Miller INTELLIMATIC S-52M Manuale utente

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Millerﬁ

May1994

Form:

OM-1547H

Effective

With

Serial

No.

KE621

826

OWNERS

MANUAL

INTELLIMATICTM

S-52M

And

S-54M

Read

and

these

instructions

and

all

Give

this

manual

the

operator.



safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.



For

help,

call

your

distributor



Call

your

distributor

you

not

understand

I~J



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

the

directions.

Appleton,

54912

414-734-9821

cover

1194

SC-090

864-C

1994

MILLER

Electnc

Mfg.

Co.

PRINTED

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

warrsnts

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

this

limited

warranty

tree

tects

material

and

workmanship

the

time

shipped

MILLER.

THIS

WAR

RANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

IMPLIED,

INCLUDINO

THE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

replace

any

war

ranted

parts

components

that

tail

due

such

detects

material

workmanship.

MILLER

must

notitied

writing

within

thirty

(30)

days

such

detect

taiture,

which

time

MILLER

will

provide

instructions

the

warranty

claim

procedures

tollowed.

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

the

event

such

tailure

within

the

warranty

time

periods.

All

warranty

time

periods

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser,

one

year

after

the

equipment

sent

the

distributor.

5YeersPerte-3YeersLabor



Original

main

power

rectitiers

Years



Parts

and

Labor



Trenatormer/Rectitier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

Semi-Automatic

and

Automatic

Wire

Feeders



Robots

Years



Parts

and

Labor



Engine

Driven

Wetding

Generators

(NOTE:

Engines

era

warranted

separately

the

engine

menutecturer

tore

period

two

years.)



Air

Compreeeors

Year



Parts

end

Labor



Motor

Driven

Guns



Process

Controllers

Water

Coolant

Systems



Units



Grids



Spot

Wetdera



Load

Benke

SDX

Trenatormera

Running

Gear/Trailers



Field

Options

(NOTE:

Field

options

ere

covered

under

True

BIueTM

tor

the

remaining

warranty

period

the

product

they

are

installed

in,

tore

minimum

one

year



whichever

greeter.)

Months



Benenea

Days



Parts

end

Labor



MIG

Guna/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kite



Replacement

Parts

MILLERS

True

BlueTM

Umited

Warranty

shell

not

apply

to:

Iteme

tumiahed

MILLER,

but

menutectured

others,

such

engines

trade

acceaeoriee.

These

items

are

covered

the

menutecturere

warranty,

any.

Consumable

components;

such

contact

tips,

cutting

nozzles,

contectors

end

relays

parts

that

teil

due

normel

wear.

Equipment

that

has

been

moditied

any

perty

other

then

MtLLER,

equi~i

ment

that

has

been

improperly

installed,

improperiy

opereted

misused

based upon

industry

standards,

equipment

which

has

not

had

reasonable

end

necessary

maintenance,

equipment

which

has

been

ueed

tor

operation

outside

the

epeciticetions

tor

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

THE USE

AND

MAINTENANCE

WELDING

EOUIPMENT.

the

event

warranty

claim

covered

this

warranty,

the

exclusive

remedies

shall

be.

MILLERS

option:

(1)

repair;

(2)

replacement;

or,

where

authorized

writing

MILLER

appropriate

cases,

(3)

the

reasonable

coat

rerair

replace

ment

euthorized

MILLER

service

station;

(4)

payment

ciodit

tor

the

pur

cheae

price

(lees

raeeonable

depreciation

based

upon

actual

use)

upon

return

the

goode

customers

risk

end

expense.

MILLERS

option

repair

replacement

will

FOB.,

Factory

Appleton,

Wisconsin,

FOB.

eta

MILLER

authorized

eer

vice

tacility

determined

MILLER.

Theretore

compensation

reimburse

ment

tor

transportation

coats

any

kind

wilt

allowed.

THE

EXTENT

PERMITTED

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS OF

PROFIT),

WHETHER

BASED

CON

TRACT,

TORT

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

REPRESENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

0rHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

OR COURSE

DEALING,

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EOUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

Some

states

the

U.S.A.

not

allow

imitations

how

long

implied

warranty

lasts,

the

exclusion

incidental,

indirect,

special

consequential

damages,

the

above

limitation

exclusion

may

not

apply

you.

This warranty

provides

ape

citic

legal

rights,

end

other

rights

may

available,

but

may

very

trorn

state

state.

Ceneda,

tegietetion

some

provinces

provides

certain

additional

warranties

remediee

other

then

stated

herein.

and

the

extent

that

they

may

not

waived,

the

limitations

end

exclusions

aet

out

above

may

not

apply.

This

Limited

Warranty

provides

apecitic

leget

rights,

end

other

rights

may

available,

but

may

vary

trom

province

province.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

damage

with

the

delivering

carrier.

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

Style

Number.

Use

the

following

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit.

The

information

located

the

rating

label

nameplate.

Model

_________

Serial

Style

No.

