Thermal Arc POWERMASTER 400SP, Service Manual

Page: 8 / 110

1-2
Octobe r 30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
WARNING
FUMES AND GASES can be haza r dous to you r
health.
Welding p r oduces fumes and gases. B r eathing
these fumes and gases can be haza r dous to you r
health.
1. Keep you r head out of the fumes. Do not b r eath
e
the fumes.
2. If inside, ventilate the a r ea and/o r use exhaust at the a r c to
r emove welding fumes and gases.
3. If ventilation is poo r , use an app r oved ai r -supplied r espi r ato r .
4. Read the Mate r ial Safety Data Sheets (MSDSs) and the
manufactu r e r ’s inst r uction fo r metals, consumables, coatings,
and cleane r s.
5. Wo r k in a confined space only if it is well ventilated, o r while
wea r ing an ai r -supplied r espi r ato r . Shielding gases used fo r
welding can displace ai r causing inju r y o r death. Be su r e the
b r eathing ai r is safe.
6. Do not weld in locations nea r deg r easing, cleaning, o r
sp r aying ope r ations. The heat and r ays of the a r c can r eact
with vapo r s to fo r m highly toxic and i rr itating gases.
7. Do not weld on coated metals, such as galvanized, lead, o r
cadmium plated steel, unless the coating is r emoved f r om
the weld a r ea, the a r ea is well ventilated, and if necessa r y,
while wea r ing an ai r -supplied r espi r ato r . The coatings and
any metals containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fi r e o r explosion.
Spa r ks and spatte r fly off f r om the welding a r c. The
flying spa r ks and hot metal, weld spatte r , hot
wo r kpiece, and hot equipment can cause fi r es and
bu r ns. Accidental contact of elect r ode o r welding
wi r e to metal objects can cause spa r ks, ove r heating,
o r fi r e.
1. P r otect you r self and othe r s f r om flying spa r ks and hot metal.
2. Do not weld whe r e flying spa r ks can st r ike flammable mate r ial.
3. Remove all flammables within 35 ft (10.7 m) of the welding
a r c. If this is not possible, tightly cove r them with app r oved
cove r s.
4. Be ale r t that welding spa r ks and hot mate r ials f r om welding
can easily go th r ough small c r acks and openings to adjacent
a r eas.
5. Watch fo r fi r e, and keep a fi r e extinguishe r nea r by.
6. Be awa r e that welding on a ceiling, floo r , bulkhead, o r pa r tition
can cause fi r e on the hidden side.
7. Do not weld on closed containe r s such as tanks o r d r ums.
8. Connect wo r k cable to the wo r k as close to the welding a r ea
as p r actical to p r event welding cu rr ent f r om t r aveling long,
possibly unknown paths and causing elect r ic shock and fi r e
haza r ds.
9. Do not use welde r to thaw f r ozen pipes.
10. Remove stick elect r ode f r om holde r o r cut off welding wi r e
at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause inju r y.
Chipping and g r inding cause flying metal. As welds
cool, they can th r ow off slag.
Welding o r cutting Elect r ode Size Filte r Welding o r cutting Elect r ode Size Filte r
To r ch solde r ing 2 Gas metal-arc
To r ch b r azing 3 o r 4 Non-fe rr ous base metal All 11
Oxygen Cutting Fe rr ous base metal All 12
Light Unde r 1 in., 25 mm 3 o r 4 Gas tungsten a r c welding All 12
Medium 1 to 6 in., 25-150 mm 4 o r 5 (TIG) All 12
Heavy Ove r 6 in., 150 mm 5 o r 6 Atomic hyd r ogen welding All 12
Gas welding Ca r bon a r c welding All 12
Light Unde r 1/8 in., 3 mm 4 o r 5 Plasma a r c welding
Medium 1/8 to 1/2 in., 3-12 mm 5 o r 6 Carbon arc air gouging
Heavy Ove r 1/2 in., 12 mm 6 o r 8 Light 12
Shielded metal-arc Unde r 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Ove r 1/4 in., 6.4 mm 14 Light Unde r 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Ove r 400 Amp 14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.