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
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER
ELECTRIC
Mfg.
Co.
AMHe~~~Ltd..
Co~any
installing,
operating,
or
maintaining
this
equipment.
This unit and
these
Instructions
are
for
use
only by
persons
trained
and
experienced
in
the safe
1079
Ap~leton,
WI 54912
USA
operation
of
welding
equipment.
Do
not allow
untrained
persons
to
install,
Tel.
414-734-9821
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
PRINTED
IN
U.S.A

_J
<,,
I
LIMITED
WARRANTY
EFFECTIVE: MARCH
15,
1989
This
warranty
supersedes
all
previous
MILLER
warranties
and is
exclusivewith
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
terms
and conditions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and unused
Equipment
fur
nished
by
Miller
is free
from
defect
in
workmanship
andmaterial
as
of
the
time
and
place
of
delivery by
Miller. No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other items
manufactured
by
others.
Such
engines,
trade
ac
cessories and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and Onan
engiqes
which have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of less
than
one
(1)
year,
such
as
spot
welder
tips, relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with the
welding
wire
includ
ing
nozzles and
nozzle
insulators
where
failure does
not
result
from
defect
in
workmanship
or
material.
Miller shall be
required
to
honor
warranty
claims
on
warranted
Equipment
in the
event
of
failure
resulting
from
a
defect within
the
following periods
from
the
date of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches 90
days
5.
All other
Millermatic Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive of labor
60
days
7.
Batteries
6
months
provided
that Miller is notified in
writing
within
thirty
(30)
days
of
the
date
of
such failure.
As
a
matter
of
general policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within the
foregoing
periods.
In
the
case
of
Millers breach of
warranty
or
any
other
duty
with
respect
to the
quality
of
any
goods,
the
exclusive
remedies
therefore shall
be,
at
Millers
option(1)repairor
(2)
replacement
or,
where
authorized
in
writing by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at an
author
ized Miller
service
station
or
(4)
payment
of
or
credit for the
pur
chase
price
(less
reasonable
depreciation
based upon
actual
use)
upon
return
of
the
goods
at Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will be
FOB.,
Fac
tory
at
Appleton,
Wisconsin,
or
FOB. at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind will
be
allowed.
Upon receipt
of
notice
of
ap
parent
defect
or
failure,
Miller shall
instruct the claimant
on
the
warranty
claim
procedures
to
be followed.
ANY
EXPRESS
WARRANTY NOT PROVIDED
HEREIN
AND ANY IMPLIED
WARRANTY,
GUARANTY OR
REPRE
SENTATION AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR BREACH OF CONTRACT
WHICH,
BUT FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM OF TRADE
OR COURSE OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY OF MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY MILLER IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY PROVIDED
BY
MILLER
IN
WRITING,
MILLER PRODUCTS ARE
INTENDED FOR
ULTI
MATE PURCHASE
BY COMMERCIALi1NDUSTRIAL
USERS
AND
FOR
OPERATION BYPERSONSTRAINEDAND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND NOT FOR
CONSUMERS
OR
CON
SUMER
USE. MILLERS WARRANTIES
DO NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
UI

ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Replace
warranty
with
the
following:
.j
-~..
i.
MILLERS
TRUE
BLUETM
LIMITED WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
alt
previous
MILLER
warranties
and
is exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
terms
and
conditiona below.
MILLER
Electric

Accessory
Kits
Mfg.
Co.,
Appleton.
Wisconsin,
warrants
tO
its
original
retail
purchaser
that
new *
Replacement
Parts
MILLER
equipment
sold
after the
effective date of this
limited
warranty
is
free
of
de
fects
in
material and
workmanship
at
the
time
it is
shipped
by
MILLER. THIS
WAR-
.
PANTY
IS
EXPRESSLY
IN LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS OR
MILLER S
True
Blue
Limited
Warranty
shall
not
apply
to:
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY AND
FIT-
NESS.
1..
Items furnished
by
MILLER.
but
manufactured
by
othirs.
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
It
Within
the
warranty
periods
listed
below. MILLER
will
repair
or
replace
any
war-
any.
ranted
parts
or
components
that tail due
to such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30) days
of such
defector
failure,
at
2..
Con~umabIe
components;
such
as
contact
lips,
cutting
nozzles.
contactora
which
lime
MILLER
will
provide
instructions
on
the
warranty
ciaim
procedures
lobe
and
relays.
followed.
3..
Equipment
that
has been
modified
by
any
party
other than
MILLER.
or
equip.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
tP,e
ment
that
has
been
improperfy Installed, improperly
operated
or
misused
event
of such
a
failure
within the
warranty
time
periods.
All
warranty
time
periods
based upon
industry
standards, or
equipment
which has
not
had reasonable
start
on
the
date that the
equipment
was
delivered
to
the
original
retail
purchaser,
and
necessary
maintenance,
or
equipment
which has been
used
for
operation
and
are as
follows:
outside oI
the
specifications
for the
equipment.
1..
5
Years
Parts
3
Years
Labor
MILLER
PRODUCTS
ARE INTENDED FOR
PURCHASE
AND
USE BY
COMMER
CIALJINDUSTRIAL
USERS AND PERSONS TRAINED
AND
EXPERIENCED
IN

