Thermal Arc POWERMASTER 400SP, Service Manual

Page: 7 / 110

1-1 Octobe r 30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live elect r ical pa r ts can cause fatal shocks
o r seve r e bu r ns. The elect r ode and wo r k ci r cuit is
elect r ically live wheneve r the output is on. The input
powe r ci r cuit and machine inte r nal ci r cuits a r e also
live when powe r is on. In semiautomatic o r
automatic wi r e welding, the wi r e, wi r e r eel, d r ive
r oll housing, and all metal pa r ts touching the
welding wi r e a r e elect r ically live. Inco rr ectly installed
o r imp r ope r ly g r ounded equipment is a haza r d.
1. Do not touch live elect r ical pa r ts.
2. Wea r d r y, hole-f r ee insulating gloves and body p r otection.
3. Insulate you r self f r om wo r k and g r ound using d r y insulating
mats o r cove r s.
4. Disconnect input powe r o r stop engine befo r e installing o r
se r vicing this equipment. Lock input powe r disconnect switch
open, o r r emove line fuses so powe r cannot be tu r ned on
accidentally.
5. P r ope r ly install and g r ound this equipment acco r ding to its
Owne r ’s Manual and national, state, and local codes.
6. Tu r n off all equipment when not in use. Disconnect powe r to
equipment if it will be left unattended o r out of se r vice.
7. Use fully insulated elect r ode holde r s. Neve r dip holde r in wate r
to cool it o r lay it down on the g r ound o r the wo r k su r face.
Do not touch holde r s connected to two welding machines at
the same time o r touch othe r people with the holde r o r
elect r ode.
8. Do not use wo r n, damaged, unde r sized, o r poo r ly spliced
cables.
9. Do not w r ap cables a r ound you r body.
10. G r ound the wo r kpiece to a good elect r ical (ea r th) g r ound.
11. Do not touch elect r ode while in contact with the wo r k
(g r ound) ci r cuit.
12. Use only well-maintained equipment. Repai r o r r eplace
damaged pa r ts at once.
13. In confined spaces o r damp locations, do not use a welde r
with AC output unless it is equipped with a voltage r educe r .
Use equipment with DC output.
14. Wea r a safety ha r ness to p r event falling if wo r king above
floo r level.
15. Keep all panels and cove r s secu r ely in place.
WARNING
ARC RAYS can bu r n eyes and skin; NOISE can
damage hea r ing. A r c r ays f r om the welding p r ocess
p r oduce intense heat and st r ong ult r aviolet r ays that
can bu r n eyes and skin. Noise f r om some p r ocesses
can damage hea r ing.
1. Wea r a welding helmet fitted with a p r ope r shade of filte r
(see ANSI Z49.1 listed in Safety Standa r ds) to p r otect you r
face and eyes when welding o r watching.
2. Wea r app r oved safety glasses. Side shields r ecommended.
3. Use p r otective sc r eens o r ba rr ie r s to p r otect othe r s f r om flash
and gla r e; wa r n othe r s not to watch the a r c.
4. Wea r p r otective clothing made f r om du r able, flame- r esistant
mate r ial (wool and leathe r ) and foot p r otection.
5. Use app r oved ea r plugs o r ea r muffs if noise level is high.
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS
KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL
BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding p r oducts and welding p r ocesses can cause se r ious inju r y o r death, o r damage to othe r equipment o r p r ope r ty, if the ope r ato r
does not st r ictly obse r ve all safety r ules and take p r ecautiona r y actions.
Safe p r actices have developed f r om past expe r ience in the use of welding and cutting. These p r actices must be lea r ned th r ough study
and t r aining befo r e using this equipment. Some of these p r actices apply to equipment connected to powe r lines; othe r p r actices apply
to engine d r iven equipment. Anyone not having extensive t r aining in welding and cutting p r actices should not attempt to weld.
Safe p r actices a r e outlined in the Ame r ican National Standa r d Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication
and othe r guides to what you should lea r n befo r e ope r ating this equipment a r e listed at the end of these safety p r ecautions. HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.