Date

Purchase

miller

9/93

EMF

INFORMATION

TABLE

CONTENTS

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

OM-1

547H

5/94

NOTE

Considerations

About

Magnetic

Fields

The

following

quotation

from

the

General

Conclusions

Section

Welding

And

The

Effects

Low

Frequency

Electric

And

reduce

magnetic

fields

the

workplace,

use

the

following

the

U.S.

Congress,

Office

Technology

Assessment,

Biological

procedures:

Effects

Power

Frequency

Electric

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

there

now

very

Keep

cables

together

twisting

taping

them.

Arrange

cables

one

side

and

away

from

the

operator.

large

volume

scientific

findings

based

experiments

the

not

coil

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of this

work

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

interpret

the

evidence

Keep

welding

power

source

and

cables

far

away

practical.

Connect

work

clamp

workpiece

the

weld

possible.

single

coherent

framework.

Even

frustrating,

does

not

yet

About

Pacemakers:

allow

draw

definite

conclusions

about

questions

possible

The

above

procedures

are

among

those

also

normally

risk

offer

clear

science-based

advice

strategies

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

avoid

potential

risks.

complete

information.

modlO.1

4/93

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTION

2

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1.

General

Information

And

Safety

2-2.

Safety

Alert Symbol

And

Signal

Words

SECTION

3

SPECIFICATIONS

3-1.

Description

SECTION

4INSTALLATION

RELOCATION

4-1.

Location

4-2.

Hub

Installation

4-3.

Wire

Guide

And

Drive

Roll

Installation

4-4.

Welding

Gun

Connections

4-5.

Voltage

Sensing

Connections

4-6.

Shielding

Gas

Connection

4-7.

Drive

Motor

Vent

Screw

4-8.

Current

Relay

(Reed

Switch)

4-9.

Internal

Program

Options

4-10.

Welding

Power

Source/Wire

Feeder

Connections

4-11.

Welding

Wire

Installation

4-12.

Welding

Wire

Threading

SECTION

5

OPERATOR

CONTROLS

5-1.

Power

Switch

5-2.

Key-Switch

5-3.

Program

Select

Push

Button

5-4.

Purge

Push

Button

5-5.

Sequence

Advance

Push

Button

5-6.

Program

Sequence

Indicator

Lights

5-7.

Jog/Hours

Push

Button

5-8.

Volts

Numeric

Display

5-9.

Volts

Increase

And

Decrease

Push

Buttons

5-10.

Wire

Speed

Numeric

Display

5-11.

Wire

Speed

Increase

And

Decrease

Push

Buttons

5-12.

Program/Time

Numeric

Display

5-13.

Time

Increase

And

Decrease

Push

Buttons

SECTION

PRESETTING

SEMIAUTOMATIC

WELDING

PROGRAMS

6-1.

Definition

Terms

6-2.

Presetting

Semiautomatic

Welding

Programs

SECTION

7

SEQUENCE

OPERATION

7-1.

Normal

Welding

Without

Dual

Scheduling

7-2.

Dual

Scheduling Using

The

Gun

Trigger

SECTION

MAINTENANCE

TROUBLESHOOTING

8-1.

Routine

Maintenance

8-2.

Aligning

Drive

Rolls

And

Wire

Guide(s)

Two

Drive

Roll

Models

8-3.

Aligning

Motor

Gear

And

Drive

Gears

Four

Drive

Roll

Models

8-4.

Reinstallation

Hub

Assembly

8-5.

Overload

Protection

8-6.

Brush

Inspection

And

Replacement

8-7.

Diagnostic

Displays

8-8.

Microprocessor

Battery

8-9.

Clearing

The

Weld

Program

Memory

(RAM)

8-10.

Encoder

Disc

Cleaning

8-11.

Circuit

Board

Handling

Precautions

8-12.

Troubleshooting

SECTION

9

ELECTRICAL

DIAGRAMS

Diagram

9-1.

Circuit

Diagram

For

Wire

Feeder

Diagram

9-2.

Wiring

Diagram

SECTION

10

PARTS

LIST

Figure

10-1.

Main

Assembly

Optional

Equipment

Figure

10-2.

Wire

Drive

Gears

Figure

10-3.

Wire

Drive

Gears

Figure

10-4.

Control

Box

LIST

CHARTS

AND

TABLES

Table

3-1.

Specifications

Table

6-1.

Program

Steps

Table

8-1.

Maintenance

Schedule

Table

8-2.

Self-Diagnostic

Checks

Table

8-3.

Troubleshooting

Table

10-1.

Drive

Roll

Wire

Guide

Kits

Drive

Roll)

Table

10-2.

Drive

Roll

Wire

Guide

Kits

Drive

Roll)

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

SECTION

REGLES

SECURITE

POUR

FONCTIONNEMENT

POSTE

SOUDAGE

LARC

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

personal

experience,

child

touching

hot

stove

harmful,

wasteful,

and

wise.

Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

welding

and

cutting

are

described

this

manual.

Research,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

improperly

used

maintained.

The

reason

for

the

safe

practices

may

not

always

given.

Some

are

based

common

sense,

others

may

require

technical

volumes

explain.

wiser

the

rules.

Read

and

understand

these

safe

practices

before

tempting

install,

operate,

service

the

equipment.

