Miller | JB475790 | Owner Manual | Miller RAMROD User manual

Miller RAMROD User manual
July 1981
FORM: OM-268C
Effective With Serial No. JB475790
MODEL
Ramrod
OWNERS
ITUIIIER
MANUAL
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.
~,
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LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
LIMITED
WARRANTY-Subject
to
the terms and conditions
As
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 accessories or other items manufactured by others. Such
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.
a
matter of
submitted
by
the
general policy only, Miller may honor claims
original user within the foregoing periods.
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
Miller in appropriate cases, 13)
replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
return of the goods at Customers risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
or, where authorized in
the reasonable cost of
.
Except
as specified below, Millers
warranty does not apply
components having normal useful life of less than one Ii)
year, such as spot welder tips, relay and contactor points,
writing by
repair
or
to
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not
result from defect in workmanship
or
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
material.
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
?
TO
ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX~
1
CLUDED AND DISCLAIMED BY MILLER.
1.
2.
Arc
welders,
power sources and components
.
.
Original
3.
main power rectifiers
1 year onlyl
llabor
All welding guns and feeder/guns
4.
All other Millermatic Feeders
5.
Replacement
6.
Batteries
1 year
3 years
EXCEPT
)
or
repair parts, exclusive of
AS
90 days
1 year
labor
.
EXPRESSLY
MILLER
WRITING,
-
ULTIMATE
PROVIDED
PRODUCTS
PURCHASE
BY
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
60 days
EXPERIENCED
6 months
WELDING
IN
THE
EQUIPMENT
USE
AND
CONSUMER USE. MILLER
provided that Miller is notified in writing within thirty 1301 days
TO,
of the date of such failure.
MILLERS
AND
NO
RESELLER
AND
NOT
MAINTENANCE
FOR
CONSUMERS
OF
OR
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
TO
EXTEND
WARRANTIES TO, ANY CONSUMER.
4
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j
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TABLE OF CONTENTS
Section No~
SECTION 1
1
1
1
1
-
-
-
-
1.
2
2
-
-
-
Introduction
General Precautions
1
3.
Arc
7
3
3
-
-
-
-
10
1.
General Information And Safety
12
2.
Receiving-Handling
Description
12
3.
12
INSTALLATION
-
1.
Location
12
Weld
13
13
3.
4.
Output Connections
Remote Amperage Control Connection
Electrical Input Connections
1.
Power Switch
4-4.
Amperage Adjustment Control
Volt-Ampere Curves
DutyCycleChart
4
Control Circuit Overload Breaker
-
-
4-3.
-
5.
SECTION 5
5
5
-
-
1.
2.
SECTION 6
6-1.
6
2.
-
6
-
3.
SECTION 7
13
OPERATOR CONTROLS
-
2.
4
-
-
2.
SECTION 4
4
1
Welding
Standards Booklet Index
INTRODUCTION
4.
SECTION 3
3
3
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
2.
SECTION 2
2
Page No.
-
15
15
16
SEQUENCE OF OPERATION
Shielded Metal-Arc
Shutting Down
-
15
15
& Switch
Welding (SMAW)
16
16
MAINTENANCE
Fan Motor
16
Internal Cleaning
Weld Cables
16
-
16
TROUBLESHOOTING
7-1.
General
7 -2.
Troubleshooting Chart
17
17
.~
SECTION 1
SECTION 1
-
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
REGLES DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1. INTRODUCTION
Contrairement a lappren
tissage de Ia vie, Iapprentissage de Ia sØcuritØ par ex
pØrience personnelle, comme lenfant qui touche un
poŒlo chaud, est dangereux, imprudent et inutile.
Instruisez-vous donc de IexpØrience 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, opera
tion, and servicing practices. Acidents 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 progres ot IexpØrionce dans co domaine
ont dØvoloppØ un materiel fiable et des mØthodes de
sØcuritØ pour Iinstallation, le fonctionnement et lentro
tien. Des accidents se produisent Iorsquo lo materiel est
inadØquatement utilisØ ou ontreteflu. La raison do ces
mØthodes do sØcuritØ pout no pas Œtre toujours donnØe.
Certaines sont fondØos sur le Sons commun, dautres
domandoront a Otre expliquees par des livres techni
ques. II est plus sage do suivre les rŁgles.
1-1. INTRODUCTION
-
rules.
-
soudage
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
dessayor dinstaller, do faire fonctionner ou de rØparer
Iappareil. Pour votre sØcuritØ personnelle et cello
dautrui, conformez-vous a ces rŁgles 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.
Manquer dobserver cos mØthodes do sØcuritØ pourrait
entrainer des blessures graves ou memo Ia mort. Quand
Ia sØcuritØ devient une habitude, le materiel pout alors
Œtre utilisØ on touto confiance.
These safe practices are divided into two Sections:
1
General Precautions, common to arc welding and
cutting; and 2 Arc Welding (and Cutting) (only).
Ces mØthodes de sØcuritØ sont divisØes en deux sec
tions:
1
Precautions gØnØrales, communes au
soudage et au coupago a larc, et 2 Soudage a larc
Reference standards: Published Standards
Normes de rØfØrenco: Des publications dos normes
amØricainos do sØcuritØ sont aussi a votro disposition
modes opØratoires plus complets quo
pour dautres
ceux du present manuel. ElIes sont donnØes dans Iln
dex des Normes do ces rŁgles do sØcuritØ. ANSI Z49-1
est Ia plus complete.
-
Lisez et comprenoz
ces
mØthdes
do sØcuritØ avant
dinstructions.
-
-
-
also available for additional and more
cedures than those given in this manual.
on safety are
complete pro
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 loal
inspection requirements also provide
ment installation, use, and service.
a
basis for
equip
(ot coupage) (uniquement).
Les codes do IACNOR,
los codes provinciaux et
municipaux donnent aussi los oxigencos pour uno in
stallation,
1-2.
1-2. GENERAL PRECAUTIONS
A.
Burn Prevention
A.
une
utilisation et
un
entretien sQrs.
PRECAUTIONS GENERALES
Prevention des brUlures
Portez des vŒtements do
protection, des gants a crispin
cuir (ou amianto), un casque ot des chaussures de
sØcuritØ. Boutonnez le col do votre chemise ot los pattes
do vos pochos, ot portez des pantalons sans rovers pour
Øviter que des Øtincelles et du laitier no sy introduisent.
en
protective clothing leather (or asbestos)
gauntlet gloves, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear
-
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Portez un masque avec lunottes do sØcuritØ ou avec
Øcrans latØ-rux do protection, des lunettes filtrantes ou
des couvre-lentilles (protØgØs par un verre clair). Pour le
soudage ou le coupago (et le burinage), il est
OBLIGATOIRE de protØger sos yeux contre lenergie de
rayonnement 01 los Øclats do metal. Romplacez le verre
protecteur IorsquiI
projections. Voir
est
brisØ, piquØ
ou
quil
a
recu des
1 .3A.2.
Evitez do porter des habits imprØgnØs dhuile
Une Øtincelle pourrait les enflammer.
ou
de
graisse.
Ne manipulez jamais sans gants un metal chaud tel quo
des chutes dØlectrode et des piŁces Ł souder.
OM-268
Page
1
Medical first aid and eye treatment. First aid facilities
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
anda
burns.
Ear
-
plugs should be
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
mont les brQlures -des yeux et do Ia peau.
Portoz dos bouche-oroillos lorsque vous travailloz au
ou dans un espace restreint. Portez un casque
dautres personnes travaillent au plafond.
in
worn when working on overhead or
a confined space. A hard hat should be worn when
others work overhead.
plafond
lorsque
Flammable hair preparations should not be used by per
employer des preparations inflammables pour lours
Les personnes dovant soudor
sonS
intending
to weld or cut.
couper
no
doivent pas
chevoux.
Toxic Fume Prevention
B.
ou
B.
Adequate ventilation. 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 Standard Z49.1 listed 1 in Standards
Prevention des gax
toxiques
Ventilation adequate: Los gaz, los vapeurs, Ia chaleur,
un enrichissomont ou un manque doxygŁne
peuvent
ontralnor un malaise, une maladie ou memo Ia mort.
RemØdiez-y par Ia ventilation dØcrito dans Ia Norme AN
SI Z49.1 paragraphe 1 de lIndex des Normes. NE yen
tilez JAMAIS a loxygŁne.
index. NEVER ventilate with oxygen.
