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MAY

1988

FORM:

121988

CWN

ERS

MANUAL

~1I

I

I~J

~

II

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

35

Cents

IMPORTANT

______________

Read

and

understand

the

entire

Contents

of

this

manual,

with

special

emphasis

on

the

safety

material

throughout

the

manual,

before

installing,

operating,

or

maintaining

this

equip

ment.

This

unit

and

these

instructions

are

for

use

only

by

persons

trained

and

experienced

in

the

safe

operation

of

welding

equipment.

Do

not

allow

un

trained

persons

to

install,

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

Effective

With

Style

No.

JD-1

MODEL

AUTO

ARC

AATC-150

NWSA

CODE

NO.

4579

PAINTED

IN

U S,A

ONEYEARLIMITEDWARRANTY

COVERAGE

-

Miller

Electric

Mfg.

Co.

warrants

to

the

buyer

REMEDY

FOR

DEFECTIVE

WELDER

-

Upon

receipt

of

any

who

purchases

this

Auto

Arc

Welder

(Welderl

for

personal,

defective

Welder,

Miller

Electric

will,

at

its

option,

repair

or

%

family

or

household

purposes

lConsumerl

that

this

Welder

replace

the

defective

Welder

at

its

expense,

refund

or

credit

will

be

free

from

defects

in

material

and

workmanship

for

a

the

purchase

price

(less

reasonable

depreciation

based

on

ac

period

of

one

year

from

the

date

of

purchase.

This

warranty

tual

use),

or

reimburse the

Consumer

for

the

cost

of

repair

or

covers

Only

the

original

purchaser

of

this

Welder.

Miller

Electric

replacement

at

an

approved

Miller

Electric

warranty

station,

does

not

authorize

any

party,

including

its

authorized

provided

that

the

purchaser

of

that

Welder

has

followed

the

distributors,

to

offer

any

other

warranty

on

behalf

of

Miller

procedure

for

obtaining

warranty

performance

set

forth

below.

~

Electric.

Upon

expiration

of

the

warranty

period,

Miller

Electric

The

Welder

so

repaired

or

used

as a

replacement

will

be

ship

~

shall

have

no

further

liability

related

to

the

Welder,

except

on

ped

to

the

purchaser

of

the

defective

Welder,

with

transporta

warranty

claims

made

during

the

warranty

period.

tion

charges

prepaid

to

any

destination

in

the

continental

United

States

Itransportation

charges

on

shipments

to

Alaska

THIS

WARRANTY

IS

OFFERED

IN

LIEU

OF

ANY

OTHER

or

Hawaii

will

be

paid

only

to

the

nearest

port

of

export).

EXPRESS

WARRANTY;

AND,

EXCEPT

TO THE

EXTENT

(4

PROHIBITED

BY

APPLICABLE

LAW,

THE

DURATION

OF

ALL

IMPLIED

WARRANTIES,

INCLUDING

BUT

NOT

THE

PURCHASERS

REMEDIES

FOR

A

DEFECTIVE

LIMITED

TO

THE

IMPLIED

WARRANTIES

OF

MERCHAN-

WELDER,

TO

THE

EXTENT

PERMITTED

BY

APPLICABLE



TABILITY

AND

FITNESS

FOR

A

PARTICULAR

PURPOSE,

IS

LAW,

ARE

LIMITED

TO

THE

REMEDY

PROVIDED

BY

THIS

LIMITED

TO

THE

DURATION

OF

THIS

WARRANTY. WARRANTY:

AND,

TO

THE

EXTENT

ENFORCEABLE

UNDER

APPLICABLE

LAW,

MILLER

ELECTRIC

SHALL

IN

(4,

Some

states

do

not

allow

limitations

on

how

long

an

implied

NO

EVENT

BE LIABLE

FOR

CONSEQUENTIAL,

INCIDENTAL

~

warranty

lasts,

so

the

above

limitation

may

not

apply

to

you.

