Auto-Axcess 450 - Miller
OM-220388AF2016 04ProcessesMIG (GMAW) WeldingPulsed MIG (GMAW-P)Flux Cored (FCAW) WeldingAutomatic WeldingDescriptionAutomatic Welding Interface AndArc Welding Power SourceAuto-Axcess 450 CEFile: Advanced Manufacturing SystemsVisit our website atwww.MillerWelds.com
From Miller to YouThank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit any other way.That’s why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.This Owner’s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. TheMiller is the first welding parts list will then help you to decide theequipment manufacturer in exact part you may need to fix the problem.the U.S.A. to be registered tothe ISO 9001 Quality System Warranty and service information for yourStandard.particular model are also provided.Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.Mil Thank 2009 09Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.
TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Additional Safety Symbols and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Front Panel Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Front Panel Controls - Continued (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8181819202222242525262728292929
TABLE OF CONTENTSSECTION 8 SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4. Process Control Module PC4 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5. Diagnostic LEDs On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7. Diagnostic LEDs On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. User Interface Module PC7 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. Diagnostic LEDs On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10. Automation Interface Module PC9 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Diagnostic LEDs On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12. Network And Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 10 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DECLARATION OF CONFORMITYfor European Community (CE marked) products.MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that theproduct(s) identified in this declaration conform to the essential requirements and provisions ofthe stated Council Directive(s) and Standard(s).Product/Apparatus Identification:ProductStock NumberAuto-Axcess 450 CEAuto-Axcess 450 CE w/RMDAuto-Axcess 450 CE w/Insight Core907274907274011907274006Council Directives: 2014/35/EU Low Voltage 2014/30/EU Electromagnetic Compatibility 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipmentStandards: IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirementsSignatory:May 12, 2015David A. WerbaDate of DeclarationMANAGER, PRODUCT DESIGN COMPLIANCE241981J
EMF DATA SHEET FOR ARC WELDING POWER SOURCEProduct/Apparatus IdentificationProductAUTO-AXCESS 450 CE VERSIONAUTO-AXCESS 450 CE W/INSIGHT COREAUTO-AXCESS 450 CE WITH RMDAUTO-AXCESS 300 CE AUTO-LINE ANALOGAUTO-AXCESS 300 CE AUTO-LINE ANALOG W/INSIGHT COREStock iance Information SummaryApplicable regulationDirective 2014/35/EUReference limitsDirective 2013/35/EU, Recommendation 1999/519/ECApplicable standardsIEC 62822-1:2016, IEC 62822-2:2016Intended use for occupational use for use by laymenNon-thermal effects need to be considered for workplace assessment YES NOThermal effects need to be considered for workplace assessment YES NO Data is based on maximum power source capability (valid unless firmware/hardware is changed) Data is based on worst case setting/program (only valid until setting options/welding programs are changed) Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)Occupational exposure is below the Exposure Limit Values (ELVs)for health effects at the standardized configurations YES NO(if NO, specific required minimum distances apply)Occupational exposure is below the Exposure Limit Values (ELVs)for sensory effects at the standardized configurations n.a YES NO(if applicable and NO, specific measures are needed) n.a YES NO(if applicable and NO, specific signage is needed)Occupational exposure is below the Action Levels (ALs) at thestandardized configurationsEMF Data for Non-thermal EffectsExposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)HeadStandardized distanceELV EI @ standardized distanceRequired minimum distanceSensory Ef fects10 cm0.17Health Ef fects10 cm0.14TrunkLimb (hand)Limb (thigh)10 cm0.233 cm0.133 cm0.301 cm1 cm1 cm1 cm1 cmDistance where all occupational ELV Exposure Indices fall below 0.20 (20%)13 cmDistance where all general public ELV Exposure Indices fall below 1.00 (100%)Tested by:275654-ATony SamimiDate tested:2016-02-15237 cm
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom 2015 097Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.1-1. Symbol UsageDANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or explained in the text.NOTICE Indicates statements not related to personal injury. Indicates special instructions.This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid thehazards.1-2. Arc Welding HazardsThe symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.Only qualified persons should install, operate, maintain, andrepair this unit.During operation, keep everybody, especially children, away.ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.D Do not touch live electrical parts.D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.D Use AC output ONLY if required for the welding process.D If AC output is required, use remote output control if present onunit.D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).D Properly install, ground, and operate this equipment according toits Owner’s Manual and national, state, and local codes.D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.D When making input connections, attach proper grounding conductor first double-check connections.D Keep cords dry, free of oil and grease, and protected from hot metaland sparks.D Frequently inspect input power cord and ground conductor fordamage or bare wiring – replace immediately if damaged – barewiring can kill.D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or repaired cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it directlywith a separate cable.D Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will bepresent.D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.D Do not connect more than one electrode or work cable to anysingle weld output terminal. Disconnect cable for process not inuse.D Use GFCI protection when operating auxiliary equipment in dampor wet locations.SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.D Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.HOT PARTS can burn.D Do not touch hot parts bare handed.D Allow cooling period before working onequipment.D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.OM-220388 Page 1
