Miller ps-100 Owner's Manual

June

1988

Millerfi

F~1LE

COPY

RETURN

TO

FOLDER

OWNERS

MANUAL

iMPORTANT

Read

and

understand

the

entire

contents

of

this

manual.

with

special

emphasis

on

the

safety

material

throughout

the

manual.

Miller

Electilc

Mfg.

Co.

A~L~C~at~

before

installing,

operating,ormaintaining

this

equipment.

This

unit

and

P0.

Box

1079

these

instructions

are

for

use

only

by

persons

trained

and

experienced

In

Appleton,

WI

54912

USA

the

safe

operationofwelding

equipment.

Do

not

allow

untrained

persons

Tel.

414-734-9821

to

install,

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

FORM:F2544B

Effective

With

Serial

No.

JJ393769

MODEL

ps-100

PRINTED

IN

U.S.A.

ACOITIONAL

COPY

PRCE70CENTS

EFFECTIVE:

FEBRUARY

16.

1988

This

warranty

supersedes

all

previous

MILLER

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY

-

Subject

to

the

terms

and

condi-

In

the

case

at

Millers

breech

of

warranty

or

any

other

duty

dons

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

with

respect

to

the

quality

of

any

goods,

the

exclusive

rwi~diemi

warrants

to

its

Distributor/Dealer

that

all

new

and

unused

therefore

shall

be,

at

Millers

option

(1)

repair

or

(2)

replacement

Equipment

furnished

by

Miller

is

free

from

defect

in

workman-

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

ship

and

materialasof

the

time

and

place

of

delivery

by

Miller.

the

reasonable

coat

of

repair

or

replacement

at

an

authorized

No

warranty

is

made

by

Miller

with

respect

to

engines,

trade

Miller

service

station

or

(4)

pa~mant

of

or

credit

for

the

purchase

accessories

or

other items

manufactured

by

others.

Such

pnce

(lees

reasonable

depreciation

based

upon

actual

use)

upon

engines,

trade

accessories

and

other

items

are

sold

subject

to

return

of

the

goode

at

Customers

risk

and

expense.

MILLERs

the

warrantiesoftheir

respective

manufacturers,

if

any

.

All

option

of

repair

or

replacement

will

be

F.O.B.,

Factory,

at

engines

are

warrantedbytheir

manufacturer

for

one

year

from

Appleton,

Weconsin,orF.O.B.,

at

a

MILLER

authorized

service

date

of

original

purchase,

except

Tecurnseh

engines

which

facility,

therefore,

no

compensation

for

transportation

costs

of

have

a

two

year

warranty.

any

kind

will

be

allowed.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

insmact

the

claimantonthe

warranty

Except

as

specified

below,

Millers

warranty

does

not

apply

claim

procedures

to

be

followed.

to

components

having

normal

useful

life

of

lees

then

one

(1)

year,

such

as

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

come

in

contact

with

the

welding

ANY

EXPRESS

WARRANTY

NOT

PROViDED

HEREIN

AND

wire

including

nozzles

and

nozzle

insulators

where

failure

dose

ANY

IMPUED

WARRANTY.

GUARANTY

OR

REPRESENTA

~

not

result

from

defect

in

workmanship

or

material.

liON

AS TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

ThIS

PROVISION,

~

Miller

shall

be

required

to

honor

warranty

claims

on

war-

MIGHT

ARISE

BY

IMPUCA11ON,

OPERATION

OF

LAW,

~

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

CUSTOM

OF

TRADE

OR

COURSE

OF

DEAUNG.

INCLUDING

~

within

the

following

periods

from

the

date

of

delivery

of

Equip-

ANY

IMPUED

WARRANTY

OF

MERCHANTABIUTY

OR

OF

merit

to

the

original

user:

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

TO

ANY

AND

AU.

EQUIPMENT

FURNISHED

BY

MILLER

IS

EX

~.f

1.

Arc

weldais,

p~re~irces,

robots,

and

c

,or~nts

.

1

yeer

CLUDED

AND

DISCLAIMED

BY

MILLER.

2.

Loadbanks

1

year

j

3.

Original

main

power

rectifiers

3

years

(labor

-

1

year

only)

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

~

4.

All

welding

guns,

feeder/gun,

and

torches

90

days

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

r1~

5.

All

other

Millermatic

Feeders

1

year

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

~

6.

Replacement

or

repair

parts,

exclusive

of

labor

..

60

days

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

AND

ij(

7.

Batteries

6

months

EXPERIENCED

IN

ThE USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

~

provided

that

Milleri.notified

in

writing

within

thirty

(30)

days

CONSUMER

USE.