OR

SPECIAL

DAMAGES

ARISING

OUT

OF

THE USE

OF,

OR

(

This

warranty

gives

you

specific

legal

rights,

and you

may

also

INABILITY

TO

USE,

THE

WELDER,

WHETHER

BASED

ON

have

other

rights

which

vary

from

state

to

state.

BREACH

OF

THIS

WARRANTY,

MILLER

ELECTRICS

NEGLIGENCE

OR

OTHER

TORT,

OR

ON

ANY

THEORY

OF

STRICT

LIABILITY.

Except

as

specified

below,

Millers

warranty

does

not

apply

to

components

having

normal

useful

life

of less

than

one

(1

I

year,

such

as

spot

welder

tips,

relay

and

contactor

~

Some

states

do

not

allow

the

exclusion

or

limitation

of

con

~...

parts

that

come

in

contact

with

the

welding

wire

including

sequential

or

incidental

damages,

so

the

above

limitations

may

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

not

apply

to

you.

defect

in

workmanship

or

material.

it$~

Miller

shall

be

required

to

honor

warranty

claims

on

war-

PROCEDURE

FOR

OBTAINING

WARRANTY

PERFORMANCE

c3i~

~

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

As

soon

as

any

defect

in

a

Welder

becomes

known,

the

pur

within

the

following

periods

from

the

date

of

delivery

of

Equip-

chaser

of

the

Welder

must,

within

thirty

(301

days,

notify

an

ment

to

the

original

user:

approved

Warranty

Station

or

Miller

Electric

in

writing

of

the

c3t~

1.

Arc

welders,

power

sources,

and

components

1

defect.

The

purchasei

must

then,

within

the

one

year

warranty

year

period,

return

the

Welder

to

Miller

Electric

at

the

following

ad-

2.

Original

main

power

rectifiers

3

years

dress:

(labor

-

1

year

only)

3.

All

welding

guns,

feeder/gunsand

plasma

torches...

~c~~

Miller

Electric

Mfg.

Co.

4.

Replacement

or

repair

parts,

exclusive

of

labor

.

.

60

days

718

South

Bounds

Street

P.O.

Box

1079

WHAT

IS

NOT

COVERED

-

This

warranty

does

not

extend

Appleton,

Wisconsin

54912

c.~..

to

any

Welder

subjected

to

misuse,

neglect,

accident,

or

in

~

warranty

repair

by

anyone

except

Miller

Electric.

Further,

this

All

transportation

charges

to

Warranty

Station

or

Miller

Electric

warranty

only

extends

to

those

purchasing

the

Welder

for

per-

must

be

prepaid.

-

sonal,

family

or

household

purposes.

Commercial

and

in

dustrial

users

are

given

a

different

warranty.

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

always

be

given.

Some

are

based

on

common

sense,

others

may

require

technical

volumes

to

explain.

It

is

wiser

to

follow

the

rules.

Read

and

understand

these

safe

practices

before

at

tempting

to

install,

operate,

or

service

the

equipment.

Comply

with

these

procedures

as

applicable

to

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

of

others.

Failure

to

observe

these

safe

practices

may

cause

seri

ous

injury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1

-Genaral

Precautions,

common

to

arcwelding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

on

safety

are

also

available

for

additional

and

more

complete

pro

cedures

than

those

given

in

this

manual.

They

are

listed

in

the

Standards

Index

in

this

manual.

ANSI

Z49.1

is

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

a

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Different

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radiation

levels.

In

addition

to

the

information

In

this

manual,

be

sure

to

consult

flux

and

electrode

manufacturers

Material

Safety

Data

Sheets

(MSDS5)

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

cuff

less

trousers

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

glasses

with

side

shields

underneath,

appropriate

filter

lenses

or

plates

(protected

by

clear

cover

glass).

This

is

a

MUST

for

welding

or

cutting,

(and

chipping)

to

protect

the

eyes

from

radiant

energy

and

flying

metal.

Repiace

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

ordepletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

as

described

in

ANSI

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

if

downstream

valves

have

been

accidentally

opened

or

left

open.

