Pipe Welding Handbook
Contents
1. Q Miller Pipe Welding TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage Saee mines et ni er ane ren nt te 1 1 2 Arc Welding Hazards ttes be ve PE I TP Deve REN ECRIRE vU FR US 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 2 4 1 6 EME Information i ieu pr AERE Fa RES BR dos RR Re o aces x TUR RUE BUR 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles utiliS68 uos end a teh sil Aster os I Aw E Are dau x 5 2 2 Dangers relatifs au soudage l arc 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM a 9 SECTION GMAW FUNDAMENTALS sssssssussss 11 3212 Basic Information isis RUM TER EU EDD ek eR2. Improper welding technique Focus electrode back further on weld puddle Spatter Long arc length Shorten arc length or decrease voltage Bad shielding gas Replace shielding gas Welding in globular transfer range Argon gas Decrease voltage Excessive melt through Excessive heat input Reduce wire feed speed Improper joint penetration Shorten root opening Other issues Unable to resolve problem Contact factory pipe welding products service 920 735 4001 B Parameter Issues ease _ meme RE AS D AR meme LL em Sew Bem _ M 247 250 Page 38 Notes Ref AWS ANSI D1 1 WELD JOINT TYPES ok NL d EN 3 GROOVE FILLET WELD POSITION HORIZONTAL BUTT 2G T JOINT 2F VERTICAL OVERHEAD BUTT 4G T JOINT 4F Ref 804 248 A 39 Ig ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Miller Electric Mfg Co 2010 01
3. Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes
4. A Process Issues Trouble Possible Causes Remedy Undercutting Travel speed too high Slow down travel speed Welding voltage too high Decrease arc length trim or voltage Dwell time not long enough Pause longer while weaving Gun angle Maintain 10 to 15 degree drag angle in RMD and 5 to 10 degree angle in pulse Porosity Inadequate shielding gas coverage Check flowmeter for 35 to 50 SCFH Gas in contaminated leaky connections Check fittings hoses and shielding gas connections Electrode contamination Replace electrode Workpiece contamination Remove paint mill scale rust oil and oxide Arc Voltage too high Decrease arc length trim or voltage Excessive contact tube to work distance 3 8 to 5 8 in 10 to 16 mm stick out for RMD or pulse 3 4 to 1 in 19 to 25 mm stick out for FCAW Incomplete fusion Weld zone surfaces not free of film or excessive oxide Grind or sand to clean off surface Insufficient heat input Increase wire feed speed Too large of a weld puddle Increase travel speed or decrease wire feed speed Improper welding technique Re evaluate welding method for proper technique Improper joint preparation Increase joint angle Excessive travel speed Decrease travel speed or increase wire feed speed Humping and crowning Excessive travel speed Slow down travel speed or weave electrode unmelted electrode on root side whiskers
5. SUE Puro 11 3 2 Welding Positions s voee E nee ev MO OU INSEL EMEND dai edu 15 3 3 GMAW MIG FCAW PipePro System 16 3 4 Typical PipeWorx Connection Diagram For MIG GMAW Equipment With Feeder On Power Source aus eue sin RR rre dh aad C ow Seld eats 17 3 5 Typical PipeWorx Connection Diagram For MIG GMAW Equipment With Feeder sise mens ace dette UR GO yaad ede ee CU esent E OU POUR EUER RP BS 18 3 6 Process Variable Definitions eee m ehe rhe 19 3 7 Joint Preparation And Typical Recommendations For 1G 5G 6G And 6GR 20 3 8 RMD Open Root Joint Preparation 21 3 9 5G Welding Technique Recommendations 23 3 10 1G Welding Technique Recommendations 27 3 11 Welding Passes And Appropriate Process With Parameter Ranges 30 3 12 Troubleshooting Guide 38 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2010 03 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text A Indicates a hazardou
6. Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip Welding Power Source Wire Feeder MIG Connection Positive Weld Cable Feeder Control Cable Connection 11 6 Gas Hose Gas Cylinder Connect 14 pin plug to rear of power source and connect 14 socket plug to rear of wire feeder Connect one end of weld cable to weld terminal on rear of power source Connect remaining end of weld cable to wire feeder drive housing Connect one end of gas hose to regulator flowmeter on gas cylinder and connect remaining end o o 10 805 144 of gas hose to gas solenoid connector on rear of feeder or Y hose for dual wire feeder 8 Work Weld Cable EF Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 9 Volt Sense Cable 10 Workpiece 11 Welding Gun M 247 250 Page 17 3 5 Typical PipeWorx Connection Diagram For MIG GMAW Equipment With Feeder On Cart Do not put feeder where welding wire hits cylinder gt gt Do not move or operate equipment when it could tip Welding Power Source Wire Feeder Feeder Cart Composite Cable MIG Connection Positive Weld Cable Gas Hose OO BR ND 8 Ga