Comply

with

these

procedures

applicable

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

serious

injury

death.

When

safety

becomes

habit,

the

equipment

can

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

General

Precautions,

common

arc

welding

and

cutting;

and

Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

safety

are

also

available

for

additional

and

complete

pro

cedures

than

those

given

this

manual.

They

are

listed

the

Standards

Index

this

manual.

ANSI

Z49.1

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

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.

addition

the

information

this

manual,

sure

consult

flux

and

elec

trode

manufacturers

for

specific

technical

data

and

precautionary

measures

concerning

their

material.

Burn

Prevention

Wear

protective

clothing

gauntlet

gloves

designed

for

use

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

glasses

with

side

shields

underneath,

appropriate

filter

lenses

plates

(protected

clear

cover

glass).

This

MUST

for

welding

cutting,

(and

chipping)

protect

the

eyes

1-1.

INTRODUCTION

Contrairement

lappren

tissage

vie,

lapprentissage

sØcuritØ

par

pØrience

personnelle,

comme

lenfant

qul

touche

poŒle

chaud,

est

dangereux,

imprudent

inutile.

lnstruisez-vous

donc

lexpØrience

dautrui.

Des

mØthodes

sØcuritØ

issues

lexpØrience

soudage

coupage

sont

dØcrites

dans

manuel.

recherche,

progres

lexpØrience

dans

domaine

ont

dØveloppØ

materiel

fiable

des

mØthodes

sØcuritØ

pour

installation,

fonctionnement

lentre

tien.

Des

accidents

produisent

lorsque

materiel

est

inadØquatement

utilisØ

entretenu.

raison

ces

mØthodes

sØcuritØ

peut

pas

Œtre

toujours

donnØe.

Certaines

sont

fondØes

sur

sens

commun,

dautres

demanderont

Œtre

expliquees

par

des

livres

techni

ques.

est

plus

sage de

suivre

regles.

Lisez

comprenez

ces

mØthodes

sØcuritØ

avant

dessayer

dinstaller,

faire

fonctionner

rØparer

lappareil.

Pour

votre

sØcuritØ

personnelle

celle

dautrui,

conformez-vous

ces

rŁgles

aux

manuels

dinstructions.

Manquer

dobserver

ces

mØthodes

sØcuritØ

pourrait

entrainer

des

blessures

graves

mŁme

mort. Quand

sØcuritØ

devient

une

habitude,

materiel

peut

alors

Œtre

utilisØ

toute

confiance.

Ces

mØthodes

sØcuritØ

sont

divisØes

deux

sec

tions:

Precautions

genØrales,

communes

soudage

coupage

larc,

Soudage

larc

(et

coupage)

(uniquement).

Normes

rØfØrence:

Des

publications

des

normes

amØricaines

sØcuritØ

sont

aussi

votre

disposition

pour

dautres

modes

opØratoires

plus

complets

que

ceux

present

manuel.

Elles

sont

donnØes

dans

lln

dex

des

Normes

ces

rŁgles

sØcuritØ.

ANSI

Z49-1

est

plus

complete.

Les

codes

IACNOR,

les

codes

provinciaux

municipaux

donnent

aussi

les

exigences

pour

une

stallation,

une

utilisation

entretien

sOrs.

1-2.

PRECAUTIONSGENERALES

Plusieurs

procØdØs

soudage

Iarc,

des

Iec

trodes

allis,

les

flux

peuvent

produire

des

vapeurs,

gaz,

niveaux

rayonnement

diffØrants.

Pour

tout

ronseignement

supplØmen

taire

manuel,

consultez

aussi

les

fabricants

dos

electrodes

des

flux

afin

dobtenir

las

rensaignaments

techniques

spØcifiquos

los

mosures

precaution

concernant

leurs

matØriaux.

Prevention

des

brOlures

Portez

des

vŒtements

protection

des

gants

crispin

spØcialement

dØsignes

pour

soudage,

casque

des

chaussures

sØcuritØ.

Boutonnez

col

votre

chemise

les

pattes

vos

poches,

portez

des

pan-

talons

sans

revers

pour

Øviter

que

des

Øtincelles

laitier

sy

introduisent.

Portez

masque

avec

lunettes

sØcuritØ

avec

Øcrans

latØ-raux

protection,

des

lunettes

filtrantes

des

couvre-lentilles

(protØgØs

par

verre

clair).

Pour

soudage

coupage

(et

burinage),

est

OM-1547

Page

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

spattered.

See

1-3A.2.

Avoid

oily

greasy

clothing.

spark

may

ignite

them.

Hot

metal

such

electrode

stubs

and

workpieces

should

never

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

qualified

first

aid

person

should

available

for

each

shift

unless

medical

facilities

are

for

mediate

treatment

flash

burns

the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

be used

per

sons

intending

weld

cut.

Toxic

Fume

Prevention

Severe

discomfort,

illness

death

can

result

from

fumes,

vapors,

heat,

oxygen

enrichment

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

described

ANSI

Stan

dard

Z49.1

listed

Standards

index.

NEVER

ventilate

with

oxygen.