Check

to

be

sure

that

the

space

is

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

be

decomposed

by

the

heat

of

the

arc

(or

flame)

to

form

PHOSGENE,

a

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

of

the

arc

can

also

decompose

trichloroethylene

and

perchloroethylene

121988

Page

1

vapors

to

form

phosgene.

DO

NOT

WELD

or

cut

where

solvent

vapors

can

be

drawn

into

the

welding

or

cutting

atmosphere

or

where

the

radiant

energy

can

penetrate

to

atmospheres

containing

even

minute

amounts

of

trichioroethylene

or

perchloroethylene.

C. Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

mate

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,

venti

lators.

If

the

work

cannot

be

moved,

move

combustibles

at

least

35

feet

away

out

of

reach

of

sparks

and

heat;

or

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

or

shields.

Walls

touching

combustibles

on

opposite

sides

should

not

be

welded

on

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

b~e

protected

by

heat-resistant

covers

or

shields.

Fire

watcher

must

be

standing

by

with

suitable

fire

extin

guishing

equipme

nt

during

and

for

sometime

after

weld

ing

or

cutting

if:

a.

appreciable

combustibles

(including

building

construction)

are

within

35

feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

or

visible)

in

floors

or

walls

within

35

feet

may

expose

combustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

should

be

obtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

combustibles,

or

that

can

produce

flammable

or

toxic

vapors

when

heated,

must

never

be

welded

on

or

cut,

unless

container

has

first

been

cleaned

as

described

in

AWS

Standard

A6.O,

listed

7

in

Standards

Index.

This

includes:

a

thorough

steam

or

caustic

cleaning

(or

a

solvent

or

water

washing,

depending

on

the

combusti

bles

solubility)

followed

by

purging

and

inerting

with

ni

trogen

or

carbon

dioxide,

and

using

protective

equip

ment

as

recommended

in

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

A

container

with

unknown

contents

should

be

cleaned

(see

preceding

paragraph).

Do

NOT

depend

on

sense

of

smell

or

sight

to

determine

if

it

is

safe

to

weld

or

cut.

Hollow

castings

or

containers

must

be

vented

before

welding

or

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

or

cut

where

the

air

may

contain

flammable

dust,

gas,

or

liquid

vapors

(such

as

gasoline).

D.

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

in

this

manual,

and

those

detailed

in

CGA

Standard

P-i

,

SAFE

HANDLING

OF

COMPRESSED

GASES

IN

CYLIN

DERS,

listed

11

in

Standards

Index.

1.

Pressure

Regulators

Regulator

relief

valve

is

designed

to

protect

only

the

regulator

from

overpressure:

it

is

not

intended

to

protect

any

downstream

equipment.

Provide

such

protection

with

one

or

more

relief

devices.

Never

connect

a

regulator

to

a

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

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.

(See

l-3C.)

ICC

or

DOT

marking

must

be

on

each

cylinder.

It

is

an

assurance

of

safety

when

the

cylinder

is

properly

han

dled.

Identifying

gas

content.

Use

only

cylinders

with

name

of

gas

marked

on

them;

do

not

rely

on

color

to

identify

gas

content.

Notify

supplier

if

unmarked.

NEVER

DEFACE

or

alter

name,

number,

or

other

markings

on

a

cylinder.

It

is

illegal

and

hazardous.

121988

Page

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,

slings,

or

magnets.

Do

NOT

expose

cylinders

to

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

Do

not

al

low

contents

to

exceed

130F.

Cool

with

water

spray

where

such

exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

objects,

and

weather.

Replace

caps

securely

when

moving

cylinders.

Stuck

valve.

Do

NOT

use

a

hammer

or

wrench

to

open

a

cylinder

valve

that

can

not

be

opened

by

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

to

mix

any

gases

in

a

cylinder.

Never

refill

any

cylinder.

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

tings

to

splice

hose.

Avoid

long

runs

to

prevent

kinks

and

abuse.

Suspend

hose

off

ground

to

keep

it

from

being

run

over,

stepped

on,

or

otherwise

damaged.