7. g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant 1 soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection M 247 250 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de
8. and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Additionalsafety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards 5 Indicates special instructions Lay This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the ha
9. drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 53 a MOVING PARTS can injure e Keep away from moving parts such as fans AJ e Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about int
10. e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag
11. near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 247 250 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace a
12. ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dess
13. pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload
14. 200 Nominal 2 5 7 7 w 5 1 Nominal 100 300 w 200 Nominal 2 5 7 7 w 5 1 Nominal 100 300 w 200 Nominal 2 5 7 7 w 5 1 Nominal 100 275 w 175 Nominal 2 5 7 0 w 4 4 Nominal 100 275 w 175 Nominal 2 5 7 0 w 4 4 Nominal 100 275 w 175 Nominal 2 5 7 0 w 4 4 Nominal 100 275 w 175 Nominal 2 5 7 0 w 4 4 Nominal 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 225 600 w 250 Nominal 5 7 15 2 w 6 4 Nominal 120 780 w 250 Nominal 3 0 19 8 w 6 4 Nominal 120 600 w 250 Nominal 3 0 15 2 w 6 4 Nominal 120 600 w 250 Nominal 3 0 15 2 w 6 4 Nominal 140 500 w 250 Nominal 3 6 12 7 w 6 4 Nominal 140 500 w 250 Nominal 3 6 12 7 w 6 4 Nominal Arc Adjust Trim 47 53 w 50 Nominal 47 53 w 50 Nominal 47 53 w 50 Nominal 47 53 w 50 Nominal 50 55 w 53 Nominal 47 53 w 50 Nominal 50 55 w 53 Nominal 50 55 w 53 Nominal 47 53 w 50 Nominal 47 53 w 50 Nominal 47 53 w 50 Nominal 47 53 w 50 Nominal 52 57 w 56 Nominal 52 57 w 56 Nominal 52 56 w 56 Nominal 52 56 w 56 Nominal 52 57 w 56 Nominal 52 57 w 56 Nominal Arc Control 30 35 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 ProPulse Steel Welding In Position RMD Stainless Steel Table 3 6 PipePro 450 RFC Welding Programs Continued Wire Size in mm Wire
15. Size in mm Wire Feed Speed IPM mpm 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 120 600 w 175 Nominal 3 0 15 2 w 4 4 Nominal 120 600 w 175 Nominal 3 0 15 2 w 4 4 Nominal 140 500 w 175 Nominal 3 6 12 7 w 4 4 Nominal 140 500 w 175 Nominal 3 6 12 7 w 4 4 Nominal Stainless Steel Wire Feed Speed IPM mpm 120 290 w 200 Nominal 3 0 7 4 w 5 1 Nominal 120 275 w 200 Nominal 3 0 7 4 w 5 1 Nominal 120 275 w 200 Nominal 3 0 7 4 w 5 1 Nominal 120 275 w 200 Nominal 3 0 7 4 w 5 1 Nominal 120 160 w 150 Nominal 3 0 4 1 w 3 8 Nominal Arc Adjust Trim 52 57 w 54 Nominal 52 57 w 54 Nominal 52 56 w 54 Nominal 52 56 w 54 Nominal 50 55 w 53 Nominal 50 55 w 53 Nominal Arc Adjust Trim 47 51 w 50 Nominal 48 52 w 50 Nominal 48 52 w 50 Nominal 48 52 w 50 Nominal 48 52 w 50 Nominal Arc Control 30 35 Arc Control 2 3 2 2 5 5 5 5 5 0 5 5 5 M 247 250 Page 31 Table 3 6 PipePro 450 RFC Welding Programs Continued Stainless Steel Wire Size Wire Feed Speed Arc Adjust Trim Arc Control Shielding Gas in mm IPM mpm 035 0 9 150 780 w 175 Nominal 53 57 w 55 Nominal 25 Tri H 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 52 57 w 56 Nominal 16 Tri A 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 48 54 w 53 Nominal 18 98 2 CO2 3 8 19 8 w 4 4 Nominal ProPulse Stainless Steel Usi