En soudant
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.
Lead
-
-,
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
confined space only while it is
tilated and, if necessary, while wearing an
a
being ven
air-supplied
mercure
et
ou en
coupant, los plomb, cadmium, zinc,
beryllium
ou
autres matØriaux semblablos
pouvent crØer des concentrations nocivos do gaz toxi
ques. On doit avoir recours a une ventilation aspirante
adequate du local, ou alors toute personne sur los Iieux,
do memo quo le soudeur, doit porter un masque a ad
duction dair.
On doit employer los deux pour le
beryllium.
Les mØtaux enrobØs
ou
tant des gaz
doivent pas Œtre chauffØs a
soit ate do Ia surface a
ne soit bien vontilØ, ou quo le
masque a adduction dair.
toxiques
lenrobage
moms
quo
travaillor, que le local
soudour
flO
Porte
un
composes de matØriaux Ømet
no
no
Ne travaillez dans un espace rostreint quo siI est bien
ventilØ ot, si nØcessaire, portez un masque a adduction
dair.
respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a confined space.
confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
Leaving
left open. Check to be
re-entering it.
sure
that the space is safe before
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 trichloroethyleno and per
chloroethylene vapors to form phosgene. DO NOT
WELD
the
or cut
welding
where solvent vapors
can
be drawn into
cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
minute amounts
of trichloroethylene or per
chloroothylene.
C.
or
Fire and
Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
Page2
On doit Øvitor los fuites do gaz dans un espaco rostreint.
Los fuites do gaz on grande quantitØ pouvont
transformer dangoreusement Ia concentration dox
ygene. Namonoz pas de bouteillos do gaz dans un
espace restreint.
En quittant un espace restreint, FERMEZ lo robinet
dalimentation do gaz de Ia bout&Ile. Ainsi on pourra
rontrer en toute sØcuritØ dans Ia piŁce, memo si los
robinots aval
ont ØtØ ouvorts par accident, ou si on los
a laissØs ouvorts.
Les vapeurs de dissolvants chiorØs peuvent Œtro dØcom
par Ia chaleur do larc (ou de Ia flamme) et
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant los poumons et los yeux. LØnergio
posØes
ultra-violotte de Iarc pout aussi dØcomposer es vapeurs
do trichloroØthyleno et de perchloroethylŁne pour
former du phosgene. NE SOUDEZ PAS ou no coupez
pas dans des endroits o los vapeurs do dissolvants pou
vent Łtre attirØes dans IatmosphŁre do soudago ou do
coupage et o IØnorgie do rayonnoment pout pØnetror
dans dos atmospheres contenant des quantitØs memo
minuscules do
trichloroØthylene ou do per
chloroethyleno.
C.
Prevention des Incendies et des explosions
Los causes dincondio
ot dexplosion
sont los com
bustibles attoints par Iarc, Ia flamme, los Øtincelles, le
laitier chaud ou los matØriaux chauffØs, le mauvais
material; misuse of compressed gases and cylinders;
and short circuits.
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.
BE AWARE THAT
To prevent fires and
explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
causeshort circuits.
emploi des
comprimØs
gaz
Sachez que les Øclats dØtincelles ou Ia chute du laitier
dans las fissures, le long des
peuvent sinfiltrer
tuyauteries, par lea fanŒtres et lea portes at par les
couvertures des murs ou du aol, sans qua Ia soudeur
portent des lunottes ne los voie. Lee Øtincelles et los
35 pieds.
scones peuvent voler jusqu
Pour prØvenir las incendies at los explosions: Veillez a ce
que votre appareil soit propre et en Otat do marche,
dØnuØ dhuile at do graisso, et do particules do metal sur
los piŁces Ølectriques qui pourraient entramnor des
courts-circuits.
trouvent a proximitØ, no soudez
Si
possible, deplacez votre travail
coupez pas.
pea,
loin des combustibles. Evitez lea ateliers do peinture au
Si des combustibles
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
et des boutoilles ainsi que los
courts-circuits.
se
ne
Avoid
paint spray rooms, dip tanks, storage areas, von
tilators. If the work cannot be moved, move com
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant covers or shields.
pistolet, los cuves dimmersion, los entrepts, los von
tilateurs. Si cola nast pas possible, placoz los com
bustibles a au moms 35 piods des Øtincellos et do Ia
chaleur et protegoz-Ies des Øtincellos avec des couvor
tures ou des Øcrans protecteurs adequate, bien ajustØs
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.
On
Fire watcher must be standing by with suitable fire ex
tinguishing equipment during and for some time after
welding
or
cutting
ignifugØs.
at
dolt pea souder (ou cou per) Ia ctØ oppose. dos
touchant los combustibles. Los murs, plafonds et
planchers proches du travail doivont Øtre protØgØs par
dos couvortures ou Øcrans protecteurs ignifuges.
ne
murs
Un surveillant dolt so tenir a proximitØ avec un matØrial
do lutte contre lincendie adØquat, pendant at quelque
temps aprŁs Ia soudage ou le coupage Si:
if:
a.
appreciable combustibles (including building
a.
construction)
are
within 35 feet
b.
appreciable combustibles are further than 35
feet but can be ignited by sparks
openings (concealed or visible) in floors or
b.
c.
c.
within 35 feet may expose com
bustibles to sparks
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
walls
d.
permit should be obtained before operation to
supervisors approval that adequate precautions
d.
quantitØs apprØciables do combustibles
(y compris une construction en chantier) so
trouvont a moms do 35 pieds.
Des quantitØs apprØciables do combustibles
sont a plus do 35 pieds mais peuvent Łtro
Des
onflammØes par des Øtincelles.
Des ouvertures (cachØes ou visibles) sur les
planchors ou los murs a moms de 35 pieds
peuvent exposer des combustibles aux
Øtincelles.
Les combustibles adjaconts aux murs,
plafonds, toits ou cloisons mØtalliques peu
vent Œtre enflammØs par une chaleur rayon
nante ou transmise.
Hot work
ensure
have been taken.
done, check that
glowing embers, and flames.
After work is
area
is free of sparks,
An empty container thØt-held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 3 in Standards index.
Avant do commoncer, avisoz Ia contremaltro pour quil
sassure quo los precautions adØquates soient prisos.
Une fois le travail terminØ, vØrifiez quil ny ait pea
ou do flammes dana Ia
local.
dOtincollos, de cendres ardentes
On
no
ayant
doit
jamais souder
contenu dos
ni couper
sur
un
recipient
pouvant produire
toxiques a Ia chauffe, Ł
combustibles,
ou
des vapeurs inflammables ou
moms que le recipient nait ØtØ lavØ au prØalablo, com
ma dØcrit dana Ia Norma AWS A6.O, figurant au
paragraphe 3 de llndex des Normes.
Cola comprend:
un
nettoyago a fond a Ia vapeur.ou
au
Thisincludes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com
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.
diasolvant ou eau salon Ia
solubilitØ du combustible) suivi dune purge at dune in
jection dazote ou do gaz carbonique, en utilisant un
equipement do protection comma recommandØ dana
lA6-O. LatmosphŁre inerto peut Otre remplacØe par un
niveau deau arrivant au-dessous du travail a effectuer.
A container with unknown contents Should be cleaned
(see paragraph above). Do NOT depend on sense of
Vous devez lever un recipient dont Ia nature do contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS a Iodorat ou a a vue pour dire- si lon pout le
souder ou Ia couper en toute sØcuritØ.
smell
or
sight
to determine if it is safe to weld dr cut.
caustique (ou
un
lavage
avec
OM-268
Page3
Hollow
castings or containers must be vented
welding or cutting. They can explode.
before
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
event
los
piŁces
Vous devez
pratiquer
pients creux
exploser.
avant de les souder ou couper: ils
un
sur
ou
rØci
peuvent
Atmospheres explosives: Ne soudez ni ne coupez
jamais dana des lioux oCi Iair peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammablos (tels
quo Iessence).
D.
Compressed Gas Equipment
D.
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.
Precautions genØrales: Suivez les precautions de ce
et cellos dØcrites a Ia Norme CGA P-i (PrØcau
tions do sØcuritØ pour Ia manipulation de gaz comprimØs
en bouteilles), paragraphe 6 do llndex des Normes.
manuel,
1.
1.