Original
main
power
rectifiers
THE
USE
AND
MAINTENANCE OP
WELDING
EQUIPMENT.
2..
3
YearsParts
and
Labor
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies

Transformer/Rectifier
Power
Sources
shall
be.
at
MILLERS
optIon: (1)
repaIr;
or
(2) replacement; or.
where
authorized
In

Plasma
Arc
Cuffing
Power Sources
writing by
MILLER
inappropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replace-
*
Semi-Automatic
and
Automatic Wire Feeders
ment at
an authorized
MILLER
service station:
or
(4)
payment
of
or Credit forthe
pur
P
b
ts
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of the
0 0
goods
at
customers
risk and
expense.
MILLERS
option
of
repair
or
replacement
3..
2
Years

Parts
and
Labor
wilt
be
FOB..
Factory
atAppleton.
Wisconsin.
or
FOB.
ate
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse-
Engine
Driven
Welding
Generators
ment
for
transportation
costs
of
any
kind
will be
allowed.
(NOTE: Engines
are
warranted
separately
by
the
engine
manufacturer.)
4
,,,
~
TO
THE
EXTENT PERMITTED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
ear

arts
and
r
ARE THE
SOLE
AND EXCLUSIVE REMEDIES.
IN NO EVENT
SHALL
MILLER BE

Motor
Driven
Guns LIABLE
FOR
DIRECT, INDIRECT. SPECIAL,
INCIDENTAL OR
CONSEQUENTIAL

Process
Controllers
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON CON

Water
coolant
Systems
TRACT,
TORT OR
ANY
OTHER
LEGAL THEORY.

HF
Units
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN AND ANY
IMPLIED
WAR-

Grids
PANTY. GUARANTY OR REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
*
Spot
Welders
REMEDY
FOR
BREACH OF
CONTRACT
TORT OR
ANY
OTHER
LEGAL

Load
Banks
THEORY
WHICH,
BUT
FOR
THIS
PROVISION, MIGHT
ARISE BY
IMPLICATION.

SDX Transformers
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
*
Running
Gear/Trailers
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY AND ALL
EQUIPMENT

Field
Options
FURNISHED BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
(NOTE:
Field
options
are
covered under
True Blue
for
the
remaining
warranty
period
of the
product
they
are
Installed
in.
or
for
a
minimum
ot
Some
states
In the
U.S.A.
do
not
allow
limitations
of
how
long
an
Implied
warranty
one
year

whichever
is
greater.)
lasts,
or
the exclusion
of
Incidental,
Indirect,
special
or
consequential
damages,
so
the above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
ape-
5.. 6 Months

Batteries
cific
legal
rights,
and
other
rights
may
be
available,
but
may vary
from
state to slate.
6..
90
Days

Parts
and
Labor
.
in
Canada,
legislation
In
some
provinces
provides
for certain additional
warranties

I
or
remedies other than
as
stated
herein,
and
to the
extent
that
they
may
not
be
u 0 C
CS
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
be
available,
but
may

Remote
Controls
vary
from
province
to
province.
_1
I WI,

AMENDMENT
TO
SECTION
9
PARTS
LIST
Amend
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs.
No. With
Description
Quantity
21-4
....
W
...
009 859
..
137 900
..
KIT,
contactor
(Eff w/KB022071)
1
21-25
081 016~.. Deleted
..
Effw/KB022071
1
~First
digit
represents
page
no

digits
following
dash
represent
item
no.
+Quantity
changes
for
090 716
Assembly
only.
BE
SURE TO PROVIDE MODEL
AND
SERIAL NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-317B
Page
2