16. Stainless Figure 3 3 RMD Root Pass Welds A precisely controlled short circuit metal transfer that provides a calm stable arc and weld puddle This provides less chance of cold lap or lack of fusion less spatter and a higher quality root pass on pipe The stability of the weld process lessens the puddle manipulation required by the operator and is more tolerant to hi lo conditions reducing training requirements Weld bead profiles are thicker than conventional root pass welds which can eliminate the need for a hot pass improving weld productivity In some stainless steel applications it may be possible to eliminate the backing purge gas to further improve productivity and reduce welding costs e Ideally suited to root pass welding e Consistent side wall fusion e Less weld spatter e Tolerant to hi lo fit up conditions e More tolerant of changes in tip to work distance e Less personnel training time e Thicker root passes can eliminate hot pass e Eliminate backing gas on some stainless steel applications RMD Ball Transfer T b e Current Waveform IEEE MM Pre short lt Wet gt Pinch k BEN BEEBE EBB eee BEBE RBBB BRR ee BEBE Eee Ball Background BEEBE EEE RPE Figure 3 4 RMD Ball Transfer M 247 250 Page 13 Pro Pulse Pro Pulse Carbon Pro Pulse Stainless This method of pulse welding provides a shorter
17. a borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctemen
18. ady stream of small droplets of weld wire are transferred into the weld Spray transfer uses larger diameter wires at higher arc voltages and lower slope settings See Figure 3 2 ca ica Steady State AN AIN 2 WORK se Figure 3 2 Mechanics Of Spray Transfer S 0567 For short circuit transfer a constant voltage welding power source is required Adjustable slope and inductance are desirable Slope slows the response rate of the welding power source and lowers maximum short circuit current A constant speed wire feeder is recommended for short circuit transfer For spray transfer either a constant voltage or constant current welding power source can be used A voltage sensing wire feeder is recommended for spray transfer The values in the following tables are a starting point for setting up a weld Most settings can be varied while welding to fine tune the arc M 247 250 Page 11 Table 3 1 Short Circuit Transfer For Mild And Low Alloy Steel Electrode Amperage Load Using CO shielding gas for mild steel Argon COz for low alloy steel Table 3 2 Spray Transfer For Mild And Low Alloy Steel Diameter Range DCEP DCEP Voltage Source 30i in 150 265 265 CVorcc or CC 035 in 175 290 CV or CC 045 in 200 315 CV or CC 1 16 in 275 500 CV or CC 3 32 in 350 600 CV or CC Using Argon 5 Oxygen shielding gas or C10 90 Argon 1096 Oxygen shielding gas f
19. arc length narrower arc cone and less heat input than with traditional spray pulse transfer Since the process is synergic arc wandering and variations in tip to work distances are virtually eliminated This provides easier puddle control for both in position and out of position welding reducing personnel training time The process also improves fusion at the toe of the weld permitting higher travel speeds and higher deposition This process coupled with RMD Pro for root pass welding permits Figure 3 5 Pro Pulse Weld Bead welding procedures with one wire and one gas to eliminate process switch over time e ideally suited to fill and cap pass welding e Easier puddle control than conventional spray pulse e Shorter arc lengths and narrow arc cone for out of position welding e More tolerant of tip to work variation e Improve fusion and fill at toe of weld e Less heat input reduces interpass cooling time and improves weld cycle time e Enables one wire and one gas weld procedures CV Peak Background SIE Taught Peak Voltage Voltage Taught Background Voltage Fixed current beginning points 4 amp CC Ramps Current CV Peak CV Background CV Peak MIT em CV Background M 247 250 Page 14 Figure 3 6 Pro Pulse Voltage And Current Waveforms 3 2 Welding Positions Welding position is determined by the pipe posi
20. building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Followthe guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment nn LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before MES starting to weld again e Do not block or filter airflow to unit N FLYING SPARKS can injure e Wear a face shield to protect eyes and face 277 e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards 79 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as
21. c Length increases the actual arc length likewise decreasing Arc Length shortens actual arc length Inductance Control Allows setting inductance in MIG and FCAW In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid Trim See Arc Length description Volts Preset voltage in MIG mode at idle actual voltage while welding and 10 seconds hold value at end of weld WFS Term used to represent wire feed speed In MIG mode wire feed setting is independent of voltage setting In Pulse and RMD adjusting wire feed speed also increases power level on wire electrode one knob control Notes 9 HOBART INSTITUT Start Your Professional DN SUELEN Over 80 000 2 hio 4 Welding Career Now Tade Square East Troy Ohio 453975 trained since 1930 1 800 332 9448 www welding org M 247 250 Page 19 3 7 Joint Preparation And Typical Recommendations For 1G 5G 6G And 6GR e Establish Good Technique As with any welding process success with the RMD process requires establishing and maintaining good prepara tion and welding techniques The following guidelines which are extremely easy to follow lead to proven success and increased productivity for welding stainless
22. commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de sou
23. dage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES E SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier
24. eed speed and voltage are synergic for the RMD and ProPulse processes Therefore when adjusting wire feed speed the voltage is automatically adjusted so it is not necessary to adjust Arc Adjust Trim These are only starting parameters the operator must make final adjustments depending on material and conditions See wire manufacturer for recommended wire feed speed and gas mixture M 247 250 Page 33 Table 3 7 PipeWorx 400 Welding Parameters Wire Size Wire Feed Speed Arc Length Shielding Gas in mm IPM mpm Steel ProPulse Steel Using A Positioner 1G Rolling The Pipe ProPulse Steel Welding In Position 5G M 247 250 Page 34 100 350 w 200 Nominal 2 5 8 9 w 5 1 Nominal 100 350 w 200 Nominal 2 5 8 9 w 5 1 Nominal 100 250 w 200 Nominal 2 5 6 4 w 5 1 Nominal 100 250 w 150 Nominal 2 5 6 4 w 3 8 Nominal 100 250 w 150 Nominal 2 5 6 4 w 3 8 Nominal 100 200 w 150 Nominal 2 5 5 1 w 3 8 Nominal 120 780 w 250 Nominal 3 0 19 8 w 6 4 Nominal 140 500 w 250 Nominal 3 6 12 7 w 6 4 Nominal 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 140 500 w 175 Nominal 3 6 12 7 w 4 4 Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0
25. ent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants gt Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation P Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent M 247 250 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practic
26. erference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area M 247 250 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive har
27. es for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s p
28. gth See wire manufacturer for recommended wire feed speed and gas mixture B Root Pass The first weld pass is referred to as the root pass and is used to fill the gap between two sections of pipe When using the GMAW process the root pass is usually with an open root weld no backing ring Generally a manual weld root pass is continuous all the way around and through the tack welds C Hot Pass The hot pass is usually a single weld that joins the root weld and both groove faces together A split hot pass is generally an acceptable procedure for 2G welding and when the root opening is larger than normal D Fill Pass The fill pass should nearly fill the groove If a bead sequence is necessary an alternating pattern should be used from face to face of the joint The location of each bead should have an adequate uniform lap for each subsequent weld bead If a narrow cavity should develop between weld beads or between the face of the joint and the weld bead it may result in a lack of fusion or contamination slag If possible grind the area to eliminate the cavity and improve the lap weld before making the next weld E Cap Pass The cap weld should completely fill the top of the joint with the least amount of excessive build up beyond the top surface of the pipe Grinding may be necessary to improve the weld bead shape and remove any contamination before making the final cap pass M 247 250 Page 37 3 12 Troubleshooting Guide
29. he pipe joint ROTATIN Ref 805 025 A 5 Stay on the leading edge of the puddle and move the electrode back across the gap Move the electrode in a half moon motion ROTATIN Ref 805 025 A M 247 250 Page 28 6 Continue moving back and forth weaving across the gap Be sure pipe rotates at a constant speed Maintain a steady arc length ROTATIN Ref 805 025 A 10 DO NOT stop welding in the root This may cause pin holes Fill the crater by welding into the previous weld start Use a short arc length to control heat Be sure to grind the weld at the stop position to ensure any pinhole is removed and weld is feathered oo ROTATIN Ref 805 028 A 11 When root weld is complete remove excess silicon with a a wire wheel or with light grinding Also grind any high spots on root pass to make it uniform in height M 247 250 Page 29 3 11 Welding Passes And Appropriate Process With Parameter Ranges A Welding Process Data Table 3 6 PipePro 450 RFC Welding Programs RMD Steel ProPulse Steel Using A Positioner Rolling The Pipe M 247 250 Page 30 Wire Size in mm 035 0 9 035 0 9 035 0 9 035 0 9 040 1 0 040 1 0 040 1 0 040 1 0 045 1 1 045 1 1 045 1 1 045 1 1 035 0 9 035 0 9 040 1 0 040 1 0 045 1 1 045 1 1 Wire Feed Speed IPM mpm 100 300 w 200 Nominal 2 5 7 7 w 5 1 Nominal 100 300 w
30. heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high
31. ields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body M 247 250 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 48rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 S
32. ir and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The f
33. les utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit gt Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circ
34. lign pipe ends together leaving a minimum of 1 8 in 3 2 mm gap D 1 8 in Ref 805 029 A Ref 805 029 A M 247 250 Page 21 3 Tack pipe ends together in four locations approximately 90 apart and 1 in 25 4 mm long on pipe that is 6 in 152 4 mm or larger diameter Use appropriate sized tack welds on smaller pipe 4 Grind each end of the tack weld to a feather edge knife edge M 247 250 Page 22 1 in 25 4 mm TACK WELDS 7 Ref 805 029 A w GRIND TO FEATHER EDGE as E i 2 din 25 4 mm 7 Ref 805 029 A 3 9 5G Welding Technique Recommendations 1 2 Start arc on sidewall or in center of tack weld not in the gap After puddle is established maintain the arc on the center of the puddle with a 1 2 to 5 8 in 12 7 to 15 9 mm tip to work distance 12 O CLOCK 6 O CLOCK MAINTAIN DRAG ANGLE 805 024 A 10 15 MAINTAIN DRAG ANGLE o Ref 805 025 A M 247 250 Page 23 3 Move across the gap Ref 805 025 A 4 Move slightly up the sidewall Ref 805 025 A 5 Stay in the puddle and move the electrode back across the gap Move the electrode down the joint in a half moon motion Ref 805 025 A M 247 250 Page 24 6 Continue moving back and forth weaving across the gap until reaching the 1 o clock position Ref 805 025 A 7 At the 1 o clock position st
35. liquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants 1 Indique des instructions sp cifiques cal Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord l
36. lying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes M 247 250 Page 2 La Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves
37. m Wash hands after handling A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic f
38. minal 3 6 19 8 w 5 1 Nominal 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 150 780 w 175 Nominal 3 8 19 8 w 4 4 Nominal 150 780 w 175 Nominal 3 8 19 8 w 4 4 Nominal 150 780 w 175 Nominal 3 8 19 8 w 4 4 Nominal 150 780 w 175 Nominal 3 8 19 8 w 4 4 Nominal 120 525 w 140 Nominal 3 0 13 3 w 3 6 Nominal 120 525 w 140 Nominal 3 0 13 3 w 3 6 Nominal 120 525 w 140 Nominal 3 0 13 3 w 3 6 Nominal 120 525 w 140 Nominal 3 0 13 3 w 3 6 Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal Table 3 7 PipeWorx 400 Welding Parameters Continued Wire Size Rolling Pipe In Position Voltage Shielding Gas in mm Wire Feed Speed IPM mpm Not 175 780 w 200 Nominal 24 5 32 w 24 5 Nominal Not Dependent Note Arc Length Length of arc from end of wire to weld puddle Wire feed speed and voltage are synergic for the RMD and ProPulse processes This means when adjusting wire feed speed the voltage is automatically adjusted so it is not necessary to adjust the Arc Len
39. ng 035 0 9 150 780 w 175 Nominal 48 52 w 51 Nominal 18 98 2 Ox A Positioner 3 8 19 8 w 4 4 Nominal Rolling The Pipe 045 1 1 140 450 w 200 Nominal 52 55 w 55 Nominal 25 Tri H 3 6 11 4 w 5 1 Nominal 045 1 1 120 525 w 200 Nominal 53 57 w 55 Nominal 16 98 2 CO2 3 0 13 3 w 5 1 Nominal 045 1 1 120 525 w 200 Nominal 53 57 w 55 Nominal 25 98 2 Ox 3 0 13 3 w 5 1 Nominal 035 0 9 150 780 w 175 Nominal 53 57 w 55 Nominal 25 Tri H 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 52 56 w 54 Nominal 16 Tri A 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 48 52 w 50 Nominal 18 98 2 CO2 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 46 50 w 48 Nominal 18 98 2 Ox ProPulse 3 8 19 8 w 4 4 Nominal Stainless Steel Welding In Position 045 1 1 120 525 w 140 Nominal 53 57 w 55 Nominal 3 0 13 3 w 3 6 Nominal 045 1 1 120 525 w 140 Nominal 50 55 w 53 Nominal 3 0 13 3 w 3 6 Nominal 045 1 1 120 525 w 140 Nominal 50 55 w 53 Nominal 3 0 13 3 w 3 6 Nominal 045 150 500 w 300 Nominal 50 55 w 53 Nominal 25 30 Argon Inconel 625 3 8 12 7 w 7 6 Nominal M 247 250 Page 32 Table 3 6 PipePro 450 RFC Welding Programs Continued Wire Size Rolling Pipe In Position Voltage Shielding Gas in mm Wire Feed Speed IPM mpm 175 780 w 200 Nominal 24 5 32 w 24 5 75 25 Flux Core GMAW 4 4 19 8 w 5 1 Nominal Nominal Note Arc Control is arc width and Arc Adjust Trim is arc length Wire f