MILLERS

WARRANTIES

DO

NOT

EXTEND

!~

of

the

date

of

such

failure.

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

.~

As

a

matter

of

general

policy

only,

Miller

cay

honor

dims

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

by

the

original

user

within

die

foreyoing

periods

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1

1-2.

General

Precautions

1

1-3.

Arc

Welding

4

1-4.

Standards

Booklet

Index

6

SECTiON

2-INTRODUCTION

2-1.

Vott-Ampere

Curves

8

2-2.

Duty

Cycle

8

2-3.

General

Information

And

Safety

8

2-4.

Receiving-Handling

8

2-5.

Description

9

SECTION

3

INSTALLATION

3-1.

Location

9

3-2.

Weld

Output

Connections

9

3-3.

Control

Module

Receptacle

Information

And

Connection

10

3-4.

Electrical

Input

Connections

11

SECTION

4-

OPERATOR

CONTROLS

4-1.

PilotLight

13

4-2.

Circuit

Breaker

13

4-3.

Control

Module

Receptacle

13

SECTION

5-

SEQUENCE

OF

OPERATiON

5-1.

Operation

13

5-2.

Shutting

Down

13

SECTION

6-

MAINTENANCE

&

TROUBLESHOOTING

6-1.

Routine

Maintenance

14

6-2.

Fan

Motor

14

6-3.

Overload

Protection

14

6-4.

Troubleshooting

Chart

16

SECTION

1



SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

We

learn

by

experience.

Learning

safety

through

per

sonal

experience,

like

a

child

touching

a

hot

stove

is

harmful,

wasteful,

and

unwise.

Let

the

experience

of

others

teach

you.

Safe

practices

developed

from

experience

in

the

use

of

welding

and

cutting

are

described

in

this

manual.

Re

search,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

is

improperly

used

or

maintained.

The

rea

son

for

the

safe

practices

may

not

alwaysbegiven.

Some

are

based

on

common

sense,

others

may

require

technical

volumes

to

explain.

It

is

wisertofollow

the

rules.

Read

and

understand

these

safe

practices

before

at

tempting

to

install,

operate,

or

service

the

equipment.

Comply

with

these

procedures

as

applicable

to

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

of

others.

Failure

to

observe

these

sale

practices

may

cause

seri

ous

injury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1-General

Precautions,

common

to

arc

welding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

on

safety

are

also

ava~able

for

additional

and

more

complete

pro

cedures

than

those

given

in

this

manual.

They

are

listed

in

the

Standards

Index

in

this

manual.

ANSI

Z49.1

is

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

a

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTiONS

Different

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radIation

levels.

In

addition

to

the

informatIon

In

thIs

manual,

be

sure

to

consult

flux

and

electrode

manufacturers

Material

Safety

Data

Sheets

(MSDSs)

for

specIfic

technical

data

and

precautIon

ary

measures

concerning

their

material.

A.

Burn

Prevention

Wear

protective

clothing-gauntlet

gloves

designed

for

use

in

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

glasses

with

side

shields

underneath,

appropriate

filter

lenses

or

plates

(protected

by

clear

cover

glass).

This

isaMUST

for

weldingorcutting,

(and

chipping)

to

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

or

spattered.

See

1

-3A.2.

Avoid

oily

or

greasy

clothing.

A

spark

may

ignite

them.

Hot

metal

such

as

electrode

stubs

and

workpieces

should

never

be

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

a

qualified

first

aid

person

should

be

available

for

each

shift

unless

medical

facilities

are

close

by

for

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

sons

intending

to

weld

or

cut.

B.

Toxic

Fume

Prevention

Severe

discomfort,

illness

or

death

can

result

from

fumes,

vapors,

heat,

or

oxygen

enrichment

or

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

as

describedinANSI

Stan

dard

Z49.1

listed

in

Standards

Index.

NEVER

ventilate

with

oxygen.

Lead

-,cadmium-,

zinc

-,

mercury-,

and

beryllium-bear

ing

and

similar

materials,

when

welded

(or

cut)

may

pro

duce

harmful

concentrations

of

toxic

fumes.

Adequate

local

exhaust

ventilation

must

be

used,

or

each

person

in

the

area

as

well

as

the

operator

must

wear

an

air-sup

plied

respirator.

For

beryllium,

both

must

be

used.

Metals

coated

with

or

containing

materials

that

emit

toxic

fumes

should

not

be

heated

unless

coating

is

re

moved

from

the

work

surface,

the

area

is

well

ventilated

and,

if

necessary,

while

wearing

an

air-supplied

respira

tor.

