Miller DIALARC 400 AC/DC User manual

Miller

February

1990

FORM:

OM-317B

Effec

five

With

Serial

No.

JK646436

MODEL:

DIALARCﬁ

400

AC/DC

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

this

manual,

with

special

emphasis

the

safety

material

throughout

the

manual,

before

MILLER

ELECTRIC

Mfg.

Co.

AMHe~~~Ltd..

Co~any

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

Instructions

are

for

use

only

persons

trained

and

experienced

the

safe

1079

Ap~leton,

54912

USA

operation

welding

equipment.

not

allow

untrained

persons

install,

Tel.

414-734-9821

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

PRINTED

U.S.A

<,,

I

LIMITED

WARRANTY

EFFECTIVE:

MARCH

15,

1989

This

warranty

supersedes

all

MILLER

warranties

and

exclusivewith

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

hereof,

Miller Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

its

Distributor/Dealer

that

all

new

and

unused

Equipment

fur

nished

Miller

free

from

defect

workmanship

andmaterial

the

time

and

place

delivery

Miller.

warranty

made

Miller

with

respect

engines,

trade

accessories

other

items

manufactured

others.

Such

engines,

trade

cessories

and

other

items

are

sold

subject

the

warranties

their

respective

manufacturers,

any.

All

engines

are

war

ranted

their

manufacturer

for

one

year

from

date

original

purchase,

except

Tecumseh

and

Onan

engiqes

which

have

two

year

warranty.

Except

specified

below,

Millers

warranty

does

not

apply

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

MILLER

MATIC

parts

that

come

contact

with the

welding

wire

includ

ing

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

workmanship

material.

Miller

shall

required

honor

warranty

claims

warranted

Equipment

the

event

failure

resulting

from

defect

within

the

following

periods

from

the

date

delivery

Equipment

the

original

user:

Arc

welders,

power

sources,

robots,

and

year

components

Load

banks

year

Original

main

power

rectifiers

years

(labor



year

only)

All

welding

guns,

feeder/guns

and

torches

days

All

other

Millermatic

Feeders

year

Replacement

repair

parts,

exclusive

labor

days

Batteries

months

provided

that

Miller

notified

writing

within

thirty

(30)

days

the

date

such

failure.

matter

general

policy

only,

Miller

may

honor

claims

submitted

the

original

user

within

the

foregoing

periods.

the

case

Millers

breach

warranty

any

other

duty

with

respect

the

quality

any

goods,

the

exclusive

remedies

therefore

shall

be,

Millers

option(1)repairor

(2)

replacement

or,

where

authorized

writing

Miller

appropriate

cases,

(3)

the

reasonable

cost

repair

replacement

author

ized

Miller

service

station

(4)

payment

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based upon

actual

use)

upon

return

the

goods

Customers

risk

and

expense.

MILLERs

option

repair

replacement

will

FOB.,

Fac

tory

Appleton,

Wisconsin,

FOB.

MILLER

authorized

service

facility,

therefore,

compensation

for

transportation

costs

any

kind

will

allowed.

Upon

receipt

notice

parent

defect

failure,

Miller

shall

instruct

the

claimant

the

warranty

claim

procedures

followed.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRE

SENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHAN

TABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FUR

NISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

EXCEPT

EXPRESSLY

PROVIDED

MILLER

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTI

MATE

PURCHASE

COMMERCIALi1NDUSTRIAL

USERS

AND

FOR

OPERATION

BYPERSONSTRAINEDAND

EXPE

RIENCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CON

SUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

TO,

AND

RESELLER

AUTHORIZED

EXTEND

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

Replace

warranty

with

the

following:

.j

-~..

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

warranty

supersedes

alt

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditiona

below.

MILLER

Electric



Accessory

Kits

Mfg.

Co.,

Appleton.

Wisconsin,

warrants

its

original

retail

purchaser

that

new *

Replacement

Parts

MILLER

equipment

sold

after

the

effective

date

this

limited

warranty

free

fects

material

and

workmanship

the

time

shipped

MILLER.

THIS

WAR-

PANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES.

EXPRESS

MILLER

True

Blue

Limited

Warranty

shall

not

apply

to:

IMPLIED.

INCLUDING

THE

WARRANTIES

MERCHANTABILITY

AND

FIT-

NESS.

1..

Items

furnished

MILLER.

but

manufactured

othirs.

such

engines

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

Within

the

warranty

periods

listed

below.