40. ng Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes M 247 250 Page 9 247 250 10 SECTION 3 GMAW FUNDAMENTALS 3 1 Basic Information A Overview Of Welding Processes The two basic types of metal transfer are short circuit and spray In short circuit transfer the wire short circuits to the workpiece and weld wire is transferred with each short circuit Short circuit transfer uses smaller wire diameters at lower arc voltages and higher slope settings See Figure 3 1 BASS 2 WORK lt Figure 3 1 Mechanics Of Short Circuiting Transfer S 0568 In spray transfer a ste
41. ogy will automatically compensate Let the arc do the work e Welding In The 5G Fixed Position Begin welding in the 12 o clock position As with the 1G position start the arc in the center of a tack weld using a 5 to 10 degree drag angle and a 3 8 to 5 8 in stick out At the start of the weld keep the arc in the center of the puddle but move the electrode back and forth across the gap using a half moon motion with the face of the moon pointing down At about the 1 o clock position gravity starts to push the puddle down the joint Once gravity takes over stop weaving and concentrate on directing the electrode into the center of the weld puddle At about the 5 o clock posi tion us a slight side to side motion until reaching 6 o clock ending the bead on the feathered tack weld The side to side motion flattens the weld bead and minimizes grinding If the weld does not end on a tack weld e g the operator breaks the arc for whatever reason this may lead to a pin hole at the end of the weld Grind out the end of the weld before resuming After completing the root pass also grind out starts stops and high points before making the first fill pass remember that the root pass with the modified process can eliminate the hot pass M 247 250 Page 20 3 8 RMD Open Joint Preparation 1 Bevel pipe end to 37 5 standard pipe bevel 37 5 leaving a 1 16 to 3 32 in 1 6 to 2 4 mm land 1 16 3 32 in 1 6 2 4 mm LAND 2 A
42. op weaving Concentrate the arc on the center of the weld puddle and move down the pipe joint until the 5 o clock position 805 026 A 8 Atthe 5 o clock position repeat steps 3 6 However at Step 6 the instruction should read until reaching the 6 o clock position instead of the 1 o clock position 12 O CLOCK 805 027 A M 247 250 Page 25 9 the weld at the 6 o clock position by moving the electrode onto the feathered tack weld 12 805 028 A 10 DO NOT stop welding in the root This may cause pin holes Be sure to grind the weld at the stop position to ensure pinhole is removed and weld is feathered Ref 805 028 A 11 When root weld is complete remove excess silicon with a a wire wheel or with light grinding Also grind any high spots on root pass to make it uniform in height M 247 250 Page 26 3 10 1G Welding Technique Recommendations 1 2 Start arc on sidewall or in center of tack weld not in the gap After puddle is established maintain the arc on the leading edge of the puddle with a 1 4 to 1 2 in 6 4 to 12 7 mm tip to work distance 12 O CLOCK 6 O CLOCK MAINTAIN DRAG ANGLE 805 024 A 10 15 MAINTAIN ROTATIN Ref 805 025 A M 247 250 Page 27 3 Move across the gap Watch the puddle not the arc ROTATIN Ref 805 025 A 4 Move slightly up the sidewall Keep the electrode near the top of t