Pressure
comprlmØ
Gaz
DØtendeurs do
pression
Regulators
La soupapo do sOrotØ dun
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream
tion with
equipment. Provide such protec
one or more
relief devices.
Never connect a regulator to
other than that for which the
cylinder containing gas
regulator was designed.
a
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
if gas leaks externally.
if delivery pressure continues to rise
Excessive Creep
with downstream valve closed.
Faulty Gauge if gauge pointer does not move off stop
Leaks
No montez
jamais
un
dØtendeur sur une boutoillo canto
celui pour lequel le dØtendeura
nant un gaz different de
ØtØ concu.
Enlovoz immØdiatement un dØtendour dØfectueux pour
formez le robinet do Ia
lo faire rØparer (dabord,
bouteille). Los symptmos suivants dØnotent Ia dØfec
tuositØ du dØtondeur:
-
-
-
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,
whore special techniques and tools are used by trained
personnel.
2.
dØtendeur est destinØe a pro
tØger seulement le dØtendeur de Ia surpression. Ella na
pas pour but do protØger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes do retenue concuos
spØcialement pour cette fonction.
Cylinders
Fuites Si le gaz fuit extØrieuroment.
Ascension excessive si Ia pression de debit continue a
monter, Ia robinet du chalumoau Øtant fermØ.
ManomŁtro dØfectueux Si laiguille du manomŁtre no
sØcarte pas do Ia goupillo do butØo Iors do Ia mise en
pression, ou no roviont pas sur Ia goupille aprŁs lØchap
pement do Ia prossion.
-
-
-
Reparation. NESSAYEZ PAS do reparor vous-mØmos.
Envoyez los dØtendeurs dØfectueux a rØparer aux
ateliers do reparation agrØØs du fabricant, oCi des techni
ques at des outils spØciaux sont utilisØs par un person
nel formØ.
Cylinders must be handled carefully to prevent leaks
damage to their walls, valves, or safety devices:
2.
Bouteilles
and
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.)
Los boutoilles doivent Œtro manipulees avec soin pour
prØvenir Ios.fuites ou degØts a louts parois, robinots ou
systemos do sCiretØ. Evitez quun circuit eloctrique soft
en contact avoc los boutoilles, y compris los rails do con
tact, los fils electriquos ou los circuits do soudago. Cola
pourrait crØor dos arcs courts-circuits pouvant ontrainer
ICC
dos accidents graves (Voir 1 .3C.).
-
DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
or
handled.
Identifying gas content Use only cylinders with name
of gas marked on them; do not rely on color to identify
gas content. Notify supplier if unmarked. NEVER
DEFACE or alter name, number, or other markings on a
cylinder. It is illegal
and hazardous.
doit portor los inscriptions ICC ou
DOT. Cest un gage do sØcuritO pourvu quo Ia bouteille
soit bien manipulØo.
Chaque bouteille
Identification du gaz: Nutilisez quo los bouteillos mdi
naturo du gaz; no vous fioz pas a Ia couleur
pour reconnaItro Ia nature du gaz. Adressoz-vous a
votro fournisseur si cola nost pas indiquØ.
quant Ia
NEFFACEZ
modifiez
ou
no
numØros ou autros indications
est
-~
Page4 Y
illegal
at
dangoroux.
los noms,
bouteille. Cela
JAMAIS
sur uno
Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited
use.
Never
use a
cylinder
or
other than its intended use, NEVER
roller.
Locate
or secure
cylinders
so
they
its contents for
as
a
support
or
Vides: Maintenez les robinets fermØs, replacez bien es
chapeaux; inscrivez Vides.; sØparez-les des Pleines
et retournez-les rapidement.
Emploi interdit: Nutilisez
que pour
me
cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
where they may be struck.
ce
support
a
une bouteille ou son contenu
elle est destinØo, mais JAMAIS cornrou~eau.
quoi
ou
Placez les bouteilles pour quelles ne tombent
quun dØtendeur (et un boyau) est monte
placez les ou attachez-les debout.
Passages
et lieux de travail. Enlevez
es
sur
elles,
bouteilles dun
pourrait les frapper.
areas
endroit o
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.
Transport des bouteilles. Avec une grue, utilisez un sup
plate-forme ou un cadre. NE
port fiable tel quune
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
cylinder valve that can not be opened by hand. Notify
a
supplier.
your
Mixing
gases. Never try to mix any gases in
cylinder.
a
Never refill any cylinder.
SOULEVEZ PAS des bouteilles du sol par leur robinet
chapeau, ou avec des chalnes, Ølingues ou aimants.
ou
bouteilles a une chaleur excessive,
laitier et aux flammes, etc., pouvant
leur rupture. Le contºnant ne doit jamais
causer
dØpasser 55C. Refroidissez en pulvØrisant de leau si
nOcessaire.
NEXPOSEZ
aux
PAS
Øtincelles,
es
au
les bouteilles et particuliŁrement les soupapes
los chocs, les chutes, les chutes dobjets et Ia
temperature. Remettez bien les chapeaux lorsque vous
dØplacez es bouteilles.
ProtØgez
contre
Robinet coincØ. NUTILISEZ PAS un marteau ou une
clØ mØtallique pour ouvrir un robinet de bouteille que
Ion ne peut pas ouvrir a Ia main. Avisez votre four
nisseur.
MØlange de
dans
Cylinder fittings should
lon
pas. Lors
never
be modified
une
gaz. Nessayez
bouteille.
jamais do mØlanger des
gaz
exchang
or
Ne rechargez jamais une bouteille. Les ØlØments de Ia
bouteille ne doivent jamais Œtre modifies ou remplacØs.
ed.
3.
Hose
3.
Prohibited
use.
Never
use
hose other than that
for the
specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and blaÆk for inert
gases.
Use ferrules or clamps designed for the hose (not or
wire or other substitute) as a binding to connect
hoses to fittings.
dinary
No copper
tings
to
Boyau
designed
tubing splices. Use only standard brass fit
splice hose.
Avoid
long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Utilisation interdite. Nutilisez
jamais
un
boyau
autre
que celui appropriØ au gaz indiquØ. La rŁgle gØnØrale
didentification est: rouge pour les gaz combustibles,
vert pour IoxygŁne, et noir pour los gaz inertes.
Utilisez des bagues ou colliers appropriØs au boyau (et
non du fil ordinaire ou autre substitUtion) pour brancher
les
boyaux a lappareillage.
Nutilisez pas des raccords en cuivre. Nutilisez que des
accessoires standard en laiton pour raccorder un boyau.
Utilisez une petite longueur do boyau. Cola Øvitera les
noeuds et lusure prØmaturØe. Suspendez le boyau au-.
dessus du sol pour Øviter quil no soit ØcrasØ, piØtinØ ou
endommage.
Coil
excess
hose to prevent kinks and
tangles.
by
Enroulez le surplus do boyau pour Øviter los noeuds et
emmŁlements. Evitez que le boyau ne soit endommagØ
par des tranchants, Øtincelles, laitier et flamme nue.
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
VØrifiez rØgulierement los fuites, Iusure
et
es rac
cordements lches.
Plongez le boyau sous pression
dans de leau; los bulbs indiqueront los fuites.
Protect hose from
sparks, slag, and
damage by sharp edges,
and
open flame.
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT use tape.
area out
and splic
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØsif.
OM-268 Page 5
4.
4.
Proper Connections
Branchements corrects
Avant de brancher lo dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteille des impuretes qui peuvent
obstruer los orifices et endommagor es sieges. Sauf
ouvrez momentanØment le robinet,
pour lhydrogŁne,
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
en
with
flammables.
clean lintless cloth.
a
eloignant
Ia sortie des personnes et des sources in
Essuyez avec un tissu propre et non
graisseux.
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
gases to
or
gas
Tighten
a
cylinder containing any other gas.
connections. When
assembling threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting
wrench.
le dØtendeur a Ia bouteille. Avant de bran
que Ia marque du dØtendeur et Ia descrip
tion de Ia bouteillo concordent, et que lorifice dentrØe
du dØtendeur et Iorifice de sortie do Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dOtondour
concu pour un gaz special (ou des gaz spØciaux) a une
Appareillez
cher, vØrifioz
bouteillo contenant dautres
gaz.
Serrez los branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges oU
cest nØcessaire. Serrez. Si los branchements perdent,
dØmontez-les, nettoyez et resserez avec une clef adØ
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
Adaptateurs. Placez, si besoin est,
and LEFT HAND threads.