MILLER

will

repair

replace

any

war-

any.

ranted

parts

components

that

tail

due

such

defects

material

workmanship.

MILLER

must

notified

writing

within

thirty

(30)

days

such

defector

failure,

2..

Con~umabIe

components;

such

contact

lips,

cutting

nozzles.

contactora

which

lime

MILLER

will

provide

instructions

the

warranty

ciaim

procedures

lobe

and

relays.

followed.

3..

Equipment

that

has

been

modified

any

party

other

than

MILLER.

equip.

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

tP,e

ment

that

has

been

improperfy Installed,

improperly

operated

misused

event

such

failure

within

the

warranty

time

periods.

All

warranty

time

periods

based upon

industry

standards,

equipment

which

has

not

had

reasonable

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser,

and

necessary

maintenance,

equipment

which

has

been

used

for

operation

and

are

follows:

outside

the

specifications

for

the

equipment.

1..

Years

Parts

3

Years

Labor

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED



Original

main

power

rectifiers

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT.

2..

YearsParts

and

Labor

the

event

warranty

claim

covered

this

warranty,

the

exclusive

remedies



Transformer/Rectifier

Power

Sources

shall

be.

MILLERS

optIon:

(1)

repaIr;

(2)

replacement; or.

where

authorized



Plasma

Arc

Cuffing

Power

Sources

writing

MILLER

inappropriate

cases.

(3)

the

reasonable

cost

repair

replace-

Semi-Automatic

and

Automatic

Wire

Feeders

ment

authorized

MILLER

service

station:

(4)

payment

Credit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

0 0

goods

customers

risk

and

expense.

MILLERS

option

repair

replacement

3..

Years



Parts

and

Labor

wilt

FOB..

Factory

atAppleton.

Wisconsin.

FOB.

ate

MILLER

authorized

ser

vice

facility

determined

MILLER.

Therefore

compensation

reimburse-

Engine

Driven

Welding

Generators

ment

for

transportation

costs

any

kind

will

allowed.

(NOTE:

Engines

are

warranted

separately

the

engine

manufacturer.)

,,,

THE

EXTENT

PERMITTED

LAW.

THE

REMEDIES

PROVIDED

HEREIN

ear



arts

and

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER



Motor

Driven

Guns

LIABLE

FOR

DIRECT,

INDIRECT.

SPECIAL,

INCIDENTAL

CONSEQUENTIAL



Process

Controllers

DAMAGES

(INCLUDING

LOSS

PROFIT).

WHETHER

BASED

ON CON



Water

coolant

Systems

TRACT,

TORT

ANY

OTHER

LEGAL

THEORY.



Units

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR-



Grids

PANTY.

GUARANTY OR

REPRESENTATION

PERFORMANCE.

AND

ANY

Spot

Welders

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL



Load

Banks

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION.



SDX

Transformers

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING.

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

Running

Gear/Trailers

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

ANY AND

ALL

EQUIPMENT



Field

Options

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

(NOTE:

Field

options

are

covered

under

True

Blue

for

the

remaining

warranty

period

the

product

they

are

Installed

in.

for

minimum

Some

states

the

U.S.A.

not

allow

limitations

how

long

Implied

warranty

one

year



whichever

greater.)

lasts,

the

exclusion

Incidental,

Indirect,

special

consequential

damages,

the

above

limitation

exclusion

may

not

apply

you.

This

warranty

provides

ape-

5..

Months



Batteries

cific

legal

rights,

and

other

rights

may

available,

but

may

vary

from

state

slate.

6..

Days



Parts

and

Labor

Canada,

legislation

some

provinces

provides

for

certain

additional

warranties



remedies

other

than

stated

herein,

and

the

extent

that

they

may

not

waived,

the

limitations

and

exclusions

set

Out

above

may

not

apply.

This

Limited



Plasma

cutting

Torches

Warranty

provides

specifIc

legal

rights,

and

other

rights

may

available,

but

may



Remote

Controls

vary

from

province

province.

I

WI,

AMENDMENT

SECTION

9

PARTS

LIST

Amend

Parts

List

follows:

Dia.

Part

Replaced

Mkgs.

No.

With

Description

Quantity

21-4

....

...

009 859

137

900

KIT,

contactor

(Eff

w/KB022071)

21-25

081

016~..

Deleted

Effw/KB022071

~First

digit

represents

page



digits

following

dash

represent

item

no.

+Quantity

changes

for

090 716

Assembly

only.

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-317B

Page

OM.3178-2/gO

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

duiing

shipment.