43. or mild and low alloy steel Table 3 3 Short Circuit Transfer For Stainless Steel 300 Series Electrode Amperage Load Power Diameter Range DCEP Voltage Source i 50 145 CV power source with 65 175 characteristics for short 100 210 circuiting transfer Using tri gas mixture 90 He 7 1 2 A 2 1 2 CO and flow rates of approximately 20 Table 3 4 Spray Transfer For Stainless Steel 300 Series Diameter Range DCEP DCEP Voltage Source o30im in 160210 210 CVorcc or CC 035 in 180 255 CV or CC 045 in 200 300 CV or CC 1 16 in 215 325 CV or CC 3 32 in 225 375 CV or CC Using Argon Oxygen shielding gas Oxygen percentage varies from 1 5 Table 3 5 Flux Cored Arc Electrode Amperage Load Diameter Range Voltage 045 in 200 300 1 16 in 200 425 5 64 in 250 450 3 32 in 300 500 7 64 in 360 550 1 8 in 425 650 Using as the shielding gas Flow rates depend on nozzle diameter surrounding air movement and electrode extension Welding in still air generally requires flow rates from 30 to 40 CFH Drafty conditions or longer electrode extension may require higher flow rates Most manufacturers recommend an extension of 3 4 to 1 1 2 in for gas shielded electrodes Follow the electrode manufacturer s recommendations M 247 250 Page 12 B Advanced Process RMD And Pro Pulse RMD Regulated Metal Deposition RMD Carbon Steel RMD
44. our les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifti
45. r essentially the operator is dragging the weld puddle Watch the puddle closely to ensure that it ties into the sidewalls Normally do not use a weave technique However if the gap is greater than 3 16 in the oper ator may need to weave the electrode slightly across the gap and up the sidewall to bridge it When the electrode is properly positioned in the weld puddle the RMD process creates a muted buzzing sound that is much softer than the cracking bacon sound of traditional short circuit GMAW Although the RMD process appears colder than typical GMAW the weld puddle fuses into the sidewall and penet rates the joint due to the calm metal transfer and stable arc The face of a good root weld appears flat neither concave or convex and as noted it is thicker than a traditional GMAW root With traditional GMAW operators position the arc on the leading edge of the puddle Do not do this with RMD as the arc will stutter and create spatter and greater penetration on the inside of the pipe note that an optimum root has about a 1 16 in reinforcement If travel soeeds become too slow and the electrode becomes unstable listen for a sound more like traditional GMAW Also the weld face will be convex If this happens grind out the high spots to prevent areas of lack of fusion on the next pass If the joint is misaligned continue to concentrate the arc in the center of the joint Do not favor the high side of the joint the new technol
46. rm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoqu
47. s Cylinder Locate end of composite cable where gas hose extends out of sleeve approximately 50 inches 1270 mm This end of the composite cable connects to the power source Connect 14 pin plug to rear of power source and connect 14 socket plug to rear of wire feeder Connect one end of weld cable to weld terminal on rear of power source and secure cable in clamp block on rear panel Connect remaining end of weld cable to wire feeder drive housing and secure cable in clamp block on feeder base Connect one end of gas hose to regulator flowmeter on gas cylinder and 805 317 B connect remaining end of gas hose to gas solenoid connector on rear of feeder or Y hose for dual wire feeder 9 Work Weld Cable 2 0 minimum EF Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 10 Volt Sense Cable 11 Workpiece 12 Welding Gun 13 Strain Relief Clamp M 247 250 Page 18 3 6 Process Variable Definitions The following is a list of terms and their definitions General Terms Arc Control The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes Increasing Arc Control value increases the arc cone width and subsequently effects the arc length end of electrode to workpiece Arc Length Distance from end of wire electrode to workpiece This term is also used to represent arc length adjustments in RMD and Pulse processes Increasing Ar
48. s situation which if not avoided A DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work
49. spositifs de protection uniquement par du personnel qua e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique RLF LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur B e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement fe