Coil

excess

hose

to

prevent

kinks

and

tangles.

Protect

hose

from

damage

by

sharp

edges,

and

by

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

in

water;

bubbles

in

dicate

leaks.

Repair

leaky

or

worn

hose

by

cutting

area

out

and

splic

ing

(1-2D3).

Do

NOT

tape.

4.

Proper

Connections

Clean

cylinder

valve

outlet

of

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

of

ignition.

Wipe

with

a

clean

lintless

cloth.

Match

regulator

to

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

area,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

a

regulator

designed

for

a

particular

gas

or

gases

to

a

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

If

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

a

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

if

one

is

required.

use

two

wrenches

to

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

be

identified

by

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

on

nut

or

shank)

for

fuel

gas.

5.

Pressurizing

Steps:

Drain

regulator

of

residual

gas

through

suitable

vent

be

fore

opening

cylinder

(or

manifold

valve)

by

turning

ad

justing

screw

in

(clockwise).

Draining

prevents

exces

sive

compression

heat

at

high

pressure

seat

by

allowing

seat

to

open

on

pressurization.

Leave

adjusting

screw

engaged

slightly

on

single-stage

regulators.

Stand

to

side

of

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

so

that

regulator

pressure

in

creases

slowly.

When

gauge

is

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

in

fol

lowing

position:

For

oxygen,

and

inert

gases,

open

fully

to

seal

stem

against

possible

leak.

For

fuel

gas,

open

to

less

than

one

turn

to

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

on

regulators.

Check

for

leaks

on

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(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

Staging-Support

Rope

staging-support

should

not

be

used

for

welding

or

cutting

operation;

rope

may

burn.

Trademark

of

Proctor

&

Gamble.

121988

Page

3

1-3.

ARC

WELDING

Comply

with

precautions

in

1-1,

1-2,

and

this

section.

Arc

Welding,

properly

done,

is

a

safe

process,

but

a

careless

operator

invites

trouble.

The

equipment

carries

high

currents

at

significant

voltages.

The

arc

is

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

in

frared

energy

radiates,

weldments

are

hot,

and

com

pressed

gases

may

be

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

in

stan

dards

referenced

in

index.

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

fight-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-

shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1-2A).

As

nec

essary,

use

additional

protective

clothing

such

as

leather

jacket

or

sleeves,

flame-proof

apron,

and

f

ire-re

sistant

leggings.

Avoid

outer

garments

of

untreated

cot-

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

to

protect

chest

and

neck

and

button

pock

ets

to

prevent

entry

of

sparks.

2.

Eye

and

Head

Protection

Protect

eyes

from

exposure

to

arc.

NEVER

look

at

an

electric

arc

without

protection.

Welding

helmet

or

shield

containing

a

filter

plate

shade

no.

12

or

denser

must

be

used

when

welding.

Place

over

face

before

striking

arc.

Protect

filter

plate

with

a

clear

cover

plate.

Cracked

or

broken

helmet

or

shield

should

NOT

be

worn;

radiation

can

pass

through

to

cause

burns.

Cracked,

broken,

or

loose

filter

plates

must

be

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

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

(particularly

a

high

intensity

gas-shielded

arc)

can

cause

a

retinal

burn

that

may

leave

a

permanent

dark

area

in

the

field

of

vision.

3.

Protection

of

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

a

sepa

rate

room

or

enclosed

bay

is

best.

In

open

areas,

sur

round

the

operation

with

low-reflective,

non-combusti

ble

screens

or

panels.

Allow

for

free

air

circulation,

par

ticularly

at

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

be

looking

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

I.

Toxic

Fume

Prevention

Comply

with

precautions

in

1-2B.

Generator

engine

exhaust

must

be

vented

to

the

outside

air.

Carbon

monoxide

can

kill.

J.

FIre

and

Explosion

Prevention

Comply

with

precautions

in

1-2G.

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

nip

ture

or

lead

to

such

a

rupture

under

rough

handling.

K.

Compressed

Gas

Equipment

Comply

with

precautions

in

1-2D.