(en
Regulator outlet (or hose) connections may be iden
by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
quate.
vonte chez votre
fournisseur)
dØtendeur. Avec deux clefs,
DROITE et A GAUCHE.
un
entre
serrez
adaptateur CGA
Ia bouteille et le
ladaptateur filetØA
tified
5.
Pressurizing Steps:
On pout reconnaltro los branchements do sortie du
dØtondeur (ou boyau) a laide du filetage a droite pour
loxygŁne et a gauche (idontifiØ par un Øcrou cannelØ)
pour los gaz combustibles.
Drain
regulator of residual gas through suitable vent
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.
5.
DØmarches do mise
en
pression
before
Stand to side of regulator while
opening cylinder
valve.
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
creases
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
User
Tenez-vous latØralement au dØtendeur on ouvrant lo
robinot de Ia bouteille. Ouvrez-le lentoment pour quo Ia
pression du dØtendeur monte progiessivoment. Lorsquo
le manomŁtre est mis sous pression (indique le max
imum) le robinet do Ia bouteille do gaz inerte ou dox
ygŁne devra Otre ouvort a fond pour assurer IØtanchØitØ
et celui do Ia boutoille do gaz combustible ouvert de
moms dun tour pour pouvoir le reformer rapidement en
cas
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.
Purgez le dØtendour de rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet do canalisation) en serrant Ia vis
do reglage (dans le sons des aiguilles dune montro).
Cette operation permet au siege de haute pression de
souvrir a Ia miso on pression, supprimant ainsi toute
surchaufte do compression. Maintenoz Ia vis do rØglage
des dØtondeurs a simple dØtente lØgŁrement ongagØe.
Avant douvrir le robinet do Ia bouteille, assuroz-vous
quo los boyaux sont branches et quo les soupapes aval
sont fermØos.
Responsibilities
Remove leaky or defective equipment from Service im
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor & Gamble
durgence.
RØfØrez-vous
votre
tableaux de pression (distribuØs par
prossion sOr et efficace
fuites a Ia premiere miso
brossez
un
sur
on
rØglage
recommandØ
de
los dØtondeurs. VØrifiez los
pression puis rØguliŁrement,
solution savonneuse (un bouchon
dlvory Liquid* ou semblable par gallon doau). Los
bulles indiquont une fuito. Enlevez loau savonneuse
aprŁs oxamen; lo savon sec ost inflammable.
E.
avoc
une
ResponsabilitØs de lusager
Otez immØdiatoment les parties percØes ou dØfec
ResponsabilitØs do lUsager du manuel
do lappareil.
tueuses. Voir les
*Marque
Page 6
aux
fournisseur) pour
de Commerce do Proctor & Gamble
F.
Leaving Equipment Unattended
F.
Close gas supply at
G.
source
G.
Rope Staging-Support
1-3. ARC WELDING
-
Comply
with
laissØ
Fermez lalimentation
and drain gas.
Rope staging-support should not be used for welding
cutting operation; rope may burn.
Appareil
or
precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
is a safe process, but a careless operator invites trouble.
equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
The
fumes rise, ultraviolet and infrared energy radiates,
weidments are hot, and compressed gases may be us
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
sans
surveillance
de gaz a Ia
source et
purgez.
Liens et supports temporalres
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
A
1-3. SOUDAGE
LARC
-
Conformez-vous
aux
precautions des paragraphes 1.1 et 1.2 de cette section.
bien exØcutØ est sOr, mais un
Le soudage a larc
soudeur negligent est un danger. Le poste de soudage
transporte des
courants ØlevØs sous de fortes tensions.
Les Øtincelles volent, les
ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrui contre
las accidents. Les precautions sont dØcrites ici et dans
las normes donnØes dans llndex.
Larc
est trŁs vif et chaud.
vapeurs montent,
lØnergie
Burn Protection
A.
A.
Comply with precautions
Protection contre lee brOlures
in 1-2.
welding arc is intense and visibly bright. Its radia
can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
The
tion
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
GET BURNED; COMPLY WITH PRECAU
DONT
Conformez-vous aux precautions du paragraphe 1.2.
Larc de soudage est intense et visiblernent vif. Son
rayonnernent peut blesser les yeux, traverser les habits
lØgers, se rØflØchir sur les surfaces claires, et brOler Ia
peau et les yeux. Les brQlures de Ia peau ressemblent a
un gros coup de soleil. Celles darcs sous gaz protecteur
sont plus graves et plus douloureuses. NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
TION S.
1.
Protective
1.
long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and f ireresistant leggings. Avoid outergarments of untreated
Wear
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets
to
VØtements de
prevent entry of
sparks.
Portez des vŒtements a manches longues (surtout pour
larc 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. De
prØfØrence ne portez pas de vŒtements en coton non
traitØ.
en
Protection de Ia peau. Portez des vOtements Øpais
foncØs. Boutonnez Ie col pour protØger Ia poitrine et le
cou, et boutonnez les poches pourprØvenir linfiltration
dØtincelles.
Eye and Head Protection
2.
2.
Protect eyes from exposure to
electric arc without protection.
arc.
NEVER look at
Protection des yeux et de Ia tŒte
an
Evitez que
JAMAIS
Welding helmet
no.
over
protection
Clothing
12
or
shield
or
containing
a
Protect filter
plate
with
a
arc.
clear
yeux soient
Ølectrique
exposØs a larc. NE regardez
sans protection.
filter
denser must be used when
face before striking
plate shade
welding. Place
vos
un arc
vous soudez, portez un Øcran ou masque avec
filtrantteintØ N 12 ou plus foncØ. Mettez-Ie sur le
visage avant damorcer larc.
Lorsque
verre
cover
plate.
ProtØgez le
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
IMMEDIATELY.
loose filter plates must be replaced
Replace clear cover plate when
broken, pitted,
spattered.
Cracked, broken,
or
or
verre filtrant dun
couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
mont peut sinfiltrer et causer des brOlures.
Los verres~filtrants fendus, brisØs ou lŒches doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez un couvre
verre brisØ, piquØ ou tachØ par des projections.
OM-268
Page
7
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes
(particularly
a
high intensity gas-shielded arc)
retinal burn that may leave
in the field of vision.
cause a
area
a
can
permanent dark
Vous devez portez des lunettes a Øcrans latØraux sous Ia
masque pour protØger les yeux dans le cas o le masque
de
ne serait pas abaissØ sur le visage avant lamorage
larc. Regarder momentanØment un arc sans protection
(pnincipalement un arc en atmosphere inerte a haute in
tensitØ) peut brQler Ia rØtine et laisser un point sombre
permanent dans Ia champ de vision.
Protection du personnel a proximitØ
3.
3.
Protection of
welding
Enclosed
Nearby
Personnel
For
area.
production welding,
Local de
a
enclosed bay is best. In open areas,
operation with Iow-reflective, noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
separate
room or
the
surround
Viewing
the weld. Provide face shields for all persons
looking directly at the weld.
who will be
Others working in
flash
area.
See that all persons
Before starting to weld, make
bay doors are closed.
B.
are
wearing
goggles.
sure
that
screen
flaps
tion, il
soudage fermØ. Pour
Ia
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 circular librement, particuliŁrement
au niveau du sol.
Donnez des masques aux personnes
directement Ia soudure.
qui regarderont
Autres personnes travaillant sur les lieux. VeillØz a ce
que toutes les personnes portent les lunettes de protec
tion.
or
Avant dattaquer
Ia soudure, assurez-vous
rebords dØcran ou les portes soient fermØs.
que
les
Toxic Fume Prevention
B.
Prevention des gaz toxiques
Comply with precautions in 1-2B.
Suivez las precautions du
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C.
Fire and
paragraphe 1.2B. LØchappe
gØnØratrice doit Otre ventilØ a lair
ment du moteur de Ia
extØrieur.
Explosion Prevention
C.
Loxyde de carbone peut
tuer.
Prevention des incendies et des explosions
Comply with precautions in 1-2C.
rated
Equipments
welding equipment.
overload arc
capacity.
It may overheat cables and cause a
Do
not
Suivez las precautions 1.2C. Puissance nominale de
lappareil. Na surchargez pas le poste de soudage a
Iarc. Cela peut surchauffer las cables et causer un in
cendie.
fire.