File

any

tion

and

Senal

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

delivering

carTler.

mation

located

the

data

card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distnbutor

and/or

the

equipment

manufactur-

Model

___________________________

ers

Transportation

Department.

Serial

Style

No.

________________

When

requesting

information

about

this

equipment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

_________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTION

2

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1

General

Information

And

Safety

2-2.

Safety

Alert

Symbol

And

Signal

Woitis

SECTION

3

SPECIFICATIONS

3-1.

Volt-Ampere

Curves

3-2.

Duty

Cycle

3-3.

Description

SECTION

INSTALLATION

RELOCATION

4-1.

Site

Selection

4-2.

Transporting

Methods

4-3.

Weld

Output

Connections

4-4.

Remote

Amperage

Control

Receptacle

Information

And

Connections

4-5.

Electrical

Input

Connections

SECTION

OPERATOR

CONTROLS

5-1.

Power

Switch

5-2.

Range

Switch

5-3.

AC/DC

Selector

Switch

5-4.

Amperage

Adjustment

Control

5-5.

Remote

Amperage

Control

Switch

5-6.

Control

Circuit

Overload

Breaker

Section

No.

Page

No.

SECTiON

6

SEQUENCE

OPERATION

6-1.

ShIelded

Metal

Arc

Welding

(SMAW)

6-2.

Shutting

Down

SECTION

MAINTENANCE

TROUBLESHOOTING

Routine

Maintenance

Oveiload

Protection

Thermal

Protection

Voltage

Reducer

Circuit

Operation

Circuit

Board

Handling

Precautions

Troubleshooting

Chart

SECTION

ELECTRICAL

DIAGRAMS

Diagram

8-1.

Circuit

Diagram

8-2.

Circuit

Diagram

For

Firing

Board

PCi

Diagram

8-3.

Circuit

Diagram

For

Voltage

Reducer

Board

PC2

SECTION

9

PARTS

LIST

Figure

9-1.

Figure

9-2.

Figure

9-3.

Figure

9-4.

Figure

9-5.

Figure

9-6.

Figure

9-7.

Figure

9-8.

Figure

9-9.

Figure

9-10.

Table

3-1.

Chart

3-1.

Chart

3-2.

Table

4-1.

Table

4-2.

Table

7-1.

Table

7-2.

7-1.

7-2.

7-3.

7-4.

7-5.

7-6.

Main

Assembly

Panel,

Front

w/Components

Switch,

PIrt

Switch,

Range

Circuit

Card,

Control

PCi

Circuit

Card,

Voltage

Reducer

PC2

Switch,

Rectifier,

Diode

Panel,

Rear

w/Components

SCR

Contactor

Primary

Terminal

LIST

CHART

AND

TABLES

Specifications

Volt-Ampere

Curves

Duty

Cycle

Weld

Cable

Size

Input

Conductor

And

Fuse

Size

Maintenance

Schedule

Troubleshooting

Chart

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

per

sonal

experience,

child

touching

hot

stove

harmful,

wasteful,

and

unwise.

Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

welding

and

cutting

are

described

this

manual.

search,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

improperly

used

maintained.

The

rea

son

for

the

safe

practices

may

not

always

given.

Some

are

based

common

sense,

others

may

require

technical

volumes

explain.

wiser

the

rules.

Read

and

understand

these

safe

practices

before

tempting

install,

operate,

service

the

equipment.

Comply

with

these

procedures

applicable

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

sen

ous

injury

death.

When

safety

becomes

habit,

the

equipment

can

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1-General

Precautions,

common

arc

welding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

safety

are

also

available

for

additional

and

complete

pro

cedures

than

those

given

this

manual.

They

are

listed

the

Standards

Index

this

manual.

ANSI

Z49.1

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Different

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radiatIon

levels.

addition

the

Information

this

manual,

sure

consult

flux

and

electrode

manufacturers

MaterIal

Safety

Data

Sheets

(MSDSs)

for

specifIc

technical

data

and

precaution

ary

measures

concerning

their

material.

Burn

Prevention

Wear

protective

clothing-gauntlet

gloves

designed

for

use

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

glasses

with

side

shields

underneath,

appropriate

filter

lenses

plates

(protected

clear

cover

glass).

This

MUST

for

welding

cutting,

(and

chipping)

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

spattered.

See

-3A.2.

Avoid

oily

greasy

clothing.

spark

may

ignite

them.