Lead

cadmium

zinc

mercury

and

beryllium

bearing

and

similar

materials,

when

welded

(or

cut)

may

produce

harmful

concentrations

toxic

fumes.

Ade

quate

local

exhaust

ventilation

must

used,

each

person

the

area

well

the

operator

must

wear

air-supplied

respirator.

For

beryllium,

both

must

ed.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

removed

from

the

work

surface,

the

area

well

ven

tilated,

the

operator

wears

air-supplied

respirator.

Work

confined

space

only

while

being

ven

tilated

and,

necessary,

while

wearing

air-supplied

respirator.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large

quantities

can

change

oxygen

con

centration

dangerously.

not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source

prevent

possible

accumulation

gases

the

space

downstream

valves

have

been

accidently

opened

left

open.

Check

sure

that

the

space

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

decomposed

the

heat

the

arc

(or

flame)

form

PHOSGENE,

highly

toxic

gas,

and

other

lung

and

eye

irritating

pro

ducts.

The

ultraviolet

(radiant)

energy

the

arc

can

also

decompose

trichloroethylene

and

per

chloroethylene

vapors

form

phosgene.

NOT

WELD

cut

where

solvent

vapors

can

drawn

into

the

welding

cutting

atmosphere

where

the

radiant

OBLIGATOIRE

protØger

ses

yeux

contre

lØnergie

rayonnement

les

Øclats

metal.

Remplacez

verre

protecteur

lorsquiI

est

brisØ,

piquØ

quil

reu

des

projections.

Voir

1.3A.2.

Evitez

porter

des

habits

imprØgnØs

dhuile

graisse.

Une

Øtincelle

pourrait

les

enflammer.

manipulez

jamais

sans

gants

metal

chaud

tel

que

des

chutes

dØlectrde

des

piŁces

souder.

Premiers

soins

traitement

des

yeux:

Tout

atelier

devrait

avoir

disposition

poste

premiers

soins

ainsi

quune

personne

compØtente,

moms

quur,

ser

vice

medical

soit

proximite

pour

soigner

immediate

ment

les

brt~lures

des

yeux

peau.

Portez

des

bouche-oreilles

lorsque

vous

travaillez

plafond

dans

espace

restreint.

Portez

casque

lorsque

dautres

personnes

travaillent

plafond.

Les

personnes

devant souder

couper

doivent

pas

employer

des

preparations

inflammables

pour

leurs

cheveux.

Prevention

des

gax

toxiques

Les

gaz,

les

vapeurs,

chaleur,

enrichissement

manque

doxygene

peuvent

entrainer

malaise,

une

maladie

mØme

mort.

RemØdiez-y

par

ven

tilation

dØcrite

dans

Norme

ANSI

Z49.1

paragraphe

Ilndex

des

Normes.

ventilez

JAMAIS

r~~

ygene.

soudant

coupant,

les

plomb,

cadmium,

zinc,

mercure

beryllium

autres

matØriaux

semblables

peuvent

crØer

des

concentrations

nocives

gaz

toxi

ques.

dolt

avoir

recours

une

ventilation

aspirante

adequate

local,

alors

toute

personne

sur

les

lieux,

mŒme

que

soudeur,

doit

porter

masque

duction

dair.

doit

employer

les

deux

pour

beryllium.

Les

mØtaux

enrobØs

composes

matØriaux

Ømet

tant

des

gaz

toxiques

doivent

pas

Œtre

chauffØs

moms

que

lenrobage

soit

tØ

surface

travailler,

que

local

soit

bien

ventilØ,

que

soudeur

porte

masque

adduction

dair.

travaillez

dans

espace

restreint

que

sil

est

bien

ventilØ

et,

nØcessaire,

portez

masque

adduction

dair.

doit

Øviter

les

fuites

gaz

dans

espace

restreint.

Les

fuites

gaz

grande

quantitØ

peuvent

transformer

dangereusement

concentration

dox

ygene.

Namenez

pas

bouteilles

gaz

dans

espace

restreint.

quittant

espace

restreint,

FERMEZ

robinet

dalimentation

gaz

bouteille.

Ainsi

pourra

rentrer

toute

sØcuritØ

dans

piŁce,

mŒme

les

robinets

aval

ont

etØ

ouverts

par

accident,

Ofl

les

laissØs

ouverts.

Les

vapeurs

dissolvants

chlorØs

peuvent

Œtre

dØcom

posØes

par

chaleur

Iarc

(ou

flamme)

former

PHOSGENE,

gaz

trŁs

toxique,

dautres

produits

irritant

les

poumons

les

yeux.

LØnergie

ultra-violette

Iarc

peut

aussi

dØcomposer

les

vapeurs

trichloroØthylene

perchloroØthylene

pour

former

phosgene.

SOUDEZ.

PAS

coupez

pas

dans

des

endroits

o

les

vapeurs

dissolvants

peu

vent

Œtre

attirØes

dans

IatmosphŁre

soudage

OM-1547

Page

energy

can

penetrate

atmospheres

containing

even

minute

amounts

trichioroethylene

per

chloroethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

material;

misuse

compressed

gases

and

cylinders;

and

short

circuits.