L.

Shock

Prevention

Exposed

hot

conductors

or

other

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

matwhen

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

equipment

is

grounded

according

to

the

National

Electrical

Code,

and

the

work

is

grounded

according

to

ANSI

Z49.1

Safety

In

Welding

And

Cut

ting,

a

voltage

may

exist

betweenthe

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

off.

When

installing,

connect

the

frames

of

each

unit

such

as

welding

power

source,

control,

worktable,

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

orflammable

liquid

such

as

oil

orfuel.

121988

Page

4

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

equipment

will

become

electrically

HOT-a

dangerous

condition

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

for

continuity.

Be

sure

conductors

are

touching

bare

metal

of

equipment

frames

at

connections.

If

a

line

cord

with

a

ground

lead

is

provided

with

the

equipment

for

connection

to

a

switchbox,

connect

the

ground

lead

to

the

grounded

switchbox.

If

a

three-prong

plug

is

added

for

connection

to

a

grounded

mating

re

ceptacle,

the

ground

lead

must

be

connected

to

the

ground

prong

only.

If

the

line

cord

comes

with

a

three-

prong

plug,

connect

to

a

grounded

mating

receptacle.

Never

remove

the

ground

prong

from

a

plug,

or

use

a

plug

with

a

broken

off

ground

prong.

2.

Electrode

Holders

Fully

insulated

electrode

holders

should

be

used.

Do

NOT

use

holders

with

protruding

screws.

3.

Connectors

Fully

insulated

lock-type

connectors

should

be

used

to

join

welding

cable

lengths.

4.

Cables

Frequently

inspect

cables

for

wear,

cracks

and

damage.

IMMEDIATELY

REPLACE

those

with

excessively

worn

or

damaged

insulation

to

avoid

possibly-lethal

shock

from

bared

cable.

Cables

with

damaged

areas

may

be

taped

to

give

resistance

equivalent

to

original

cable.

Keep

cable

dry,

free

of

oil

and

grease,

and

protected

from

hot

metal

and

sparks.

5.

Terminals

And

Other

Exposed

Parts

Terminals

and

other

exposed

parts

of

electrical

units

should

have

insulating

covers

secured

before

opera

tion.

6.

Electrode

a.

Equipment

with

output

on/oft

control

(contactor)

Welding

power

sources

for

use

with

the

gas

metal

arc

welding

(GMAW),

gas

tungsten

arc

welding

(GTAW)

and

similar

processes

nor

mally

are

equipped

with

devices

that

permit

on

off

control

of

the

welding

power

output.

When

so

equipped

the

electrode

wire

becomes

elec

trically

HOT

when

the

power

source

switch

is

ON

and

the

welding

gun

switch

is

closed.

Never

touch

the

electrode

wire

or

any

conducting

ob

ject

in

contact

with

the

electrode

circuit

unless

the

welding

power

source

is off.

b.

Equipment

without

output

on/off

control

(no

contacto

r)

Welding

power

sources

used

with

shielded

metal

arc

welding

(SMAW)

and

similar

proc

esses

may

not

be

equipped

with

welding

power

output

on-off

control

devices.

With

such

equip

ment

the

electrode

is

electrically

HOT

when

the

power

switch

is

turned

ON.

Never

touch

the

electrode

unless

the

welding

power

source

is

of

f.

7.

Safety

Devices

Safety

devices

such

as

interlocks

and

circuit

breakers

should

not

be

disconnected

or

shunted

out.

Before

installation,

inspection,

or

service,

of

equipment,

shut

OFF

all

power

and

remove

line

fuses

(or

lock

or

red-tag

switches)

to

prevent

accidental

turning

ON

of

power.

Disconnect

all

cables

from

welding

power

source,

and

pull

all

115

volts

line-cord

plugs.

Do

not

open

power

circuit

or

change

polarity

while

weld

ing.

If,

in

an

emergency,

it

must

be

disconnected,

guard

against

shock

burns,

or

flash

from

switch

arcing.

Leaving

equipment

unattended.