FUMES AND GASES can be hazardous.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at thearc to remove welding fumes and gases. The recommended wayto determine adequate ventilation is to sample for the compositionand quantity of fumes and gases to which personnel are exposed.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Safety Data Sheets (SDSs) and themanufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breathing air is safe.D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.ARC RAYS can burn eyes and skin.Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.D Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).D Wear approved safety glasses with side shields under yourhelmet.D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.D Wear body protection made from durable, flame resistant material (leather, heavy cotton, wool). Body protection includesoil-free clothing such as leather gloves, heavy shirt, cufflesstrousers, high shoes, and a cap.WELDING can cause fire or explosion.Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires andburns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.D Do not weld where flying sparks can strike flammable material.D Protect yourself and others from flying sparks and hot metal.D Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.D Watch for fire, and keep a fire extinguisher nearby.D Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.D Do not weld on containers that have held combustibles, or onclosed containers such as tanks, drums, or pipes unless they areproperly prepared according to AWS F4.1 and AWS A6.0 (seeSafety Standards).D Do not weld where the atmosphere can contain flammable dust,gas, or liquid vapors (such as gasoline).D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.D Do not use welder to thaw frozen pipes.OM-220388 Page 2D Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.D Wear body protection made from durable, flame resistant material(leather, heavy cotton, wool). Body protection includes oil-freeclothing such as leather gloves, heavy shirt, cuffless trousers, highshoes, and a cap.D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.D After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.D Use only correct fuses or circuit breakers. Do not oversize or bypass them.D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.D Read and understand the Safety Data Sheets (SDSs) and themanufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.FLYING METAL or DIRT can injure eyes.D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.D Wear approved safety glasses with sideshields even under your welding helmet.BUILDUP OF GAS can injure or kill.D Shut off compressed gas supply when not in use.D Always ventilate confined spaces or useapproved air-supplied respirator.ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.D Wearers of Pacemakers and other ImplantedMedical Devices should keep away.D Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.NOISE can damage hearing.Noise from some processes or equipment candamage hearing.D Wear approved ear protection if noise level is high.CYLINDERS can explode if damaged.Compressed gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.D Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.D Keep cylinders away from any welding or other electrical circuits.D Never drape a welding torch over a gas cylinder.D Never allow a welding electrode to touch any cylinder.D Never weld on a pressurized cylinder explosion will result.D Use only correct compressed gas cylinders, regulators, hoses,and fittings designed for the specific application; maintain themand associated parts in good condition.D Turn face away from valve outlet when opening cylinder valve. Donot stand in front of or behind the regulator when opening the valve.D Keep protective cap in place over valve except when cylinder is inuse or connected for use.D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.D 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 MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or nearcombustible surfaces.D Do not install unit near flammables.D Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.FALLING EQUIPMENT can injure.D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.D Use equipment of adequate capacity to lift andsupport unit.D If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.D Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.D Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94 110) when manually lifting heavy parts or equipment.OVERUSE can cause OVERHEATINGMOVING PARTS can injure.D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guardsclosed and securely in place.D Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.D Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.READ INSTRUCTIONS.D Read and follow all labels and the Owner’sManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.D Use only genuine replacement parts from the manufacturer.D Perform installation, maintenance, and service according to theOwner’s Manuals, industry standards, and national, state, andlocal codes.D Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle beforestarting to weld again.D Do not block or filter airflow to unit.H.F. RADIATION can cause interference.FLYING SPARKS can injure.D Wear a face shield to protect eyes and face.D Shape tungsten electrode only on grinder withproper guards in a safe location wearing properface, hand, and body protection.DD Sparks can cause fires — keep flammables away.DSTATIC (ESD) can damage PC boards.D Put on grounded wrist strap BEFORE handlingboards or parts.D Use proper static-proof bags and boxes tostore, move, or ship PC boards.DDD High-frequency (H.F.) can interfere
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