AWARE

THAT

flying

sparks

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

doors,

and

through

wall

floor

openings,

out

sight

the

goggled

operator.

Sparks

and

slag

can

fly

feet.

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

oil,

grease,

and

(in

electrical

parts)

metallic

particles

that

can

cause

short

circuits.

combustibles

are

area,

NOT

weld

cut.

Move

the

work

practicable,

area

free

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

yen

tilators.

the

work

cannot

moved,

move

com

bustibles

least

feet

away

out

reach

sparks

and

heat;

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

shields.

Walls

touching

combustibles

opposite

sides

should

not

welded

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

tinguishing

equipment

during

and

for

some

time

after

welding

cutting

if:

appreciable

combustibles

(including

building

construction)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

visible)

floors

walls

within

feet

may

expose

com

bustibles

sparks

combustibles

adjacent

walls,

ceilings,

roofs,

metal

partitions

can

ignited

radiant

conducted

heat.

Hot

work

permit

should

obtained

before

operation

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

done,

check

that

area

free

sparks,

glowing

embers,

and

flames.

empty

container

that

held

combustibles,

that

can

produce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O,

listed

Standards

index.

This

includes:

thorough

steam

caustic

cleaning

(or

solvent

water

washing,

depending

the

corn-

coupage

o

lenergie

rayonnement

peut

pØnØtrer

dans

des

atmospheres

contenant

des

quantites

mŒme

minuscules

trichloroØthylŁne

per

chloroethylene.

Prevention

des

incendies

des

explosions

Les

causes

dincendie

dexplosion

sont

les

com

bustibles

atteints

par

larc,

flamme,

les

Øtincelles,

laitier

chaud

les

matØriaux

chauffØs,

mauvais

emploi

des

gaz

comprimØs

des

bouteilles

ainsi

que

courts-circuits.

Sachez

que

les

Øclats

dØtincelles

chute

laitier

peuvent

sinfiltrer

dans

les

fissures,

long

des

tuyauteries,

par

les

fenØtres

les

portes

par

les

couvertures

des

murs

sol,

sans

que

soudeur

portant

des

lunettes

les

voie.

Les

Øtincelles

les

scones

peuvent

voler

jusqu

pieds.

Pour

prØvenir

les

incendies

les

explosions:

Veillez

que

votre

appareil

soit

propre

Øtat

marche,

dØnuØ

dhuile

graisse,

particules

metal

sur

les

piŁces

electriques

qui

pourraient

entralner

des

courts-circuits.

des

combustibles

trouvent

proximitØ,

soudez

pas,

coupez

pas.

possible,

dØplacez

votre

travail

loin

des

combustibles.

Evitez

ateliers

peinture

pistolet,

les

cuves

dimmersion,

les

entrepts,

les

yen

tilateurs.

cela

nest

pas

possible,

placez

les

com

bustibles

moms

pieds

des

Øtincelles

chaleur

protØgez-Ies

des

Øtincelles

avec

des

couver

tures

des

Øcrans

protecteurs

adequats,

bien

ajustØs

ignifugØs.

doit

pas

souder

(ou

couper)

ctØ

oppose

des

murs

touchant

les

combustibles.

Les

murs,

plafonds

planchers

proches

travail

doivent

Œtre

proteges

par

des

couvertures

Øcrans

protecteurs

ignifugØs.

surveillant

doit

tenir

proximitØ

avec

materiel

lutte

contre

lincendie

adequat,

pendant

quelque

temps

aprŁs

soudage

coupage

si:

Des

quantites

apprØciables

dØ

combustibles

compris

une

construction

chantier)

trouvent

moms

pieds.

Des

quantites

apprØciables

combustibles

sont

plus

pieds

mais

peuvent

Œtre

enflammØes

par

des

Øtincelles.

Des

ouvertures

(cachØes

visibles)

sur

planchers

les

murs

moms

de 35

pieds

peuvent

exposer

des

combustibles

aux

Øtincelles.

Les

combustibles

adjacents

aux

murs,

plafonds,

toits

cloisons

mØtalliques

peu

vent

Œtre

enflammØs

par

une

chaleur

rayon

nante

transmise.

Avant

commencer,

avisez

contremaitre

pour

quiI

sassure

que

les

precautions

adequates

soient

prises.

Une

fois

travail

terminØ,

vØrifiez

quiI

ny

ait

pas

dØtincelles,

cendres

ardentes

flammes

dans

local.

doit

jamais

souder

couper

sur

recipient

ayant

contenu

des

combustibles,

pouvant

produire

des

vapeurs

inflammables

toxiques

chauffe,

moms

que

recipient

nait

ØtØ

lavØ

prealable,

com

dØcrit

dans

Norme

AWS

A6.O,

figurant

paragraphe

llndex

des

Normes.

Cela

comprend:

nettoyage

fond

vapeur

caustique

(ou

lavage

avec

dissolvant

eau

selon

solubilitØ

combustible)

suivi

dune

purge

dune

in-

OM-1547

Page

bustibles

solubility)

followed

purging

and

inerting

with

nitrogen

carbon

dioxide,

and

using

protective

equipment

recommended

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

container

with

unknown

contents

should

cleaned

(see

paragraph

above).