Work

in

a

confined

space

only

while

it

is

being

ventilated

and,

if

necessary,

while

wearing

an

air-supplied

respira

tor.

Gas

leaks

in

a

confined

space

should

be

avoided.

Leaked

gas

in

large

quantities

can

change

oxygen

con

centration

dangerously.

Do

not

bring

gas

cylinders

into

a

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

at

source

to

prevent

possible

accumulation

of

gases

in

the

space

it

downstream

valves

have

been

accidentally

opened

or

left

open.

Check

to

be

sure

that

the

space

is

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

be

decomposed

by

the

heat

of

the

arc

(or

flame)

to

form

PHOSGENE,

a

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

of

the

arc

can

also

decompose

trichloroethylene

and

perchloroethylene

F2544

Page

1

vapors

to

form

phosgene.

DO

NOT

WELD

or

cut

where

solvent

vapors

can

be

drawn

into

the

weldingorcutting

atmosphere

or

where

the

radiant

energy

can

penetrate

to

atmospheres

containing,

even

minute

amounts

of

trichioroethylene

or

perchioroethylene.

C.

Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

mate

rial;

misuse

of

compressed

gases

and

cylinders;

and

short

circuits.

BE

AWARE

THAT

flying

sparks

or

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

or

doors,

and

through

wall

or

floor

openings,

out

of

sight

of

the

goggled

operator.

Sparks

and

slag

can

fly

35

feet.

To

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

of

oil,

grease,

and

(in

electrical

parts)

of

metallic

particles

that

can

cause

short

circuits.

If

combustibles

are

in

area,

do

NOT

weld

or

cut.

Move

the

work

if

practicable,

to

an

area

free

of

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

verdi

lators.

if

the

work

cannot

be

moved,

move

combustibles

at

least35feet

away

out

of

reach

of

sparks

and

heat;

or

protect

against

Ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

or

shields.

Walls

touching

combustibles

on

opposite

sides

should

not

be

welded

on

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

be

protected

by

heat-resistant

covers

or

shields.

Fire

watcher

must

be

standing

by

with

suitable

fire

extin

guishing

equipment

during

and

for

some

time

afterweld

ingorcutting

if:

a.

appreciable

combustibles

(including

building

construction)

are

within35feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

orvisible)

In

floors

orwalls

within

35

feet

may

expose

combustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

shouldbeobtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

corrtustibles,

or

that

can

produce

flammableortoxic

vapors

when

heated,

must

never

be

welded

on

or

cut,

unless

container

has

first

been

cleaned

as

described

in

AWS

Standard

A6.O,

listed

7

in

Standards

Index.

This

includes:

a

thorough

steam

or

caustic

cleaning

(or

a

solvent

orwaterwashing,

depending

on

the

combusti

bles

solubility)

followed

by

purging

and

inerting

with

ni

trogen

or

carbon

dioxide,

and

using

protective

equip

ment

as

recommended

in

A6.O.

Waterfilling

just

below.

working

level

may

substitute

for

inerting.

A

container

with

unknown

contents

should

be

cleaned

(see

preceding

paragraph).

Do

NOT

depend

on

sense

of

smell

or

sight

to

determineifit

is

safe

to

weld

or

cut.

Hollow

castings

or

containers

must

be

vented

before

weldingorcutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

or

cut

where

the

air

may

contain

flammable

dust,

gas,

or

liquid

vapors

(such

as

gasoline).

D.

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

in

this

manual,

and

those

detailed

in

CGA

Standard

P-i

,

SAFE

HANDLING

OF

COMPRESSED

GASES

IN

CYLIN

DERS,

listed

ii

in

Standards

Index.

i.

Pressure

Regulators

Regulator

relief

valve

is

designed

to

protect

only

the

regulator

from

overpressure;

it

is

not

intended

to

protect

any

downstream

equipment.

Provide

such

protection

with

oneormore

relief

devices.

Never

connect

a

regulator

to

a

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

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

pres

sure

release.

Repair.

Do

NOT

attempt

to

repair.

Send

faulty

regula

tors

for

repair

to

manufacturers

designated

repair

cen

ter,

where

special

techniques

and

tools

are

used

by

trained

personnel.

2.

Cylinders

Cylinders

must

be

handled

carefully

to

prevent

leaks

and

damage

to

their

walls,

valves,

or

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

including

third

rails,

electrical

wires,

or

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

to

a

serious

ac

cident.

(See1-3C.)