Always

shut

OFF

and

disconnect

all

power

to

equipment.

Power

disconnect

switch

must

be

available

near

the

welding

power

source.

M.

Protection

For

Wearers

of

Electronic

Life

Sup

port

Devices

(Pacemakers)

Magnetic

fields

from

high

currents

can

affect

pacemaker

operation.

Persons

wearing

electronic

life

support

equipment

(pacemaker)

should

consult

with

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

1-4.

STANDARDS

BOOKLET

INDEX

For

more

information,

refer

to

the

following

standards

or

their

latest

revisions

and

comply

as

applicable:

1.

ANSI

Standard

Z49.1,

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

American

Welding

Society,

550 N.W.

LeJeune

Rd,

Miami,

FL

33126.

2.

NIOSH,

SAFETY

AND

HEALTH

IN

ARC

WELDING

AND

GAS

WELDING

AND

CUTTING

obtainable

from

the

Superintendent

of

Documents,

U.S.

Gov

ernment

Printing

Office,

Washington,

D.C.

20402.

3.

OSHA,

SAFETY

AND

HEALTH

STANDARDS,

29CFR

1910,

obtainable

from

the

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

4.

ANSI

Standard

Z87.1,

SAFE

PRACTICES

FOR

OCCUPATION

AND

EDUCATIONAL

EYE

AND

FACE

PROTECTION

obtainable

from

the

Ameri

can

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

5.

ANSI

Standard

Z41.1,

STANDARD

FOR

MENS

SAFETY-TOE

FOOTWEAR

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

6.

ANSI

Standard

Z49.2,

FIRE

PREVENTION

IN

THE

USE

OF

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

121988

Page

5

7.

AWS

Standard

A6.0,

WELDING

AND

CUTTING

CONTAINERS

WHICH

HAVE

HELD

COMBUS

TIBLES

obtainable

from

the

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126.

8.

NFPA

Standard

51,

OXYGEN-FUEL

GAS

SYS

TEMS

FOR

WELDING,

CUTTING,

AND

ALLIED

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

9.

NFPA

Standard

70,

NATIONAL

ELECTRICAL

CODE

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

10.

NFPA

Standard

51B,

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

11.

CGA

Pamphlet

P-i,

SAFE

HANDLING

OF

COM

PRESSED

GASES

IN

CYLINDERS

obtainable

from

the

Compressed

Gas

Association,

1235

Jef

ferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

12.

CSA

Standard

W117.2,

CODE

FOR

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

Ca

nadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1R3.

13.

NWSA

booklet,

WELDING

SAFETY

BIBLIOGRA

PHY

obtainable

from

the

National

Welding

Supply

Association,

1900

Arch

Street,

Philadelphia,

PA

19103.

14.

American

Welding

Society

Standard

AWSF4.1,

RECOMMENDED

SAFE

PRACTICES

FOR

THE

PREPARATION

FOR

WELDING

AND

CUTTING

OF

CONTAINERS

AND

PIPING

THAT

HAVE

HELD

HAZARDOUS

SUBSTANCES,

obtainable

from

the

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126.

15.

ANSI

Standard

Z88.2,

PRACTICE

FOR

RESPIRA

TORY

PROTECTION,

obtainable

from

the

Ameri

can

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

SECTION

2



INTRODUCTION

Max.

Rated

Welding

Cu~rrent

Welding

Power

Source

Voltage

Range

Dimensions

Weight

Net

I

Ship

30

lbs.

32

lbs.

(13.6

kg)

(15

kg)

150

amperes

at

20%

duty

cycle

20

-

80

Volts

AC

Height

-

7

1/4

in

(184

mm)

Width

-

8

1/2

in

(216

mm)

Length

-

14

in

(356

mm)

Figure

2-1.

SpecIfications

2-1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

Information

presented

in

this

manual

and

on

various

la

bels,

tags,

and

plates

provided

on

the

unit

pertains

to

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

be

read,

understood,

and

followed

for

the safe

and

effective

use

of

this

equip-

me

nt.