NOT

depend

sense

smell

sight

determine

if it

safe

weld

cut.

Hollow

castings

containers

must

vented

before

welding

cuthng.

They

can

explode.

Explosive

atmospheres.

Never

weld

cut

where

the

air

may

contain

flammable

dust,

gas,

liquid

vapors

(such

gasoline).

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

this

manual,

and

those

detailed

CGA

Standard

P-i,

SAFE

HANDLING

COMPRESSED

GASES

CYLINDERS,

listed

Standards

index.

Pressure

Regulators

Regulator

relief

valve

designed

protect

only.

the

regulator

from

overpressure;

not

intended

pro

tect

any

downstream

equipment.

Provide

such

protec

tion

with

one

relief

devices.

Never

connect

regulator

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

repair

(first

cylinder

valve).

The

following

symp

toms

indicate

faulty

regulator:

Leaks

gas

leaks

externally.

Excessive

Creep

delivery

pressure

continues

rise

with

downstream

valve

closed.

Faulty

Gauge

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

stop

after

pressure

release.

Repair.

NOT

attempt

repair.

Send

faulty

regulators

for

repair

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

trained

personnel.

2. Cylinders

Cylinders

must

handled

carefully

prevent

leaks

and

damage

their

walls,

valves,

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

including

third

rails,

electrical

wires,

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

serious

cident.

(See

1-3C.)

ICC

DOT

marking

must

each

cylinder.

assurance

safety

when

the

cylinder

properly

handled.

jection

dazote

gaz

carbonique,

utilisant

Øquipement

protection

comme

recommandØ

dans

lA6-O.

LatmosphŁre

inerte

peut

Œtre

remplacØe

par

niveau

deau

arrivant

au-dessous

travail

effectuer

Vous

devez

layer

recipient

dont

nature

conten

est

inconnue

(voir

paragraphe

ci-dessus).

vous

fiez

PAS

lodorat

vue

pour

dire

lon

peut

souder

couper

toute

sØcuritØ.

Vous

devez

pratiquer

event

sur

les

piŁces

red

pients

creux

avant

les

souder

couper:

ils

peuvent

exploser.

Atmospheres

explosives:

soudez

coupez

jamais

dans

des

lieux

oCi

Iair

peut

contenir

des

poussiŁres,

gaz

vapeurs

liquides

inflammables

(tels

que

Iessence).

Gaz

comprimØ

Precautions

gØnØrales:

Suivez

les

precautions

manuel,

celles

dØcrites

Norme

CGA

P-i

(PrØcau

tions

sØcuritØ

pour

manipulation

gaz

comprimØs

bouteilles),

paragraphe

Ilndex

des

Normes.

DØtendeurs

pression

soupape

sOretØ

dun

dØtendeur

est

destinØe

pro

tØger

seulement

dØtendeur de

surpression.

Elle

na

pas

pour

but

protØger

les

boyaux

chalumeau:

protege

ceux-ci

par

des

soupapes

retenue

conues

spØcialement

pour

cette

fonction.

montez

jamais

dØtendeur

sur

une

bouteille

conte

nant

gaz

different

celui

pour

lequel

dØtendeur

ØtØ

concu.

Enlevez

immØdiatement

dØtendeur

dØfectueux

pour

faire

rØparer

(dabord,

fermez

robinet

bouteille).

Les

symptmes

suivants

dØnotent

dØfec

tuositØ

dØtendeur:

Fuites

gaz

fuit

extØrieurement.

Ascension

excessive

pression

debit

continue

monter,

robinet

chalumeau

Øtant

fermØ.

ManomŁtre

dØfectueux

laiguille

manomŁtre

sØcarte

pas

goupille

butØe

lors

mise

pression,

ou ne

revient

pas

sur

goupille

aprŁs

lØchap

pement

pression.

Reparation.

NESSAYEZ

PAS

rØparer

vous-mŒmes.

Envoyez

les

dØtendeurs

dØfectueux

reparer

aux

ateliers

reparation

agrees

fabricant,

o

des

techni

ques

des

outils

spØciaux

sont

utilisØs

par

person

nel

formØ.

Bouteilles

Les

bouteilles

doivent

Œtre

manipulØes

avec

soin

pour

prØvenir

les

fuites

dØgts

leurs

parois,

robinets

systŁmes

sOretØ.

Evitez

quun

circuit

Ølectrique

soit

contact

avec

les

bouteilles,

compris

les

rails

con

tact,

les

fils

electriques

les

circuits

soudage.

Cela

pourrait

crØer

desarcs

courts-circuits

pouvant

entraIner

des

accidents

graves

(Voir

i.3C.).

Chaque

bouteille

doit

porter

les

inscriptions

ICC

DOT.

Cest

gage

sØcuritØ

pourvu

que

bouteille

soit

bien

manipulØe.

OM-1547

Page

Identifying

gas

content.

Use

only

cylinders

with

name

gas

marked

them;

not

rely

color

identify

gas

content.

Notify

supplier

unmarked.