ICCorDOT

marking

must

be

on

each

cylinder.

It

is

an

assurance

of

safety

when

the

cylinder

is

properly

han

dled.

Identifying

gas

content.

Use

only

cylinders

with

name

of

gas

marked

on

them;

do

not

rely

on

color

to

identify

gas

content.

Notify

supplier

if

unmarked.

NEVER

DEFACE

or

alter

name,

number,

or

other

markings

on

a

cylinder.

It

is

illegal

and

hazardous.

F2544

Pace

2

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.

Locate

or

secure

cylinders

so

they

cannot

be

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

of

areas

where

they

may

be

struck.

Transporting

cylinders.

With

a

crane,

use

a

secure

sup

port

such

as

a

platform

or

cradle.

Do

NOT

lift

cylinders

off

the

ground

by

their

valves

or

caps,

or

by

chains,

stings,

or

magnets.

Do

NOT

expose

cylinders

to

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

Do

not

al

low

contents

to

exceed

130F.

Cool

with

water

spray

where

such

exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

objects,

and

weather.

Replace

caps

securely

when

moving

cylinders.

Stuck

valve.

Do

NOT

use

a

hammer

or

wrench

to

open

a

cylinder

valve

that

can

not

be

opened

by

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

to

mix

any

gases

in

a

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

be

modified

or

ex

changed.

3.

Hose

Prohibited

use.

Never

use

hose

other

than

that

de

signed

for

the

specified

gas.

A

general

hose

identifica

tion

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

or

clamps

designed

for

the

hose

(not

ordi

nary

wire

or

other

substitute)

as

a

binding

to

connect

hoses

to

fittings.

No

copper

tubing

splices.

Use

only

standard

brass

f

it

tingstosplice

hose.

Avoid

long

runs

to

prevent

kinks

and

abuse.

Suspend

hose

off

ground

to

keep

it

from

being

run

over,

stepped

on,

or

otherwise

damaged.

Coil

excess

hose

to

prevent

kinks

and

tangles.

Protect

hose

from

damage

by

sharp

edges,

and

by

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

in

water;

bubbles

in

dicate

leaks.

Repair

leaky

or

worn

hose

by

cutting

area

out

and

splic

ing

(1-203).

Do

NOT

tape.

4.

Proper

Connections

Clean

cylinder

valve

outlet

of

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

soui~es

of

ignition.

Wiper

withaclean

lintiess

cloth.

Match

regulator

to

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

area,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

a

regulatordesigned

for

a

particular

gasorgases

to

a

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

If

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

a

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

if

one

is

required.

use

two

wrenches

to

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

be

identified

by

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

on

nut

or

shank)

for

fue

gas.

5.

Pressurizing

Steps:

Drain

regulator

of

residual

gas

through

suitable

vent

be

fore

opening

cylinder

(or

manifold

valve)

by

turning

ad

justing

screw

in

(clockwise).

Draining

prevents

exces

sive

compression

heat

at

high

pressure

seat

by

allowing

seat

to

open

on

pressurization.

Leave

adjusting

screw

engaged

slightlyonsingle-stage

regulators.

Stand

to

side

of

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

so

that

regulator

pressure

in

creases

slowly.

When

gauge

Is

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

in

fol

lowing

position:

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

sale

and

efficient,

recommended

pressure

settings

on

regulators.

Check

for

leaks

on

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capfull

of

Ivory

Liquid

or

equivalent

per

gallon

of

water).

Bubbles

indi

cate

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.

F.

Leaving

Equipment

Unattended

Close

gas

supply

at

source

and

drain

gas.

G.

Rope

Stag

lng~Support

Rope

staging-support

should

not

be

used

for

welding

or

cutting

operation;

rope

may

burn.

Trademark

of

Proctor

&

Gamble:

F2544

Page

3

1-3.

ARC

WELDING

Comply

with

precautions

in

1-1,

1-2,

and

this

section.

Arc

Welding,

properly

done,

isasale

process,

but

a

careless

operator

invites

trouble.

The

equipment

cames

high

currents

at

significant

voltages.

The

arc

is

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

in

frared

energy

radiates,

weidments

are

hot,

and

com

pressed

gases

may

be

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

in

stan

dards

referenced

in

index.

H.

Burn

Protection

Comply

with

precautions

in

1-2.

The

welding

arc

is

intense

and

visibly bright.

its

radiation

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

bums

resemble

acute

sunburn,

those

from

gas-

shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1

-2A).

As

nec

essary,

use

additional

protective

clothing

such

as

leather

jacket

or

sleeves,

flame-proof

apron,

and

fire-re

sistant

leggings.