Loose cable connections may overheat
cause a fire.
or
flash and
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
Les branchements lches
faire des Øtincelles et
ou
de cable peuvent surchauffer
incendie.
causer un
jamais un arc sur une buteille ou autre rØci
pression. Cela crØerait un point de rupture
entralnant a plus ou moms longue ØchØance lexplosion
Namorcez
pient
sous
du reservoir.
handling.
D.
Compressed Gas Equipment
Comply with precautions
E.
in 1-2D.
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
Gaz comprimØ
Suivez las precautions 1.2D.
E.
Shock Prevention
Exposed hot conductors
D.
Prevention des
dØcharges Ølectriques
Des conducteurs charges ou metal nu incorporØs au cir
cuit de soudage ou a un appareil chargØ sans mise a Ia
terre peuvent donner une dØcharge fatale a Ia personne
dont le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans protec
tion appropriØe.
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
without
ness or sweat can not
moisture
between
be avoided. Sweat, sea water, or
and an electrically HOT
body
reduces the body surface
or grounded metal
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
part
-
-
Pour vous protØger contre les dØcharges Ølectriques,
maintenez votre corps et vOtements secs. Ne travaillez
jamais dans un endroit humido sans isolation adequate
contre les dØcharges Ølectriques. Lorsque vous no
pouvez Øviter lhumiditØ ou Ia sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
Ieau de mer, ou lhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal a a masse, rØduisent
Ia rØsistance Ølectrique de Ia surface du corps, permet
tant lentrØe de courants dangereux, voire mortels.
1.
1.
Grounding
the
installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
quid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT
a dangerous condi
tion that can shock, possibly fatally.
-
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a 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.
A Iinstallation, branchez los chassis de chaque ØlØment
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire los
telluriques en toute sØcuritØ. Lappareil chargØ
par les courants vagabonds peut donner une dØcharge
risquant dŒtre mortelle. NE BRANCHEZ PAS VOTRE
PRISE DE TERRE a une conduite Øloctrique, ou a un
tuyau de gaz ou de liquide inflammable tel quo lhuile ou
un combustible.
courants
vØrifiez Ia
Connexion triphasØe. Avant linstallation
phase nØcessaire a lappareil. Si soul le triphasØ est
disponible, no branchez lappareil monophasØ qua deux
des fils de Ia ligno triphasØe. NE BRANCHEZ PAS le
conducteur do terre de Iappareil au troisiŁme fil (sous
tension), autrement lappareil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Avant le soudage, vØrifiez si Ia prise do terre est
uniforme. En branchant, assurez-vous que los con
ducteurs touchent Ia metal flu du chØssis do lappareil.
Lorsquun
Si vous avez en plus une fiche a trois broches pour Ia
Ia broche
terre, no branchez le conducteur de terre qu
de terre. Si le cordon dalimontation a une fiche a trois
broches, roliez-lo a uno prise femello tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre sorait
brisØe.
Pince-Ølectrodes
use
holders with
protruding
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pinco-Ølectrodes avec vis saillantes.
screws.
3.
Connoctours
Connectors
Fully insulated lock-type connectors should be used
join welding cable lengths.
4.
Œtre alimentØ Ł partir dun cof
le conductour do terre doit Œtre reliØ
Electrode Holders
Fully insulated electrode holders should be used. Do
3.
appareil doit
fret dalimentation,
a celui-ci.
2.
NOT
lappareil
-
When
2.
Mise a Ia terre de
Equipment
to
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler do longs cØbles.
4.
Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
lethal shock
or damaged insulation to avoid possibly
-
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
Cables
VØrifiez frØquemment Iusure, los fissures et laltØration
des cables. REMPLACEZ IMMEDIATEMENT ceux dont
Iisolation sorait trop usØe ou altØrØe pour prØvenir los
dØcharges mortelles provoquØes par un cable dØnudØ.
Vous pouvoz enrouler los parties ondommagØes do
ruban adhØsif on Øpaissour suffisante pour donner une
rØsistance do cable neuf. Maintenez les cables secs,
dØpourvus dhuile et de graisse at mettoz-Ies a labri du
metal chaud et des Øtincelles.
OM-268 Page 9
5.
Terminals And Other
Exposed Parts.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
TŒtes de cables et autres
Avant Ia mise en marche, les tŒtes de cables et autres
parties dOnudØes dun appareil Ølectrique doivent Otre
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 clear of wire and other HOT parts.
Le fil-Ølectrode est chargØ lorsque lorsque linterrupteur
dalimentation du poste a souder au MIG est sur MAR
CHE et que lon appuie sur Ia gchette du pistolet.
Evitez que les mains et le corps soient
fil et autres ØlØments charges.
7.
Safety
devices such
interlocks and circuit breakers
should not be disconnected or shunted out.
source, and
pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment
Always shut OFF and
equipment.
Power disconnect switch must be available
welding
Dispositif
near
1-4. STANDARDS BOOKLET INDEX
coupe-circuit
Avant linstallation, linspection ou Ia reparation de Iap
pareil, mettez lalimentation sur ARRET et enlevez les
fusibles generaux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez tous les cables de Ia source de cou rant ainsi que les
prises des cordons dalimentation en 115 volts.
Lors du
ne
cours
soudage, nouvrez pas le circuitdalimentation
changez pas Ia polaritØ. Sil est dØbranchØ au
dune
dØcharge
urgence, faites attention
ou aux
aux
brOlures de
jaillissements dØtincelles.
Appareil laissØ
sans surveillance. Mettez toujours
ARRET et dØbranchez lappareil.
-
For
or
more
ne
the
power source.
formation, refer to the following standards
revisions and comply as applicable:
sur
in
their latest
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 2501 NW 7th St., Miami, FL
33125.
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.
Linterrupteur
imitØ de Ia
1-4.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
INDEX
ou aux normes
se
trouver a prox
DES
NORMES
Pour
plus de
de IACNOR
amØricaines suivantes:
-
aux normes
1.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par lAmerican Welding
Society, 2501 N.W. 7th Street, Miami, FL 33125
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
3.
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
darrŒt doit toujours
de courant.
source
renseignements, rØfØrez-vous
NIOSH,
3.
OSHA, SAFETY AND HEALTH STANDARDS,
1910, distribuØ par U.S. Government
Printing Office, Washington, D.C. 20402.
29CFR
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par lAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018.
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY
TOE FOOTWEAR distribuØ par lad
dresse donnee en 4.
-
Page 10
le
de sØcuritØ
Le dispositif de sØcuritØ-verroulllage et
doit pas Œtre dØbranchØ ou dØshuntØ.
et
unattended.
disconnect all power to
5.
en contact avec
as
Before installation, inspection, or service, of equip
ment, shut OFF all power and remove line fuses (or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
2.
Fils-Ølectrodes
Safety Devices
7.
1.
parties dØnudØes
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par laddresse ~onnee en 4.
7.
AWS
TING
7.
AWS
CUT
Standard A6.0, WELDING AND
Standard A6.O, WELDING AND CUT
CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par Iaddresse
donnee
en
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 2501
NW 7th
Street, Miami,
8.
FUEL GAS
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 laddresse donnØe
en 8
10.
NFPA Standard 518, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
8
ii.
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 Wii7.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
Rexdale
178
Boulevard,
Rexdale, Ontario,
Canada M9W iR3.
13.
NWSA
FL 33125.
8.
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
NFPA
-
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL CODE obtainable from the National Fire
Protection
Association, 470 Atlantic Avenue,
Boston, MA 02210.
10.
NFPA Standard SiB, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
ii.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
GSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Standards
Canadian Standards Association,
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
NFPA
-
booklet,
BIBLIOGRAPHY
WELDING
distribuØ
Welding Supply Association, 1900
Philadelphia,
14.
PA
SAFETY
Ia
par
National
Arch Street
19103.
American
Welding Societe Standard AWSF4.i
Safe Practices for the Prepara
Welding and Cutting of Containers and
Recommended
13.
WELDING
SAFETY
booklet,
BIBLIOGRAPHY obtainable from the National
NWSA
Welding Supply Association,
Philadelphia, PA 19103.
14.
Piping That Have Held Hazardous
distribuØ par lAmerican Welding
NW 7th Street, Miami, FL 33125.
1900 Arch Street,
Welding Society Standard AWSF4.i
Safe Practices for the PrØpara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding Society,
2501 NW 7th Street, Miami, FL 33125.
American
Recommended
15.
tion for
15.