Hot

metal

such

electrode

stubs

and

workpieces

should

never

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

qualified

first

aid

person

should

avadab~e

for

each

shift

unless

medical

facilities

are

for

mediate

treatment

flash

burns

the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

used

per

Sons

intending

weld

cut.

Toxic

Fume

Prevention

Severe

discomfort,

illness

death

can

result

from

fumes,

vapors,

heat,

oxygen

enrichment

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

described

ANSI

Stan

dard

Z49.1

listed

Standards

Index.

NEVER

ventilate

with

oxygen.

Lead

cadmium-,

zinc

mercury-,

and

beryllium-bear

ing

and

similar

materials,

when

welded

(or

cut)

may

pro

duce

harmful

concentrations

toxic

fumes.

Adequate

local

exhaust

ventilation

must

used,

each

person

the

area

well

the

operator

must

wear

air-sup

plied

respirator.

For

beryllium,

both

must

used.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should not

heated

unless

coating

moved

from

the

work

surface,

the

area

well

ventilated

and,

necessary,

while

wearing

air-supplied

respira

tor.

Work

confined

space

only

while

being

ventilated

and,

necessary,

while

wearing

air-supplied

respira

tor.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large quantities

can

change

oxygen

con

centration

dangerously.

not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source

prevent

possible

accumulation

gases

the

space

downstream

valves

have

been

accidentally

opened

left

open.

Check

sure

that

the

space

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

decomposed

the

heat

the

arc

(or

flame)

form

PHOSGENE,

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

the

arc

can

also

decompose

trichloroethylene

and

perchioroethylene

vapors

form

phosgene.

NOT

WELD

cut

where

solvent

vapors

can

drawn

into

the

welding

cutting

OM-317

Page

atmosphere

where

the

radiant

energy

can

penetrate

atmospheres

containing

even

minute

amounts

trichioroethylene

perchioroethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

mate

rial;

misuse

compressed

gases

and

cylinders;

and

short

circuits.

AWARE

THAT

flying

sparks

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

doors,

and

through

wall

floor

openings,

out

sight

the

goggled

operator.

Sparks

and

slag

can

fly

feet.

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

oil,

grease,

and

(in

electrical

parts)

metallic

particles

that

can

cause

short

circuits.

combustibles

are

area,

NOT

weld

cut.

Move

the

work

practicable,

area

free

cdmbustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

venti

lators.

the

work

cannot

moved,

move

combustibles

least

feet

away

out

reach

sparks

and

heat;

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

shields.

Walls

touching

combustibles

opposite

sides

should

not

welded

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

extin

guishing

equipment

during

and

for

some

time

afterweld

ing

cutting

if:

appreciable

combustibles

(including

building

construction)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

orvisible)

floors

orwalls

within

feet

may

expose

combustibles

sparks

combustibles

adjacent

walls,

ceilings,

roofs,

metal

partitions

can

ignited

radiant

conducted

heat.

Hot

work

permit

should

obtained

before

operation

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

done,

check

that

area

free

sparks,

glowing

embers,

and

flames.

empty

container

that

held

combustibles,

that

can

produce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O,

listed

Standards

Index.

This

includes:

thorough

steam

caustic

cleaning

(or

solvent

water

washing,

depending

the

combusti

bles

solubility)

followed

purging

and

inerting

with

trogen

carbon

dioxide,

and

using

protective

equip-

ment

recommended

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

container

with

unknown

contents

should

cleaned

(see

preceding

paragraph).

NOT

depend

sense

smell

sight

determine

safe

weld

cut.

Hollow

castings

containers

must

vented

before

welding

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

cut

where

the

air

may

contain

flammable

dust,

gas,

liquid

vapors

(such

gasoline).

Compressed

Gas

EquIpment

Standard

precautions.

Comply

with

precautions

this

manual,

and

those

detailed

CGA

Standard

P-I,

SAFE

HANDLING

COMPRESSED

GASES

CYLIN

DERS,

listed

Standards

Index.

Pressure

Regulators

Regulator

relief

valve

designed

protect

only

the

regulator

from

overpressure;

not

intended

protect

any

downstream

equipment.

Provide

such

protection

with

one

relief

devices.

Never

connect

regulator

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

repair

(first

cylinder

valve).

The

following

symp

toms

indicate

faulty

regulator:

Leaks-if

gas

leaks

externally.

Excessive

Creep-if

delivery

pressure

continues

rise

with

downstream

valve

closed.

