unit is equipped with input voltage jumper links on
the primary terminal board which allow operation from
different line voltages. This unit is shipped with the
OM-267
Page 13
jumper links positioned for the highest voltage stated on
the nameplate. If the unit is to be operated from a lower
input voltage, remove right side panel and reposition
the jumper links to correspond to the available line
voltage (see input voltage label on or near primary ter
1
$0
I
II
I
I
IQI
L~J
minal board.
101
0
L_J
roi
VOLTAGE
INPUT
JUMPER LINK PLACEMENT can damage unit.
Position jumper links as shown on the input
voltage label located on or near primary terminal
C A~L.JTl~ON
________(INCORRECT
iOi
I
iQi
0
IOU
L.J
L_J
board.
I
r-
IMPORTANT: Store unused jumper links
across
ed terminals.
I
I
;
I
I
I
For 1500V Models
2.
0
10~
lol
l~i
L_J
0
link-
OL_
The primary of the main transformer has three selection
taps to allow compensation for a high or low incoming
line voltage. Selection is made at the primary terminal
board. The taps on the primary terminal board are mark
ed in percentage: +5%, 0, and -5%. If the line voltage
is high, the +5% tap would be used. If line voltage is
(437V)
Figure 3-3. Line Voltage Compensation Selection
Taps For 1500V Models
low, the -5% tap would be used.
CAUTION: Ensure that the unit is
IMPORTANT All three
jumper links
the
primary
same
percent
on
down before
making
completely
shut
any weld output connections.
_____________
terminal board must be connected for the
compensation.
A.
The welding power source is shipped from the factory
with the links set at zero percent compensation. Thus, if
line voltage is relatively close to the requirement, the
position of the jumper links need not to be changed.
Location
The POSITIVE and NEGATIVE weld output terminals
are located on the lower portion of the front panel.
B.
3-3. WELD OUTPUT CONNECTIONS (Figure
To obtain the full rated output from this unit, it is
3-4)
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
Welding Cables
-
Table 3-2.
Welding
Amperes, DC
If
welding cables
ordered with this unit, the
to ensure the best
welding performance:
Welding Cable Size
Length Of Cable (Copper)
Total
were not
steps listed should be followed
In Weld Circuit
100
150
200
250
300
350
400
4
4
2
2
2
1
1/0
2
2
2
1
1/0
2/0
200
1
1
1
1/0
2/0
3/0
1/0
3/0
4/0
250
1/0
1/0
3/0
2/0
4/0
2-2/0
2-2/0
2-2/0
2-3/0
2-3/0
2-2/0
2-3/0
3/0
2/0
3/0
4/0
3/0
4/0
2-2/0
100
150
-
50
300
2/0
350
3/0
1/0
2/0
3/0
400
3/0
3/0
500
4/0
4/0
4/0
2-2/0
2-3/0
600
4/0
4/0
2-2/0
2-3/0
2-4/0
4/0
2-3/0
2-3/0
2-4/0
500MCM
2-4/0
3/0
410
2-4/0
2-4/0
500MCM
1000MCM
1000MCM
1000MCM
700
4/0
4/0
2-3/0
2-4/0
500MCM
1000MCM
1000MCM
1000MCM
800
2-2/0
2-2/0
2-3/0
2-4/0
1000MCM
1000MCM
1000MCM
1000MCM
900
2-3/0
2-3/0
2-4/0
500MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000
2-3/0
2-3/0
2-4/0
I000MCM
I000MCM
I000MCM
1000MCM
1000MCM
SOOMCM
1000MCM
1000MCM
150O
500MCM
500MCM
1000MCM
1000MCM
1000MCM
1750
1000MCM
1000MCM
1000MCM
1000MCM
2000
1000MCM
1000MCM
1000MCM
1250
2-4/0
2-4/0
TA-052 764
NOTE:
A.
B.
5OFEETORLESS.
CABLE SIZE IS BASED ON DIRECT CURRENT
(DC). 100%
DUTY CYCLE AND EITHER A
4 VOLTS OR LESS DROP OR A CURRENT DENSITY OF NOT OVER 300 CIRCULAR MILS
PER AMP.
C.
Page 14
WELD CABLE INSULATION WITH A VOLTAGE RATING TO WITHSTAND THE OPENCIRCUIT VOLTAGE (OCV) OF THE WELDING POWER SOURCE MUST BE USED. WHILE
MOST WELDING POWER SOURCES HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
100 VOLTS. SOME WELDING POWER SOURCES OF SPECIAL DESIGN MAY HAVE HIGH
ER OPEN-CIRCUIT VOLTAGE.
ly. Figure 4-3 enables the operator to determine the safe
output of the welding power source at various duty
will cause
we/ding
cycles.
Exceeding the indicated duty cycle
overheating and thereby damage to the
IMPORTANT
______________
power
source.
SECTION 5- MAINTENANCE
5-1.