Substances,
Societe, 2501
ANSI Standard Z88.2 Practice For Respiratory
Protection
distribuØ par lAmerican
National
Standards Institute, 1430 Broadway, New York,
NY 10018.
ANSI Standard Z88.2 Practice for Respiratory
obtainable from the American Na
Protection
tional Standards Institute, 1430
York, NY 10018.
Broadway,
New
OM-268 Page 11
SECTION 2
INTRODUCTION
-
Input
At Rated
Load
Max.
Rated
Welding
Welding
Current
Open-
Current
Range
Amperes
Circuit
Amperes
200 @
28 Volts,
Amperes
45
80
At
230V
200(208)V
Voltage
dc
41
35-250
40% Duty Cycle
Output
60 Hz. Three-Phase
Figure
2-1.
L
kva
kw
Dimensions
20.5
16.32
9.1
~
-
295 lb.
(134
-
Depth
-
1305
lb.
kg)j(138
26 in. (660 mm)
kg)
Specifications
statements
____________
and maintenance
include installation, operating,
or practices which if not
procedures
carefully followed could result in serious personal injury
General
A.
Ship
Net
28-3/4 in. (730 mm)
Width
16 in. (406 mm)
Height
WARNING
2-1. GENERAL INFORMATION AND SAFETY
Weight
Overall
460V
or
Information presented in this manual and
on
various
labels, tags, and plates provided on this unit pertains to
equipment design, installation, operation, maintenance
and troubleshooting which should be read, understood
and followed for the safe and effective
use
of this
loss of life.
I~.tU1I.]~I statements include
and maintenance procedures or
installation, operating
practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
equip
A third
ment.
signal word,
IMPORTANT
highlights
instruc
_______________
B.
tions which need special emphasis to obtain the most
efficient operation of this equipment.
Safety
2-2.
operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated and maintained only by qualified.
The
installation,
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
the end of Section 1
Arc
Welding
-
Safety Rules
For
RECEIVING-HANDLING
Prior to installing
equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading and freight bill will be furnished by the carrier on
-
this
request if occasion
Number of the
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
___________
different levels of hazard.
SECTION 3
3-1.
-
LOCATION
t.~1I1l.T~r IMPROPER LIFTING OF EQUIPMENT
can
result
in
personal
injury
and
equipment
damage.
Use
2-3.
equipment
DESCRIPTION
-
be
This
supplied.
unit
is
a
three-phase
power source that produces dc current for
Shielded Metal-Arc Welding (SMAW).
welding
INSTALLATION
Do not place any filtering device over the intake air
passages of this welding power source.
Warranty is void if any type of filtering device is used.
This
equipment of adequate capacity
to lift the
unit.
If using lift forks to handle this unit, be sure the lift
forks are long enough to extend out of the op
welding power source has a lifting device for mov
ing the unit and holes in the base for mounting pur
poses. Figure 3-1 gives unit dimensions.
The location should allow
posite side of the base.
Using lift forks too short will expose internal com
ponents to damage should the tips of the lift forks
The service life and
penetrate the bottom of the unit.
when the unit is
RESTRICTED AIR FLOW causes overheating and
to internal parts.
possible damage
Maintain
at
least
18
inches
(457
mm)
unrestricted space on all sides of unit and
underside free of obstructions.
Page 12
file claim arises.
When requesting information concerning this equip
ment, it is essential that Model Description and Serial
Power Source.
____________
to
Operation Of
of
keep
room to remove cover
and
panels for maintenance and repair.
efficiency of this unit are reduced
subjected to high levels of dust, dirt,
moisture, corrosive
vapors, and extreme heat.
1.
Locate weld output terminals
on
the lower front
panel.
2.
Connect
and work cables to the
NEGATIVE weld output ter
minals. Ensure that connections are clean and
electrode
POSITIVE
and
tight.
Table 3-1.
Welding Cable Size
TOTA L LEN GTH OF CABLE (COPP ER) IN WELD CIRCUIT
WELDING
100
150
200
250
300
100
4
4
4
3
2
1
50
AMPERES
150
3
3
200
2
2
250
1
2
1
400
1/0
1/0
2/0
3/0
3/0
1/0
2/0
3/0
4/0
4/0
2/0
3/0
4/0
4/0
22/0
1
1
1/0
350
1/0
A -002 624
NOTE:
~A.
50 FEET OR LESS.
~B.
CABLE
-
C.
Figure 3-1. Dimensional Drawing
CONNECTIONS
OUTPUT
3-2. WELD
(Figure
comply in any of these areas may
satisfactory welding performance.
Failure to
result in less than
A.
If
ordered, with this unit, the
be followed to ensure the best
not
were
steps listed should
AN OPENCIRCUIT VOLTAGE OF LESS THAN
VOLTS. SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN.CIRCUIT
VOLTAGE
short as possible and place cables
together. Excessive cable length adds
Keep cables
close
or
-
source
amperage control
circuitry.
clockwise.
A.
Select adequate size welding cable for the an
ticipated maximum weld current. Use total
length of welding cable in the circuit to deter
mine cable size. For example: If the electrode
holder cable is 75 feet (23 m) long and the work
3.
Do not
use
4.
Install
electrode
damaged
manufacturers
or
to
cable
ensure
INPUT CONNECTIONS
following
the local electric utility if there is any question about the
type of electric system available at the installation site or
how proper connections to the welding power source
B.
operator
safety.
be made.
Matching The Welding Power Source To
The Available Input Voltage
200
~o
Install lugs corresponding in size and capacity to
the weld cables to remaining end of electrode
Input Requirements
This welding power source is designed to be operated
from three-phase, 60 Hertz, ac input power which has a
voltage rating that corresponds with one of the elec
trical input voltages shown on the nameplate. Consult
instructions. An insulated elec
trode holder must be used to
Electrical
are to
frayed cables.
holder
ELECTRICAL
3-4.
cause
cable is 25 feet (8 m) long, select the size cable
recommended in Table 3-1 for 100 ft (31 m).
5.
REMOTE AMPERAGE CONTROL CONNEC
(Figure 4-1) The REMOTE AMPERAGE CON
TION
as
resistance which may reduce output
overloading of the unit.
2.
3-3.
To connect the remote control, insert remote control
plug into the three-pole twistlock receptacle and rotate
welding performance:
1.
CIRCULAR MILS PER AMP.
WELD CABLE
INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT
AGE (OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
TROL receptacle provides a connection point between
an optional remote control and the welding power
Welding Cables
welding cables
BASED ON DIRECT CURRENT (DC),
60% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
100
-
cables.
IS
HAVE
To obtain the full rated output from this unit, it is
necessary to select, install, and maintain proper welding
4-1)
SIZE
~
VOLTS
~O
CL~
~Q
0L2 0L3
230 VOLTS
o~
GPO.
o~
CL
230 VOLTS
B.
Installation
clamp
to
o~O
o~o
cable.
G~O.
CLI
CL! CL3
GPO.
CLI CL! CL)
TA012
ITA~1:I~lI~~
262
460 VOLTS
o~o
Install work
0L2 CL)
TA022
holder cable and to both ends of work cable.
6.
O~
ELECTRIC SHOCK
can
130
Figure 3-2. Input Voltage Jumper Link Arrange
kill.
ment
Do not touch five electrical parts.
Shut unit down and be sure it cannot be acciden
tally energized before making
nections.
output
con
The input voltage jumper links provided on the primary
terminal board permit the welding power source to be
operated from various line voltages. The voltages from
OM-268
Page 13
which this unit may be operated are stated
nameplate and on the input voltage label.
Figure 3-3
See
the
on
for location of this label.
input voltage jumper links are positioned for the
highest of the voltages stated on the nameplate. If the
unit is to be operated at a lower voltage, the jumper
links must be moved. Figure 3-2 shows the various posi
tions of the jumper links on the standard unit.
lugs must correspond to the input and
ground conductor size (see Table 3-2). Attach terminal
lugs to input and ground conductors. The hole diameter
in the lugs must be the right size to fit the line and
ground terminal studs.
The terminal
The
through
ground conductor
panel. This hole will
conduit fittings. See Figure 3-3 for hole
input conductors plus
the
access
accept standard
hole
on
the
one
rear
location and size.