NEVER

DEFACE

alter

name,

number,

other

markings

cylinder.

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

Prohibited

use.

Never

use

cylinder

its

contents

for

other

than

its

intended

use,

NEVER

support

roller.

Locate

secure

cylinders

they

cannot

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

areas

where

they

may

struck.

Transporting

cylinders.

With

crane,

use

secure

sup

port

such

platform

cradle.

NOT

lift

cylinders

off

the

ground

their

valves

caps,

chains,

slings,

magnets.

NOT

expose

cylinders

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

not

allow

contents

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.

NOT

use

hammer

wrench

open

cylinder

valve

that

can

not

opened

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

mix

any

gases

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

modified

exchang

ed.

Hose

Prohibited

use.

Never

use

hose

other

than

that

designed

for

the

specified

gas.

general

hose

identification

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

clamps

designed

for

the

hose

(not

dinary

wire

other

substitute)

binding

connect

hoses

fittings.

copper

tubing

splices.

Use

only

standard

brass

fit

tings

splice

hose.

Avoid

long

runs

prevent

kinks

and

abuse.

Suspend

hose

off

ground

keep

from

being

run

over,

stepped

on,

otherwise

damaged.

Coil

excess

hose

prevent

kinks

and

tangles.

Protect

hose

from

damage

sharp

edges,

and

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

water;

bubbles

dicate

leaks.

Identification

gaz:

Nutilisez

que

les

bouteilles

mdi

quant

nature

gaz;

vous

fiez

pas

couleur

pour

reconnaItre

nature

gaz.

Adressez-vous

votre

fournisseur

cela

nest

pas

indiquØ.

NEFFACEZ

modifiez

JAMAIS

les

noms,

numØros

autres

indications

sur

une

bouteille.

Cela

est

illegal

dangereux.

Vides:

Maintenez

lŁs

robinets

fermØs,

replacez

bien

les

chapeaux;

inscrivez

Vides;

sØparez-les

des

Pleines

retournez-les

rapidement.

Emploi

interdit:

Nutilisez

une

bouteille

son

contenu

que

pour

quoi

elle

est

destinØe,

mais

JAMAIS

com

support

rouleau.

Placez

les

bouteilles

pour

quelles

tombent

pas.

Lors

quun

dØtendeur

(et

boyau)

est

monte

sur

elles,

placez

les

attachez-les

debout.

Passages

lieux

travail.

Enlevez

les

bouteilles

dun

endroit

o

lon

pourrait

les

frapper.

Transport

des

bouteilles.

Avec

une

grue,

utilisez

sup

port

fiable

tel

quune

plate-forme

cadre.

SOULEVEZ

PAS

des

bouteilles

sol

par

leur

robinet

chapeau,

avec

des

chalnes,

Ølingues

aimants.

NEXPOSEZ

PAS

les

bouteilles

une

chaleur

excessive,

aux

Øtincelles,

laitier

aux

flammes,

etc.,

pouvant

causer

leur

rupture.

contenant

doit

jamais

dØpasser

55C.

Refroidissez

pulvØrisant

leau

nØcessaire.

ProtØgez

les

bouteilles

particuliŁrement

les

soupapes

contre

chocs,

les

chutes,

les

chutes

dobjets

temperature.

Remettez

bien

les

chapeaux

lorsque

vous

dØplacez

les

bouteilles.

Robinet

coincØ.

NUTILISEZ

PAS

marteau

une

clØ

mØtallique

pour

ouvrir

robinet

bouteille

que

lon

peut

pas

ouvrir

main.

Avisez

votre

four

nisseur.

MØlange

gaz.

Nessayez

jamais

mØlanger

des

gaz

dans

une

bouteille.

rechargez

jamais

une

bouteille.

Les

ØlØments

bouteille

doivent

jamais

Œtre

modifies

remplaces.

Boyau

Utilisation

interdite.

Nutilisez

jamais

boyau

autre

que

celui

appropriØ

gaz

indiquØ.

regle

gØnØrale

didentification

est:

rouge

pour

les

gaz

combustibles,

vert

pour

loxygene,

noir

pour

les

gaz

inertes.

Utilisez

des

bagues

colliers

appropriØs

boyau

(et

non

fil

ordinaire

autre

substitution)

pour

brancher

les

boyaux

lappareillage.

Nutilisez

pas

des

raccords

cuivre.

Nutilisez

que

des

accessoires

standard

laiton

pour

raccorder

boyau.

Utilisez

une

petite

longueur

boyau.

Cela

Øvitera

les

noeuds

lusure

prØmaturØe.

Suspendez

boyau

dessus

sol

pour

Øviter

quil

soit

ØcrasØ,

piØtinØ

endommagØ.

Enroulez

surplus

boyau

pour

Øviter

les

noeuds

emmŒlements.

Evitez

que

boyau

soit

endommage

par

des

tranchants,

Øtincelles,

laitier

flamme

nue.

OM-1

547

Page

Repair

leaky

worn

hose

cutting

area

out

and

splic

ing

(t-2D3).

NOT

use

tape.

Proper

Connections

Clean

cylinder

valve

outlet

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

ignition.