CAUTION
the
Depressing
_________
STOP button does not
welding power source
remove
CONTROL
power from all of the
POWER
internal
circuitry. Completely ter
we/ding power source
lockout procedures before
minate all electrical power to the
by employing machinery
attempting any inspection or work on the inside of the
unit. If the we/ding power source is connected to a
disconnect switch, padlock the switch in an open posi
tion. If connected to a fuse box, remove the fuses and
padlock the cover in the closed position. If the unit is
connected to a circuit breaker, or other disconnecting
device without locking facilities, attach a red tag to the
device to warn others that the circuit is being worked
FAN MOTOR
All models are equipped with an
exhaust fan and rely on forced draft for adequate cool
ing. The fan motor is manufactured with lifetime-
lubricated sealed ball
be
bearings and
no
attention should
required.
5-2. INTERNAL
out or
CLEANING
vacuuming of the
-
Occasional
blowing
dust and dirt from around the
internal components is recommended. This should be
periodically depending upon the location of the.
done
unit and the amount of dust and dirt in the atmosphere.
welding power source outer enclosure should be
The
removed and a clean, dry air stream or vacuum suction
should be used for this cleaning operation.
on.
5-3. CONTROL CIRCUIT PROTECTION
-
The
en
tire control circuit of the
Ik~I ~sflI V..hI
unit for
Periodically inspect the labels
~
legibility.
c/early readable
on this
All labels must be maintained in a
state and
replaced
when necessary.
See the Parts List for part number of labels.
SECTION 6
-
power
source
tected
by a 600 volt, 3
This fuse is located under the top
tor W. Should this fuse open, the
would completely shut down.
cover
beside contac
welding
power
soure
TROUBLESHOOTING
It is assumed that proper installation has been made, ac
to Section 3 of this manual, and that the
cording
welding
welding power source is pro
ampere, cartridge type fuse Fl.
has been functioning properly
until this trouble developed.
CAUTION: Hazardous voltages are present on the in
circuitry of the welding power source as long as
power is connected to the unit. Disconnect power
ternal
before
attempting any inspection or work on the inside
Troubleshooting of internal circuitry should
be performed by qualified personnel only.
of the unit.
conjunction with the circuit diagram
performing troubleshooting procedures. If the
trouble is not remedied after performing these pro
Use this chart in
while
cedures, the
nearest
Factory Authorized Service Sta
tion should be contacted. In all
malfunction, the manufacturers
should be strictly followed.
TROUBLE
No output.
cases
of
equipment
recommendations
The
following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding power source.
REMEDY
PROBABLE CAUSE
Thermostat TP1 open.
Allow unit
Replace
Circuit breaker CB open.
a
cooling period.
defective TP1.
Reset CB.
Replace defective CB.
Fuse Fl is blown.
*Replace defective Fl.
*lf it becomes necessary to replace any fuse in the welding power source,
type, and rating is used.
ensure
that
a
fuse of the proper size,
OM-267
Page
17
Circuit
Diagram No. 8-086 792
Figure 6-1. Circuit Diagram For 1000 Models
TEl
LO
460Y
L
ONLY
L
}RD.
500
AMPERE
SECTION
1000
POSITIVE
NEGATIVE
AMPERE
SECTION
A
POSITIVE
B
Circuit Diagram No. 8-088 038
Figure 6-2. Circuit Diagram
Page 18
For 1500A Models
L
460V
L
ONLY
J~RD.
Circuit
Figure
6-3. Circuit
Diagram
Diagram
No. B-088 039
For 1500V Models
OM-267
Page
19
December1982
FORM: OM-267D
Effective With Serial No. JC646118
PARTS
LIST
9
10 1112 9
\~U LII
13
____
14
15
16
Figure
OM-267 Page 1
A
Left Side View
Quantity
Item
No.
Dia.
Part
Mkgs.
No.
+
3
4
T2
W
4
W
5
7
7
Fl
*604 259
SRi ,11
SRi
VR1
SRi 1
Ru
VR
8
9
9
9
10
ii
12
13
14
15
15
16
-
Wi
Ri
7
059 572 COVER, opening exit cable
070 558 PANEL, rear
036 630 TRANSFORMER, controflO0 VA 115-230/460
048 597 CONTACTOR, 3 pole 110-120/208-240 (consisting of)
004 104 CONTACTOR, 3 pole 210 amp 600 V w/115 VAC (con
048599
004259
*048 600
*004 258
034 821
6
V1,2
Al ,2
Al
A2
PB!
PL1
CB
Shunt
Shunt
Description
1000
f
1500A
I
1500V
Left Side View
Figure A
1
2
Model
012 638
079 827
079
037
031
085
035
827
157
689
294
645
045 586
031 689
037 156
085
035
025
059
059
044
011
*027
027
027
034
059
059
079
072
059
601
601
059
038
602
602
038
295
645
638
118
118
104
636
629
631
628
945
563
616
388
425
567
841
842
566
909
249
219
032
1
1
1
1
1
1
1
1
1
1
1
1
sisting of)
.COIL,115/23OvoIts
1
1
.COIL,i20voltsac
KIT, point contact
KIT, point contact
INTERLOCK, contactor normally open
FUSE, cartridge 30 amp 600 volts
HOLDER, fuse cartridge 30 amp 600 volts
RECTIFIER, silicon diode (consisting of)
RECTIFIER, silicon diode (consisting of)
DIODE, rectifier 275 amp 250 volts straight polarity
CAPACITOR, ceramic 0.01 uf 500 volts
RESISTOR, WWfixed 5 watt 2000 ohm
-
1
1
1
.