B.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

of

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

of

others.

Therefore,

this

equipment

is

to

be

in

stalled,

operated,

and

maintained

only

by

qualified

per

sons

in

accordance

with

this

manual

and

all

applicable

codes

such

as,

but

not

limited

to,

those

listed

at

the

end

of

Section

1



Safety

Rules

For

Operation

Of

Arc

Weld

ing

Power

Source.

Safety

instructions

specifically

pertaining

to

this

unit

ap

pear

throughout

this

manual

highlighted

by

the

signal

words

WARNING

and

CAUTION

which

identify

differ

ent

levels

of

hazard.

WARNING

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

serious

personal

injury

or

loss

of

life.

CAUTION

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

minor

personal

injury

or

damage

to

this

equipment.

A

third

signal

word,

IMPORTANT

highlights

instruc

tions

which

need

special

emphasis

to

obtain

the

most

ef

ficient

operation

of

this

equipment.

2-2.

RECEIVING-HANDLING

Priorto

installing

this

equipment,

clean

all

packing

mate

rial

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

121988

Page

6

transit

must

be

filed

by

the

purchaser

with

the

carrier.

A

copy

of

the

bill

of

lading

will

be

furnished

by

the

manu

facturer

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

itis

essentialthat

Model

Description

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

2-3.

DESCRIPTION

This

unit

converts

the

output of

an

ac

welding

power

source

to

provide

dc

output

for

Shielded

Metal

Arc

Weld

ing

and

scratch

start

Gas

Tungsten

Arc

Welding.

The

unit

is

equipped

with

2

four-foot

interconnecting

cables

and

jack

plugs.

The

cooling

fan

operates

on

the

welding

power

source

secondary

voltage.

2-4.

DUTY

CYCLE

(Figure

2-2)

The

duty

cycle

is

the

percentage

of

the

ten

minute

period

that

this

unit

can

be

operated

at

a

given

output

without

causing

damage

and

overheating.

This

unit

is

rated

at

20

percent

duty

cycle.

This

means

the

unit

can

be

oper

ated

at

rated

load

for

two

minutes

out

of

every

ten.

Dur

ing

the

remaining

eight

minutes,

the

unit

should

idle

to

permit

proper

cooling.

If

the

welding

amperes

are

de

creased,

the

duty

cycle

will

increase.

Figure

2-2

enables

the

operator

to

determine

the

output

of

the

unit

at

vari

ous

duty

cycles.

a

CAUTION:

EXCEEDING

DUTY

CYCLE

RAT

INGS

will

damage

the

unit.

I

Do

not

exceed

indicated

duty

cycles.

SECTION

3-INSTALLATION

3-1.

LOCATION

The

service

life

and

efficiency

of

the

unit

are

reduced

when

it

is

subjected

to

high

levels

of

dust,

dirt,

moisture,

corrosive

vapors,

and

extreme

heat.

4A

CAUTION:

RESTRICTED

AIR

FLOW

causes

overheating

and

possible

damage

to

inter

nal

parts.



Do

not

restrict

air

flow

to

any

part

of

the

con-

trol.

3-2.

FIELD

INSTALLATION

ONTO

SW2225

(If

appli

cable)

(Figure

3-1)

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

Shut

down

welding

power

source,

and

dis

connect

input

power

employing

lockout/tagging

procedures

before

beginning

this

installation.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon

necting

device.

To

install

unit

onto

SW2225,

proceed

as

follows:

1.

install

brackets

to

unit

using

sheet

metal

screws

in

wrapper.

2.

Drill

two

5/32

in.

(4

mm)

diameter

holes

in

SW2225

wrapper

on

each

side

at

locations

shown

in

Figure

3-1.

3.

install

unit

onto

SW2225

wrapper

using

supplied

screws.

3-3.

CONNECTION

TO

WELDING

POWER

SOURCE

(Figure

3-2)

4A

WARNING:

ELECTRIC

SHOCK

can

kill.



Shut

down

the

welding

power

source

and

be

sure

it

cannot

be

accidentally

energized

before

connecting

the

converter.