Faulty

Gauge-if

gauge

pointer

does

not

move

oft

stop

when

pressurized,

nor

returns

stop

after

pres

sure

release.

Repair.

NOT

attempt

repair.

Send

faulty

regula

tors

for

repair

manufacturers

designated

repair

cen

ter,

where

special

techniques

and

tools

are

used

trained

personnel.

Cylinders

must

handled

carefully

prevent

leaks

and

damage

their

walls,

valves,

safety

devices:

Avoid

electrical

Circuit

contact

with

cylinders

including

third

rails,

electrical

wires,

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

serious

cident.

(See

l-3C.)

ICC

DOT

marking

must

each

cylinder.

assurance

safety

when

the

cylinder

properly

han

dled.

Identifying

gas

content.

Use

only

cylinders

with

name

gas

marked

them;

not

rely

color

identify

gas

content.

Notify

supplier

unmarked.

NEVER

DEFACE

alter

name,

number,

other

markings

cylinder.

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

Prohibited

use.

Never

use

cyinder

its

contents

for

other

than

its

intended

use,

NEVER

support

roUer.

OM-317

Page

Locate

secure

cylinders

they

cannot

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

areas

where

they

may

struck.

Transporting

cylinders.

With

crane,

use

secure

sup

port

such

platform

cradle.

NOT

lift

cylinders

off

the

ground

their

valves

caps,

chains,

slings,

magnets.

NOT

expose

cylinders

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

not

low

contents

exceed

130F.

Cool

with

water

spray

where

such

exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

objects,

and

weather.

Replace

caps

securely

when

moving

cylinders.

Stuck

valve.

NOT

use

hammer

wrench

open

cylinder

valve

that

can

not

opened

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

mix

any

gases

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

modified

changed.

Hose

Prohibited

use.

Never

use

hose

other

than

that

signed

for

the

specified

gas.

general

hose

identifica

tion

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

clamps

designed

for

the

hose

(not

ordi

nary wire

other

substitute)

binding

connect

hoses

fittings.

copper

tubing

splices.

Use

only

standard

brass

fit

tings

splice

hose.

Avoid

long

runs

prevent

kinks

and

abuse.

Suspend

hose

off

ground

keep

from

being

run

over,

stepped

on,

otherwise

damaged.

Coil

excess

hose

prevent

kinks

and

tangles.

Protect

hose

from

damage

sharp

edges,

and

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

immerse

pressured

hose

water;

bubbles

dicate

leaks.

Repair

leaky

worn

hose

cutting

area

out

and

splic

ing

-2D3).

NOT

tape.

Proper

Connections

Clean

cylinder

valve

outlet

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

ignition.

Wipe

with

clean

lintless

cloth.

Match

regulator

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

area,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

regulator

designed

for

particular

gas

gases

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

arid

regulator,

one

required.

use

two

wrenches

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Reguiatoroutiet(orhose)

connections

may

identified

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

nut

shank)

for

fuel

gas.

Pressurizing

Steps:

Drain

regulator

residual

gas

through

suitable

vent

fore

opening

cylinder

(or

manifold

valve)

turning

justing

screw

(clockwise).

Draining

prevents

exces

sive

compression

heat

high

pressure

seat

allowing

seat

open

pressurization.

Leave

adjusting

screw

engaged

slightly

single-stage

regulators.

Stand

side

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

that

regulator

pressure

creases

slowly.

When

gauge

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

fol

lowing

position:

For

oxygen,

and

inert

gases,

open

fully

seal

stem

against possible

leak.

For

fuel

gas,

open

less

than

one

turn

permit

quick

emergency

shutoff.

Use

pressure

charts

(availabe

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

regulators.

Check

for

leaks

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capfull

Ivory

Liquid*

equivalent

per

gallon

water).

Bubbles

indi

cate

leak.

Clean

off

soapy

water

afterlest;

dried

soap

combustible.

User

Responsibilities

Remove

leaky

defective

equipment

from

service

mediately

for

repair.

See

User

Responsibility

statement

equipment

manual.

Leaving

Equipment

Unattended

gas

supply

source

and

drain

gas.

Rope

Staging-Support

Rope

staging-support

should

not

used

for

welding

cutting

operation;

rope

may

bum.

*Trademark

Proctor

Gamble.

OM-317

Page

1-3.

ARC

WELDING

Comply

with

precautions

1-1,

1-2,

and

this

section.

Arc

Welding,

property

done,

safe

process,

but

careless

operator

invites

trouble.

The

equipment

carnes

high

currents

significant

voltages.