Line Disconnect Switch
If the input voltages on the nameplate differ from those
shown in Figure 3-2, the jumper links must be position
ed as shown on the input voltage label on the unit. See
Figure 3-3
Insert the
Input Voltage Jumper Links
for location of this label.
IMPORTANT: If only
one jumper link is required on
grouped terminals, it is recommended that
the unused jumper links be placed across the terminals
which are to be used. This will pre vent losing the jumper
links which are not required for this connection.
_____
each of the
Input Conductor Connections
C.
ELECTRIC SHOCK can kill.
a fusible line disconnect
switch be installed in the input circuit to the
WARNING
________
It is recommended that
welding power source.
This would provide a safe and convenient means to
completely remove all electrical power from the welding
power source whenever it is necessary to internally in
spect
or
B-9O~ 988-4
Figure
Do not connect
power.
provides guidelines for selecting the proper
size input conductors and line fuses. The input conduc
tors should be covered with an insulating material that
meets local electrical standards.
Table 3-2. Input Conductor And Fuse Size
Input Conductor Size
(10)
I
-
230V
460V
8
12
(10)
(14)
AWG
575V
I
Fuse Size In
200(208)V
230V
70
60
14
(14)
I
Amperes
I
460V
575V
30
25
input conductor sizes are based on National Electrical Code specifica
ampacities of insulated copper conductors, having a
temperature rating of 75C, with not more than three conductors in a
conductor sizes.
raceway or cable. Numbers in I ( are equipment ground
tions for allowable
Page
14
an
kill.
input
conductor to the
ground
terminal in the unit.
Do not connect the
ground conductor
to
an
input
line terminaL
Incorrect input connections can result in an electrically
energized welding power source chassis. The ground
terminal is connected to the welding power source
chassis and is for grounding purposes only.
Connect the input conductors to the line terminals on
primary terminal board and connect the ground con
the
Table 3-2
8
can
__________
Employ lockout/tagging procedures on input
line before making input connections to the
we/ding power source.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or tagging circuit breaker or other
disconnecting device.
Connect input conductors to the welding power
source before connecting to single-phase input
I
3-3. Input Conductor Connections
WARNING ELECTRIC SHOCK
service the unit.
1200(208)V I
Line Terminals
ductor to the ground terminal. (Refer to the input
voltage label for identification of these terminals.) The
remaining end of the ground conductor should be con
nected to a proper ground. Use a grounding method
that is acceptable to the local electrical inspection
authority.
SECTION .4
-
OPERATOR CONTROLS
Amperage Adjustment Control
ro1
:
Control Circuit
Overload Breaker
Power Switch
Remote Amperage_
Control Switch
2
Remote
Control
Amperage
Receptacle~~
Front Access
Door
Negative
Weld
Output Terminal
Positive Weld
Output Terminal
J
TB901 903.4
Figure
4-1. Front Panel View
(Figure 4-1) Placing the
position energizes the
welding power source, making the unit operational.
Placing the POWER switch in the OFF position shuts
POWER
4-1.
POWER
SWITCH
switch
in
the
-
ON
output capabilities of the
and
of each
max.
welding power
range. Voltage
coarse
within each range is
AMPERAGE ADJUSTMENT control.
adjustment
source at
mm.
and amperage
provided by the
the unit down.
With the
CONTROL
4-2. AMPERAGE ADJUSTMENT
SWITCH (Figure 4-1)
&
use of the volt-ampere curves it is possible to
determine the load voltage at any particular weld cur-
rent.
80
Amperage Adjustment Control
A.
70
The AMPERAGE ADJUSTMENT control
60
provides fine
550
amperage adjustment. Rotating the control clockwise
increases amperage output. The scale surrounding the
v
40
a
30
control is calibrated in percent and should not be read
as an amperage value.
20
0
The
Il~l~1;lf..t~I~
control may be
AMPERAGE
ADJUSTMENT
SO
0
100
50
DC
adjusted while we/ding.
200
250
300
AMPERIS
8002 510
Figure 4-2. Volt-Ampere Curve
B.
Remote
Amperage Control Switch
4-4.
If
a
Remote
REMOTE
Amperage Control is used, place the
AMPERAGE
CONTROL
switch
in
the
REMOTE position.
When
a remote
control is
used, it has complete control
DUTY CYCLE CHART
(Figure 4-3)
The duty
is the percentage of a
ten minute period that a welding power source can safe
ly be operated at a given output. This welding power
source is rated at 40 percent duty cycle. This means
that the welding power source can be safely operated at
cycle of
a
welding
power
-
source
of weld output.
rated load for four minutes out of every ten. During the
remaining six minutes, the unit should idle to permit
If a remote control is not used, place the REMOTE
AMPERAGE CONTROL switch is in the STANDARD
position. When this switch is in the STANDARD posi
tion, only the AMPERAGE ADJUSTMENT control
proper cooling. If the welding amperes are decreased,
the duty cycle will increase. Figure 4-3 enables the
operator to determine the safe output of the welding
power
source at
various
duty cycles.
varies the amperage.
CAUTION:
4-3. VOLT-AMPERE
volt-ampere
curves
CURVES (Figure 4-2)
The
show the voltage and amperage
-
will.damage
EXCEEDING DUTY CYCLE RATINGS
the
welding power source.
duty cycles indicated.
Do not exceed
OM-268
Page 15
4-5. CONTROL CIRCUIT OVERLOAD BREAKER
(Figure 4-1) The amperage control circuit is pro
OUTPUT
RATED
300
-
tected
overload by a circuit breaker. Should an
overload occur, the circuit breaker would open and
weld output would go to minimum. Manually
depress
the circuit breaker to reset it.
250
n~
~~
200
4
against
-
~
(5
z
~
ISO
h-..
-.
~.,
00
35
30
25
50
40
70
60
90
80
100
% DUTY CYCLE
B-002 523
Figure 4-3. Duty Cycle Chart
SECTION 5
ELECTRIC SHOCK
WARNING:
SEQUENCE OF OPERATION
-
kill; MOVING
can
2.
____
serious injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT can
PARTS
can
Place REMOTE AMPERAGE CONTROL switch
position (see Section 4-2).
in desired
cause
damage internal parts.
Keep
all
covers
and
in
pane/s
place
while
3.
Rotate AMPERAGE ADJUSTMENT control
remote amperage
operating.
Wear correct eye, ear, and body protection.
AND GASES can seriously harm your
FUMES
or
control to desired
position.
Warranty is void if the welding power source is operated
with any portion of the outer enclosure removed.
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
adjustment
4.
Place POWER switch in ON position.
5.
Begin welding.
health.
enough ventilation to keep fumes and gases
breathing zone.
See Section 1
Safety Rules For Operation Of Arc
Welding Power Source for basic welding safety infor
Use
from the
5-2. SHUTTiNG DOWN
-
1.
Stop welding.
2.
Allow unit to idle for
mation.
5-1. SHIELDED METAL-ARC WELDING (SMAW)
1.
Make all necessary connections
Section 3.
as
instructed in
SECTION 6
WARNING
ELECTRIC SHOCK
can
-
kill.
__________
input
Disconnect
and
power
tagging procedures
inspecting or servicing.
Lockout/tagging procedures consist
of
disconnect switch in open
from fuse box, or tagging
breaker
lockout!
disconnecting
employ
3.
with
no
MAINTENANCE
ing. The fan motor is manufactured with
bearings and requires no maintenance.
or
other
out or
vacuuming
lifetime sealed
the labels
on
the
CLEANING
-
Occasional
blowing
of the dust and dirt from around the
internal components is recommended. This should be
periodically depending on the location of the unit
and the amount of dust and dirt in the atmosphere. The
done
welding
Periodically inspect
cooling period
Place POWER switch in OFF position.
6-2. INTERNAL
device.
IMPORTANT
a
applied.
before internally
padlocking line
position, removing fuses
circuit
load
ed and
a
power source outer enclosure should be
clean, dry airstream
or vacuum
remov
suction should
______________
unit for
legibility. All labels must be maintained in a
clearly readable state and replaced when necessary.
be used for this
See Parts List for part number of labels.
6-3. WELD CABLES
Periodically inspect cables for
breaks in insulation and ensure that all connections are
clean and tight. Repair or replace cables as necessary.
Clean and tighten connections periodically.
6-1. FAN MOTOR
haust fan and relies
Page 16
-
This unit is
on
equipped with an ex
forced draft for adequate cool-
cleaning operation.