Avoid

outer

garments

of

untreated

cot

ton.

Bare

skin

protection.

Wear

dark,

substantIal

clothing.

Button

collar

to

protect

chest

and

neck

and

button

pock

ets

to

prevent

entry

of

sparks.

2.

Eye

and

Head

Protection

Protect

eyes

from

exposure

to

arc.

NEVER

look

at

an

electric

arc

without

protection.

Welding

helmetorshield

containing

a

filter

plate

shade

no.12or

denser

must

be

used

when

welding.

Place

over

face

before

striking

am.

Protect

filter

plate

withaclear

cover

plate.

Cracked

or

broken

helmet

or

shield

should

NOT

be

worn;

radiation

can

pass

through

to

cause

bums.

Cracked,

broken,

or

loose

filter

plates

must

be

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

bro

ken,

pitted,

or

spattered.-

Flash

goggles

with

side

shields

MUST

be

worn

under

the

helmet

to

give

some

protection

to

the

eyes

should

the

helmet

not

be

lowered

over

the

face

before

an

arc

is

struck.

Looking

at

an

arc

momentarily

with

unprotected

eyes

(particularlyahigh

intensity

gas-shielded

arc)

can

cause

a

retinal

bum

that

may

leave

a

permanent

dark

area

in

the

field

of vision.

3.

Protection

of

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

a

sepa

rate

room

or

enclosed

bay

is

best.

In

open

areas,

sur

round

the

operation

with

low-reflective,

non-combusti

ble

screens

or

panels.

Allow

for

free

air

circulation,

par

ticularly

at

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

be

looking

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

I.

Toxic

Fume

Prevention

Comply

with

precautions

in

1

-2B.

Generator

engine

exhaust

must

be

vented

to

the

outside

air.

Carbon

monoxide

can

kilt.

J.

Fire

and

Explosion

Prevention

Comply

with

precautions

in

1-2C.

Equipments

rated

capacity.

Do

not

overload

arc

weld

ing

equipment.

It

may

overheat

cables

and

cause

a

fire.

Loose

cable

connections

may

overheat

or

flash

and

cause

a

fire.

Never

strike

an

arc

on

a

cylinder

or

other

pressure

ves

sel.

It

creates

a

brittle

area

that

can

cause

a

violent

rup

ture

or

leadtosuch

a

rupture

under

rough

handling.

K.

Compressed

Gas

Equipment

Comply

with

precautions

in1-2D.

L

Shock

Prevention

Exposed

hot

conductorsorother

bar

metal

in

the

weld

ing

circuit,

or

in

ungrounded,

electrically-HOT

equip

ment

can

fatally

shock

a

person

whose

body

becomes

a

conductor.

DO

NOT

STAND,

SIT,

LIE,

LEAN

ON,

OR

TOUCH

a

wet

surface

when

welding,

without

suitable

protection.

To

protect

against

shock:

Keep

body

and

clothing

dry.

Never

work

in

damp

area

without

adequate

insulation

against

electrical

shock.

Stay

on

a

dry

duckboard,

or

rubber

mat

when

dampness

or

sweat

can

not

be

avoided.

Sweat,

sea

water,

or

mois

ture

between

body

and

an

electrically

HOT

part-or

grounded

metal-reduces

the

body

surface

electrical

re

sistance,

enabling

dangerous

and

possible

lethal

cur

rents

to

flow

through

the

body.

1.

Grounding

the

Equipment

When

arc

welding

equipmentIsgrounded

according

to

the

National

Electrical

Code,

and

the

work

is

grounded

according

to

ANSI

Z49.1

usafety

In

Welding

And

Cut

ting,

a

voltage

may

exist

between

the

electrode

and

any

conducting

object.

Examples

of

conducting

objects

in

clude,

but

are

not

limited

to,

buildings,

electrical

tools,

work

benches,

welding

power

source

cases,

workpieces,

etc.

Never

touch

the

electrode

and

any

metal

object

unless

the

welding

power

source

Is

oft.

When

installing,

connect

the

framesofeach

unit

such

as

welding

power

source,

control,

work

table,

and

water

cir

culatorto

the

building

ground.

Conductors

must

be

ade

quate

to

carry

ground

currents

safely.

Equipment

made

electrically

HOT

by

stray

current

may

shock,

possibly

f

a-

tally.

Do

NOT

GROUND

to

electrical

conduit,

orto

a

pipe

carrying

ANY

gas

ortlammable

liquid

such

as

oil

or

fuel.

F2544

Pace

4