Wipe

with

clean

lintless

cloth.

Match

regulator

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

agree,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

regulator

designed

for

particular

gas

gases

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

one

required.

Use

two

wrenches

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

iden

tified

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

nut

shank)

for fuel

gas.

Pressurizing

Steps:

Drain

regulator

residual

gas

through

suitable

vent

before

opening

cylinder

(or

manifold

valve)

turning

adjusting

screw

(clockwise).

Draining

prevents

cessive

compression

heat

high

pressure

seat

allowing

seat

open

pressurization.

Leave

adjusting

screw

engaged

slightly

single-stage

regulators.

Stand

side of

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

that

regulator

pressure

creases

slowly.

When

gauge

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

following

position:

For

oxygen,

and

inert

gases,

open

fully

seal

stem

against

possible

leak.

For

fuel

gas,

open

less

than

one

turn

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

regulators.

Check

for

leaks

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capful

Ivory

Liquid*

equivalent

per

gallon

water).

Bubbles

dicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

combustible.

User

Responsibilities

Remove

leaky

defective

equipment

from

service

mediately

for

repair.

See

User

Responsibility

statement

equipment

manual.

*Trademark

Proctor

Gamble

VØrifiez

reguliŁrement

les

fuites,

lusure

les

rac

cordements

lches.

Plongez

boyau

sous

pression

dans

leau;

les

bulles

indiqueront

les

fuites.

Reparation.

Coupez

partie

percØe

usØe,

rac

cordez

(1-2D3).

NUTILISEZ

JAMAIS

ruban

adhØsif

Branchements

corrects

Avant

brancher

dØtendeur,

nettoyez

sortie

robinet

bouteille

des

impuretØs

qui

peuvent

obstruer

les

orifices

endommager

les

sieges.

Sauf

pour

lhydrogŁne,

ouvrez

momentanØment

robinet,

eloignant

sortie

des

personnes

des

sources

flammables.

Essuyez

avec

tissu

propre

non

graisseux.

Appareillez

dØtendeur

bouteille.

Avant

bran

cher,

vØrifiez

que

marque

dØtendeur

descrip

tion

bouteille

concordent,

que

lorifice

dentrØe

dØtendeur

Iorifice

sortie

bouteille

aillent

ensemble.

BRANCHEZ

JAMAIS

dØtendeur

concu

pour

gaz

special

(ou

des

gaz

spØciaux)

une

bouteille

contenant

dautres

gaz.

Serrez

les

branchements.

Lorsque

vous

assemblez

des

branchements

filetØs,

nettoyez

polissez

les

sieges

o

cest

nØcessaire.

Serrez.

les

branchements

perdent,

dØmontez-les,

nettoyez

resserez

avec

une

clef

adØ

quate.

Adaptateurs.

Placez,

besoin

est,

adaptateur

CGA

(en

vente

chez

votre

fournisseur)

entre

bouteille

dØtendeur.

Avec

deux

clefs,

serrez

ladaptateur

filetØ

DROITE

GAUCHE.

peut

reconnaitre

les

branchements

sortie

dØtendeur

(ou

boyau)

laide

filetage

droite

pour

loxygŁne

gauche

(identifiØ

par

Øcrou

cannelØ)

pour

les

gaz

combustibles.

DØmarches

mise

pression

Purgez

dØtendeur

rØsidu

gaz

avant

douvrir

bouteille

(ou

robinet

canalisation)

serrant

vis

rØglage

(dans

sens

des

aiguilles

dune

montre).

Cette

operation

permet

siege

haute

pression

souvrir

mise

pression,

supprimant

ainsi

toute

surchauffe

compression.

Maintenez

vis

reglage

des

dØtendeurs

simple

dØtente

lØgerement

engagee.

Avant

douvrir

robinet

bouteille,

assurez-vous

que

les

boyaux

sont

branches

que

les

soupapes

aval

sont

fermØes.

Tenez-vous

latØralement

dØtendeur

ouvrant

robinet

bouteille.

Ouvrez-Ie

lentement

pour

que

pression

dØtendeur

monte

progressivement.

Lorsque

manomŁtre

est

mis

sous

pression

(indique

max

imum)

robinet

bouteille

gaz

inerte

dox

ygŁne

devra

Œtre

ouvert

fond

pour

assurer

lØtanchØitØ

celui

bouteille

gaz

combustible

ouvert

moms

dun

tour

pour

pouvoir

refermer

rapidement

cas

durgence.

RØfØrez-vous

aux

tableaux

pression

(distribuØs

par

votre

fournisseur)

pour

rØglage

recommandØ

pression

sUr

efficace

sur

les

dØtendeurs.

VØrifiez

Ies

fuites

premiere

mise

pression puis

rØguliŁrement,

brossez

avec

une

solution

savonneuse

(un

bouchon

dlvory

Liquid*

semblable

par

gallon

deau).

Les

bulles

indiquent

une

fuite.

Enlevez

leau

savonneuse

aprŁs

examen;

savon

sec

est

inflammable.

Marque

Commerce

Proctor

Gamble

OM-1

547

Page