-
SECTION 7
7-1. GENERAL
-
It is assumed that the unit
was
-
TROUBLESHOOTING
tion should be contacted. In all cases of equipment
recommendations
malfunction, the manufacturers
should be strictly followed.
pro
to Section 3 of this
manual,
the operator is familiar with the function of controls, the
welding power source was working properly, and that
perly installed according
the trouble is not related to the
welding
chart is
power
I~~Ii~II~cr ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Disconnect unit from input power before internal
The following
diagnose and provide remedies for
of the troubles that may develop in this welding
7-2. TROUBLESHOOTING CHART
some
process.
designed
-
to
ly inspecting
MOVING PARTS
source.
Keep clear
HOT SURFACES
Use this chart in
conjunction with the Circuit diagram
while performing troubleshooting procedures. If the
No output
or
welding
serious
injury.
moving parts.
can cause severe
burns.
cooling period before servicing.
Troubleshooting of internal parts to be performed only
by qualified persons.
PROBABLE CAUSE
cur-
servicing.
can cause
Al/ow
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
TROUBLE
of
or
REMEDY
Open line fuse.
Replace line fuse,
POWER Switch defective.
Replace switch, if defective.
Loose
Secure connections.
if open.
rent.
Erratic weld current.
welding
connec-
tions.
Bad
Fan does not
Welding
run.
current
low.
or
damp electrodes.
Use
new
dry electrodes.
Fan motor defective.
Replace fan motor, if defective.
Low line
Use correct
voltage.
voltage.
welding cable which
long or too small for
welding current.
Use proper size cable. See Section 3-2.
Loose
Secure connections.
Use of
is too
connections
workpiece
or
to
welding cable
connections.
Welding
current
low,
AMPERAGE
ADJUSTMENT does not control cur-
Jumper links in wrong posi-
Position
tion.
Section 3-4B.
CONTROL
OVERLOAD
CIRCUIT
is
jumper links for voltage being used. See
Reset the circuit breaker. See Section 4-5.
BREAKER
open.
rent.
OM-268 Page 17
GR-GROuNO
B- BRASS
C
-
COPPER
REMOTE CONTROL
(OPTIONAL-EXTRA)
Figure
Circuit Diagram No. A-070 383
7-1. Circuit
Diagram
For 200(208)/230 Volts Models
z
RL
1
_B_ ~R_
R-GROUD
B-BRASS
C-COPPER
Circuit
REMOTE
CONTROL
(OPT IONAL -EX IRA)
Figure
Page 18
7-2. Circuit
Diagram
For 230/460 Volts Models
Diagram
No. A-070 750
July 1981
FORM: OM-268C
Effective With Serial No. JB475790
MODEL
Ramrod
PARTS
LIST
Item
Dia.
Part
No.
Mkgs
No.
Figure
Main
A
1
2
Description
SR2
RECTIFIER, integrated 30 amp 400 volts
BRACKET, mtg rectifier
GASKET, lifting eye
RESISTOR, WW adj 100 watt 2 ohm
PANEL, rear w/components (Fig B Pg 2)
TERMINAL, primary (Fig C Pg 2)
TRANSFORMER, power main (Fig D Pg 3)
4
026 627
R2
7
TEl
8
Ti
030 627
Figure
9
11
MA1
12
Z
B
038 145
031 560
031 530
-
-
-
F
031 520
1
1
1
1
1
1
1
1
BASE
w/components (Fig
031 549 AMPLIFIER, magnetic (Fig E Pg 3)
Figure
10
1
WRAPPER
035914
053 006
5
6
Assembly
027 689
3
Quantity
PANEL, front
-
F
Pg 4)
1
1
1
STABILIZER
12
11
Fi~ E.
ID 901 903 B
Figure
A
-
Main
Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-268Pagel
-~
Item
Dia.
Part
No.
Mkgs.
No.
Panel, Rear
Figure B
1
005 131
2
7
032612
027 686
006 809
000601
037 306
037 305
8
026 947
3
4
SRi
5
VS1,R3
6
9
031 689
032 603
024 601
C1-6
FM
Quantity
Description
-
W/Components (Fig A Pg 1 Item 6)
WINDTUNNEL.
BLADE, fan 60 Hz 12 inch 4 wing 23 degree
PANEL, rear
RECTIFIER, silicon (consisting of)
1
1
SUPPRESSOR
DIODE, 150 amp 300 volts reverse polarity
DIODE, 150 amp 300 volts straight polarity
INSULATOR
CAPACITOR, ceramic 0.01 uf 500 volts dc w/leads & terminals
MOTOR, fan 230 volts (consisting of)
3
3
2
6
1
2
.BEARING
1
4
2
6
Figure
B
-
Panel, Rear
-
W/Components
6
TA-038 145
Figure C
Item
Part
No.
No.
Figure C
038 145
hex
NUT, brass
TERMINAL BOARD
3
4
010913
5
038 618
7
Quantity
Terminal, Primary (Fig A Pg 1 Item 7)
038 058
038 887
6
Terminal, Primary
Description
601 835
2
-
-
regular
STUD, brass w/hex collar 10-32
WASHER,flat-brass3/16
-
24
10-32
x
LINK,jumper
601 836 NUT, brass-jam 1/4-20
038 888 STUD, brass w/hex collar 1/4-20
-
1-3/8
12
12
6
6
x
1-1/2
3
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM268
Page
2
Item
Part
No.
No.
Figure
D
1
Description
031 560 Transformer, Power
-
Main
(Fig
Pg
A
Quantity
1 Item 8)
**027 717
TRANSFORMER SUBASSEMBLY (consisting of)
027715
STRIP,glasticl/16x3x4-1/4
010338
WEDGE, hardwood single bevel 1/4 x 1 x 5-1/2
**Q~4 341 COIL, pri sec with tertiary winding
**~~4 342 COIL, pri-sec
2
3
4
-
4
-
5
2
1
1
Figure D
-
Transformer, Power
-
Main
TC-O3~ 549
Figure
Item
Part
No.
No.
Figure
E
1
**~3~ 550
025 068
025
021
**~4
**024
3
4
5
6
069
-
Amplifier, Magnetic
Quantity
Description
031 549 Amplifier, Magnetic
2
E
(Fig
A
AMPLIFIER SUBASSEMBLY
.
.
(consisting of)
STRIP, fiber0.007x2-3/4x5
3
STRIP,glasticl/32x1-11/16x3
WEDGE, phenolic single bevel 1/4
6
999
344 COIL, control dc
343 COIL, control ac
.
Pg 1 Item 11)
-
x
1
x
13
5
3
-
**Replace At Factory Or Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
-
Page3
Item
Dia.
Part
No.
Mkgs.
No.
Panel. Front
Figure F
1
2
3
019
031
011
*003
039
4
S2
5
CB
6
RC1
7
Ri
8
Si
030
022
026
Pos
039
9
10
11
12
13
18
19
20
21
22
23
531
609
693
607
653
171
191
047
W/Components (Fig A Pg 1 Item 10)
-
NAMEPLATE (order by model & serial numbers)
1
KNOB, pointer-rheostat
PANEL,front
SWITCH, toggle SPDT 10 amp 125 volts
CIRCUITBREAKER, manual-resetloamp250volts
RECEPTACLE, twistlock 3P3W 20 amp 250 volts
RHEOSTAT, WW 150 watt 15 ohm
SWITCH, toggle 3 pole 30 amp
INSULATION, switch
TERMINAL, power output red (consisting of)
1
-
601 976 .SCREW,cap-hexhdl/2-13x1-1/2
TERMINAL BOARD
039 049
601 880
NUT, hex-jam 1/2-13
039044 .BUSBAR
601 879
NUT, hex-fuIll/2-13
039 046 TERMINAL, power output black (consisting of)
601 976 .SCREW,cap-hexhdl/2-13x1-1/2
TERMINAL BOARD
039 045
601 880 .NUT,hexjaml/2-13
BUS BAR
039 044
601 879
NUT, hex-fulll/2-13
front
+ 027 682 DOOR, access
046 497 LABEL, general precautionary
605 583 CATCH, spring loaded door
1
1
1
1
1
1
1
1
1
1
1
.
15
17
627
Quantity
.
14
16
Description
1
1
.
Neg
-
1
1
1
.
1
1
.
1
.
-
-
1
1
1
~ s_s
Figure F Panel, Front W/Components
*Recommended 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.
-
-
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