IMPORTANT:

If

the

welding

power

source

has

weld

output

terminals,

install

lugs

of

adequate

amperage

ca

pacity

to

the

cables

from

the

converter.

300

250

RATED

OUTPUT



~-



U,

iu

150

~

w

0.

~

4

~100

uJ

~

75

50~

-.

~h











- -

~





10

15

20 25 30

40

50

00

70 00

90

100

%

DUTY

CYCLE

8-088

987

Figure

2-2.

Duty

Cycle

Chart

a

121988

Page

7

A.

Jack

Plug

Assembly

4A

WARNING:

ELECTRIC

SHOCK

can

kill;

ARCING

can

burn

skin

or

damage

electrical

connections.



Do

not

touch

live

electrical

parts.



Be

sure

that

unit

is

completely

shutdown

be

fore

making

any

weld

output

connections.



Do

not

change

position

of

the

welding

cable

jack

plugs

while

welding.



Be

sure

the

jack

plugs

are

secure

in

correct

receptacles

before

welding.

The

red

jack

plugs

are

supplied

to

provide

connections

to

the

weld

output

receptacles

on

the

welding

power

source.

Assemble

the

jack

plugs

as

follows:

1.

Remove

1

inch

(25.4

mm)

of

insulation

from

one

end

of

welding

cable.

2.

Clamp

cable

in

a

vise

with

the

uninsulated

end

ex

tending

upward

out

of

vise

approximately

1-3/4

inches

(44.5

mm).

3.

Place

steel

tie

wire

(item

A)

approximately

1/4

inch

(6.4

mm)

from

end

of

insulation.

4.

Make

a

half

turn

around

the

cable

bringing

looped

ends

of

tie

wire

together.

A~

B?L1~

D

E

~

~

F

~

024.4

Figure

3-2.

Jack

Plug

InstallatIon

11.

Insert

the 1/4-20

setscrews

into

the

center

and

bot

tom

holes

in

jack

plug

and

tighten

(E).

12.

Remove

cable

from

vise

and

insert

jack

plug

into

in

sulating

sleeve.

Slide

insulating

sleeve

over

jack

plug

and

cable

until

hole

in

insulating

sleeve

lines

up

with

remaining

hole

in

jack

plug

(F).

13.

Insert

the

8-32

self-tapping

screw

(F)

through

hole

in

insulating

sleeve

into

jack

plug

and

tighten.

B.

Cable

Installation

Connect

the

cables

from

the

converter

to

the

appropri

ate

weld

output

receptacles

on

the

welding

power

source.

IMPORTANT:

lithe

welding

power

source

has

high

and

low

current

ranges,

best

welding

results

wi//be

obtained

using

the

range

with

higher

open

circuit

voltage.

3-4.

WELD

OUTPUT

CONNECTIONS

4A

WARNING:

ELECTRIC

SHOCK

can

kill;

ARCING

can

burn

skin

or

damage

electrical

connections.



Do

not

touch

live

electrical

parts.



Be

sure

that

unit

is

completely

shut

down

be

fore

making

any

weld

output

connections.



Do

not

change

position

of

the

welding

cable

jack

plugs

while

welding.



Be

sure

the

jack

plugs

are

secure

in

correct

receptacles

before

welding.

5.

Insert

a

3/8

inch

(9.5

mm)

diameter

rod

through

looped

ends

of

tie

wire.

6.

Twist

tie

wire

(B)

until

entire

tie

wire

is

twisted

and

is

tight

around

insulation

of

cable.

7.

Clip

off

looped

ends

of

tie

wire.

8.

Bend

the

twisted

tie

wire

over

and

along

the side

(C)

of

uninsulated

portion

of

cable.

9.

Wrap

the

strip

of

copper

foil

tightly

around

uninsu

lated

end

of

cable

and

twisted

tie

wire

(D).

10.

Push

the

jack

plug

onto

cable

over

copper

foil

(E).

Figure

3-1.

Installation

On

Top

Of

SW2225

121988

Page

8