1
-
.
-
-
.
1
1
1
1
1
1
1
1
1
2
12
6
1
1
12
6
12
6
.
1
1
6
6
1
6
6
.
.VARISTOR,8joulei50volts
RECTIFIER, silicon diode (consisting of)
.
CAPACITOR, ceramic 0.01 uf 500 volts
DIODE, rectifier275 amp2SO voltsstraight polarity
RESISTOR, WWfixed5watt2000ohm
VARISTOR, 8 joule 150 volts
METER, voltsdc0-l00 scale
METER, amp dc 50 MV 0-800 scale
METER, amp dc 50 MV 0-800 scale
METER, amp dc 50 MV 0-1 .5K scale
SWITCH, push button start stop 60 amp 110 volts
1
18
18
1
1
6
2
2
6
1
6
2
2
.
.
.
-
BULB, incandescent
-
-
slide base 120 volts
HOUSING, light-slide base 125 volts
LENS, light red clear
CIRCUIT BREAKER, manualreset2P5amp240voltsac
BAFFLE, air-top rectifier
BRACKET, mounting-terminal board
SHUNT, meter 50 MV 800 amp
SHUNT, meter 50 MV 1500 amp
TERMINAL, power output (consisting of)
-
-
.NUT,brass-hexjam5/8-1l
.
.
NUT, brass
-
hex full 5/8-i 1
TERMINAL BOARD
STUD, brass 5/8-il x 3
WASHER, flat SAE 5/8
.WASHER, lock-externaltooth5/8
.
-
.
.
BUS BAR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
16
8
16
16
8
2
8
8
8
4
8
2
8
8
8
2
8
8
8
4
4
eRecommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-267
Page
2
29
I
30
j
r
:~
31
32
I
I
Figure
Page
3
B
Right Side View
Quantity
Item
No.
Dia.
Part
Mkgs.
No.
Figure B
27
Model
Description
1000
Right Side View
009
070
030
604
083
031
1
1
1
1
1
1
1
1
C18
TEl
059 555 TERMINAL, primary
1
1
1
1
12
12
SR12
Cl 7
-
-
TEl
(consisting of)
044098 TERMINAL, primary (consisting of)
038 897
TERMINAL BOARD, primary
038980
TERMINAL BOARD, primary
602221
WASHER, lock internal tooth 3/8
010910
WASHER, flat SAE 3/8
601 837
NUT, brass hex 3/8-16
-
-
-
TE2
Ri
30
038 621
038 804
038 898
038 620
BLOCK, terminal 30 amp 4 pole
STUD, brass3/8-16x2-1/2
LINK, terminal connecting
LINK, jumper terminal block 30
-
-
FM
083 640 RESISTOR. qrid
083 637 WIN DTUNNEL, 20 inch
014425 BAR, support windtunnel
33
Ti
Ti
11
35
CT1,2
35 CT1,2
TP1
032616
032 605
059 983
070 644
079718
070 897
044 147
**79 719
**059 576
**079 529
**070 724
**045 971
080 075
036 612
026 181
071 624
070 555
010 014
026 627
1
1
1
2
1
1
1
12
12
18
36
36
54
12
6
12
18
3
1
2
-
1
2
BASE
2
1
TRANSFORMER,
TRANSFORMER,
TRANSFORMER,
power
power
power
-
-
-
(consisting of)
main (consisting of)
main (consisting ol)
COIL, primary/secondary
COIL, primary/secondary
COIL, primary/secondary
TRANSFORMER, current 300/5
TRANSFORMER, current 800/5
THERMOSTAT, normally closed (located in coils)
PANEL, side
COVER, top
1
1
1
1
6
6
2
2
2
6
6
2
2
1
1
6
1
2
cover
1
6
CLAMP
-
2
1
1
2
1
main
TRANSFORMER SUBASSEMBLY
TRANSFORMER SUBASSEMBLY
eye
18
1
BLADE, fan 60 Hz 20 inch 3 wing 21 deg
MOTOR, 1/4hp230voltsacl625rpm
BUS BAR, jumper secondary
GASKET, lifting
1
amp
-
34
1500V
1
R12
34
34
I
1
Ru
31
32
1500A
139 VISOR, front-top
556 PANEL, front
691 RESISTOR, carbon 1 watt 4700 ohm
288 RESISTOR, WW fixed 10 watt 2 ohm
719 RECTIFIER, silicon control
640 CAPACITOR, electrolytic 500 uf 200 volts dc
601 375 RING, mounting capacitor
031 683 CAPACITOR, paper oil 0.5 uf 200 volts dc
28
29
29
I
2
1
*Replace
at Factory or Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERiNG REPLACEMENT PARTS.
OM-267 Page 4
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