50. steel pipe Start with pipe joint sections that have the standard 37 5 degree bevels for a total included angle of 75 degrees The lands can range from a knife edge to 3 32 in Use a minimum 1 8 in root opening to ensure proper root rein forcement on the weld s backside An easy way to space the gap is with a filler rod that matches the desired gap size Tack Welding System Tack the pipe with the RMD process making tacks in this order at the 12 6 3 and 9 o clock positions Re move the filler metal spacer after making the first tack then check the gap with a tool designed for that purpose Tacks on smaller diameter pipe can be 1 4 to 1 2 in long Tack on larger pipe may be 1 in or longer Note that tack welds will shrink during cooling causing the gap to close up In areas with less than a 1 8 in gap grind the joint using a 3 32 in cutting wheel to open the root Finish preparing the pass by grinding each tack weld to a feather edge to ensure that the root pass consumes the tack weld e Welding In The 1G Rolled Position Start the arc in the center of a tack around the 1 30 to 2 o clock position Hold the gun perpendicular to the pipe with a 5 to 10 degree drag angle Use a 3 8 to 5 8 in electrode stick out In some cases this may require a re cessed contact tip to help maintain correct stick out Establish the weld puddle and position the electrode in the center of the weld puddle at the pipe rolls away from the operato
51. t en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage M 247 250 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage
52. tion and if the pipe is in a fixed position or rotating 5G Fixed 1G Rotating 45 5 2G Fixed 6G Inclined Fixed Ref 805 024 A Ref 805 028 A Figure 3 7 Pipe Positions M 247 250 Page 15 3 3 GMAW MIG FCAW PipePro System EZ M m Attach volt sense lead as close to arc as possible 2 Do not mount feeder on top of power source Do not put feeder where welding wire hits cylinder gt gt gt Do not move or operate equipment when it could tip 1 Welding Power Source EF Attach volt sense lead as close to arc as possible WIN M 4 o DOO Q PD Negative Volt Sense Cable Positive 4 Weld Cable Negative Weld Cable Workpiece Welding Gun Wire Feeder Gas Hose Gas Oylinder 804 097 B Ref 804 374 C 10 14 Pin Feeder Control Cable 11 Interconnect Cable Connect 14 pin socket into wire feeder control cable or optional extension cable Connect 72 pin connector to I O receptacle RC72 on rear of power source Connect 10 pin connector into receptacle RC8 on rear of power source Maximum cable length not to exceed 150 feet M 247 250 Page 16 3 4 Typical PipeWorx Connection Diagram For MIG GMAW Equipment With Feeder gt gt a A ND On Power Source zd Pi
53. ubpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2010 03 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symbo
54. uit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger A Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m tal
55. us ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service Lh LA CHUTE DE L EQUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds N 3 n L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal po nd e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les ye
56. ux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir o cuits imprim s AS 2 e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes M 247 250 Page 7 Les PIECES MOBILES peuvent causer des blessures Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PIECES MOBILES peuvent causer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou di
57. w zero Nominal RMD Stainless Steel Table 3 7 PipeWorx 400 Welding Parameters Continued Stainless Steel Wire Size in mm Wire Feed Speed IPM mpm 120 350 w 200 Nominal 3 0 8 9 w 5 1 Nominal 120 350 w 200 Nominal 3 0 8 9 w 5 1 Nominal 120 350 w 200 Nominal 3 0 8 9 w 5 1 Nominal 120 350 w 200 Nominal 3 0 8 9 w 5 1 Nominal 120 250 w 150 Nominal 3 0 6 4 w 3 8 Nominal 120 250 w 150 Nominal 3 0 6 4 w 3 8 Nominal 120 250 w 150 Nominal 3 0 6 4 w 3 8 Nominal 120 250 w 150 Nominal 3 0 6 4 w 3 8 Nominal Arc Length 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal 3 0 to 3 0 w zero Nominal M 247 250 Page 35 Table 3 7 PipeWorx 400 Welding Parameters Continued Stainless Steel Arc Length Shielding Gas Wire Size Wire Feed Speed in mm IPM mpm ProPulse Stainless Steel Using A Positioner 1G Rolling The Pipe ProPulse Stainless Steel Welding In Position 5G M 247 250 Page 36 150 780 w 250 Nominal 3 8 19 8 w 6 4 Nominal 150 780 w 250 Nominal 3 8 19 8 w 6 4 Nominal 225 600 w 250 Nominal 5 7 15 2 w 6 4 Nominal 150 780 w 250 Nominal 3 8 19 8 w 6 4 Nominal 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 120 780 w 200 Nominal 3 0 19 8 w 5 1 Nominal 140 780 w 200 No
58. zards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as
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