The

arc

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

frared

energy

radiates,

weidments

are

hot,

and

com

pressed

gases

may

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

stan

dards

referenced

index.

Burn

Protection

Comply

with

precautions

1-2.

The

welding

arc

intense

and

visibly

bright.

its

radiation

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-

shielded

arcs

are

severe

and

painful.

~ONT

GET

BURNED;

COMPLY

WITH

PRECAUTlOI~IS.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

addition

gloves,

hat,

and

shoes

-2A).

nec

essary,

use

additional

protective

clothing

such

leather

jacket

sleeves,

flame-proof

apron,

and

fire-re

sistant

leggings.

Avoid

outer

garments

untreated

cot

ton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

protect

chest

and

neck

and

button

pock

ets

prevent

entry

sparks.

Eye

and

Head

Protection

Protect

eyes

from

exposure

arc.

NEVER

look

electric

arc

without

protection.

Welding

helmet

shield

containing

filter

plate

shade

no.

denser

must

used

when

welding.

Place

over

face

before

striking

arc.

Protect

filter

plate

with

clear

cover

plate.

Cracked

broken

helmet

shield

should

NOT

worn;

radiation

can

pass

through

cause

burns.

Cracked,

broken,

loose

filter

plates

must

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

bro

ken,

pitted,

spattered.

Flash

goggles

with

side

shields

MUST

worn

under

the

helmet

give

some

protection

the

eyes

should

the

helmet

not

lowered

over

the

face

before

arc

struck.

Looking

arc

momentarily

with

unprotected

eyes

(particularly

high

intensity

gas-shielded

arc)

can

cause

retinal

bum

that

may

leave

permanent

dark

area

the

field

vision.

Protection

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

sepa

rate

room

enclosed

bay

best.

open

areas,

sur

round

the

operation

with

low-reflective,

non-combusti

ble

screens

panels.

Allow

for

free

air

circulation,

par

ticularly

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

looking

directly

the weld.

Others

working

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

weld,

make

sure

that

screen

flaps

bay

doors

are

closed.

Toxic

Fume

Prevention

Comply

with

precautions

-2B.

Generator

engine

exhaust

must

vented

the

outside

air.

Carbon

monoxide

can

kill.

Fire

and

ExplosIon

Prevention

Comply

with

precautions

-2C.

Equipments

rated

capacity.

not

overload

arc

weld

ing

equipment.

may

overheat

cables

and

cause

fire.

Loose

cable

connections

may

overheat

flash

and

cause

fire.

Never

strike

arc

cylinder

other

pressure

ves

sel.

creates

brittle

area

that

can

cause

violent

rup

ture

lead

such

rupture

under

rough

handling.

Compressed

Gas

Equipment

Comply

with

precautions

-2D.

Shock

Prevention

Exposed

hot

conductors

other

bare

metal

the

weld

ing

circuit,

ungrounded,

electrically-HOT

equip

ment

can

fatally

shock

person

whose

body

becomes

conductor.

DO NOT

STAND,

SIT,

LIE,

LEAN

ON,

TOUCH

wet

surface

when

welding,

without

suitable

protection.

protect

against

shock:

Wear

dry

insulating

gloves

and

body

protection.

Keep

body

and

clothing

dry.

Never

work

damp

area

without

adequate

insulation

against

electrical

shock.

Stay

dry

duckboard,

rubber

mat

when

dampness

sweat

can

not

avoided.

Sweat,

sea

water,

moisture

tween

body

and

electrically

HOT

part

grounded

metal

reduces

the

electrical

resistance,

and

could

able

dangerous

and

possibly

lethal

currents

flow

through

the

body.

voltage

will

exist

between

the

electrode

and

any

con

ducting

object

the

work

circuit.

Examples

conduct

ing

objects

include,

but

are

not

limited

to,

buildings,

elec

trical

tools,

work

benches,

welding

power

source

cases,

workpieces,

etc.

Never

touch

the

electrode

and

any

metal

object

unless

the

welding

power

source

Is off.

Grounding

the

Equipment

Arc

welding

equipment

must

grounded

according

the

National

Electrical

Code,

and

the

work

must

grounded

according

ANSI

Z49.1

Safety

Welding

And

Cutting.

When

installing,

connect

the

frames

each

unit

such

welding

power

source,

control,

worktable,

and

water

culatorto

the

building

ground.

Conductors

must

ade

quate

carry

ground

currents

safely.

Equipment

made

OM-317

Page

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