OM.3178-2/gO
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam- Use the
following
spaces
to
record
the Model
Designa
age
that
may
have
occurred
duiing
shipment.
File
any
tion and
Senal
or
Style
Number
of
your
unit.
The
infor
claims for
loss
or
damage
with
the
delivering
carTler. mation
is located
on
the data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from the
distnbutor
and/or
the
equipment
manufactur-
Model
___________________________
ers
Transportation
Department.
Serial
or
Style
No.
________________
When
requesting
information about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date of Purchase
_________________
Number.
TABLE
OF CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
RULES FOR
OPERATION
OF ARC WELDING POWER SOURCE
1-1.
Introduction
1
1-2.
General Precautions 1
1-3.
Arc
Welding
4
1-4.
Standards
Booklet Index
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1
.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Woitis
6
SECTION
3
SPECIFICATIONS
3-1.
Volt-Ampere
Curves
8
3-2.
Duty
Cycle
8
3-3.
Description
8
SECTION
4-
INSTALLATION OR
RELOCATION
4-1.
Site
Selection
8
4-2.
Transporting
Methods
9
4-3.
Weld
Output
Connections
9
4-4.
Remote
Amperage
Control
Receptacle
Information And
Connections
10
4-5.
Electrical
Input
Connections
10
SECTION
5-
OPERATOR CONTROLS
5-1.
Power
Switch
13
5-2.
Range
Switch
13
5-3.
AC/DC
Selector
Switch
13
5-4.
Amperage Adjustment
Control
13
5-5.
Remote
Amperage
Control
Switch
13
5-6.
Control
Circuit Overload
Breaker
13

Section
No.
Page
No.
SECTiON
6
SEQUENCE
OF
OPERATION
6-1.
ShIelded
Metal
Arc
Welding
(SMAW)
6-2.
Shutting
Down
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
Routine Maintenance
Oveiload
Protection
Thermal
Protection
Voltage
Reducer Circuit
Operation
Circuit
Board
Handling
Precautions
Troubleshooting
Chart
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
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.
20
Figure
9-2.
22
Figure
9-3.
24
Figure
9-4.
25
Figure
9-5.
26
Figure
9-6.
28
Figure
9-7.
30
Figure
9-8.
30
Figure
9-9.
31
Figure
9-10.
32
Table
3-1.
7
Chart
3-1.
7
Chart
3-2.
8
Table
4-1.
9
Table
4-2.
11
Table
7-1.
15
Table
7-2.
16
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
14
14
14
15
15
15
15
16
17
17
18
Main
Assembly
Panel,
Front
-
w/Components
Switch,
PIrt
Switch,
Range
Circuit
Card,
MA
Control
PCi
Circuit
Card,
Voltage
Reducer
PC2
Switch,
PB
Rectifier,
Si
Diode
Panel,
Rear
-
w/Components
SCR Contactor
&
Primary
Terminal
LIST
OF
CHART
AND
TABLES
Specifications
Volt-Ampere
Curves
Duty
Cycle
Weld
Cable Size
Input
Conductor
And
Fuse
Size
Maintenance Schedule
Troubleshooting
Chart

SECTION
1
-
SAFETY
RULES FOR
OPERATION OF ARC
WELDING
POWER
SOURCE
1-1. INTRODUCTION
We learn
by experience.
Learning
safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
unwise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Re
search,
development,
and
field
experience
have
evolved
reliable
equipment
and safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained. The
rea
son
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical
volumes
to
explain.
It
is wiser
to
follow the
rules.
Read
and
understand
these safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with these
procedures
as
applicable
to
the
par
ticular
equipment
used
and their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
sen
ous
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These safe
practices
are
divided into
two Sections:
1-General
Precautions,
common
to
arc
welding
and
cut
ting;
and 2-Arc
Welding (and
Cutting)
(only).
Reference standards: Published
Standards
on
safety
are
also
available for additional and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1 is
the
most
complete.
The National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
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.
In
addition
to
the
Information
In
this
manual,
be
sure
to
consult flux
and electrode
manufacturers
MaterIal
Safety
Data
Sheets
(MSDSs)
for
specifIc
technical data
and
precaution
ary
measures
concerning
their
material.
A.
Burn
Prevention
Wear
protective
clothing-gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear helmet
with
safety goggles
and
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting, (and
chipping)
to
protect
the
eyes
from radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See I
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal such
as
electrode
stubs
and
workpieces
should
never
be handled without
gloves.
Medical
first
aid and
eye
treatment.
First
aid facilities
and
a
qualified
first
aid
person
should
be
avadab~e
for
each
shift unless
medical
facilities
are
close
by
for
im
mediate
treatment
of flash
burns
of
the
eyes
and skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
Sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Stan
dard
Z49.1
listed
in
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
of
toxic
fumes.
Adequate
local
exhaust ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear an
air-sup
plied
respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should not
be heated
unless
coating
is
re
moved
from
the work
surface,
the
area
is
well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Work in
a
confined
space
only
while
it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks
in
a
confined
space
should
be avoided.
Leaked
gas
in
large quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation of
gases
in
the
space
if
downstream
valves have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that
the
space
is safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
prod
ucts.
The
ultraviolet
(radiant)
energy
of
the
arc can
also
decompose
trichloroethylene
and
perchioroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be drawn
into the
welding
or
cutting
OM-317
Page
1

atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
perchioroethylene.
C. Fire
and
Explosion
Prevention
Causes
of
fire and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
rial;
misuse of
compressed
gases
and
cylinders;
and
short circuits.
BE
AWARE
THAT
flying
sparks
or
falling slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles are
in
area,
do
NOT
weld
or
cut.
Move
the work
if
practicable,
to
an
area
free
of
cdmbustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
venti
lators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35
feet
away
out
of reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be
welded
on
(or
cut).
Walls,
ceilings,
and floor
near
work should
be
protected by
heat-resistant
covers or
shields.
Fire watcher
must
be
standing
by
with suitable fire extin
guishing
equipment
during
and for
some
time
afterweld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35 feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed orvisible)
in
floors orwalls
within 35
feet
may expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted heat.
Hot
work
permit
should
be obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is free
of
sparks,
glowing
embers,
and flames.
An
empty
container that held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be welded
on
or
cut,
unless
container
has first
been cleaned
as
described
in
AWS Standard
A6.O,
listed
7
in
Standards
Index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective
equip-
ment
as
recommended
in
A6.O.
Waterfilling just
below
working
level
may
substitute
for
inerting.
A
container with
unknown
contents
should
be
cleaned
(see
preceding
paragraph).
Do
NOT
depend
on sense
of
smell
or
sight
to
determine
if
it
is safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be vented before
welding
or
cutting. They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
EquIpment
Standard
precautions. Comply
with
precautions
in
this
manual,
and those detailed
in
CGA
Standard
P-I,
SAFE
HANDLING
OF
COMPRESSED GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it is
not
intended
to
protect
any
downstream
equipment.
Provide such
protection
with
one
or more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that for which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty regulator:
Leaks-if
gas
leaks
externally.
Excessive
Creep-if
delivery
pressure
continues
to
rise
with
downstream valve closed.
Faulty
Gauge-if
gauge
pointer
does not
move
oft
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pres
sure
release.
Repair.
Do NOT
attempt
to
repair.
Send
faulty
regula
tors
for
repair
to
manufacturers
designated
repair
cen
ter,
where
special
techniques
and tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical Circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short circuit
arcs
that
may
lead
to
a
serious
ac
cident.
(See
l-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
it
is
an
assurance
of
safety
when the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked. NEVER DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cyinder
or
its
contents
for
other than its
intended
use,
NEVER
as
a
support
or
roUer.
OM-317
Page
2

Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
al
low
contents
to
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.
Do
NOT
use a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder fittings
should
never
be
modified
or
ex
changed.
3.
Hose
Prohibited
use.
Never
use
hose
other than
that
de
signed
for the
specified
gas.
A
general
hose
identifica
tion rule
is:
red
for
fuel
gas, green
for
oxygen,
and black
for
inert
gases.
Use ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary wire
or
other
substitute)
as a
binding
to
connect
hoses
to
fittings.
No
copper
tubing splices.
Use
only
standard brass fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks and
abuse.
Suspend
hose
off
ground
to
keep
it from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose from
damage
by sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or worn
hose
by
cutting
area
out
and
splic
ing
(1 -2D3).
Do NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition. Wipe
with
a
clean lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label and
cylinder
marking
area,
and
that the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and smooth
seats
where
necessary.
Tighten.
If
connection
leaks, disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your sup
plier)
between
cylinder
arid
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked
RIGHT
and LEFT
HAND
threads.
Reguiatoroutiet(orhose)
connections
may
be
identified
by right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for fuel
gas.
5.
Pressurizing Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
be
fore
opening
cylinder
(or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise).
Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage regulators.
Stand
to
side of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator maximum)
leave
cylinder
valve
in
fol
lowing position:
For
oxygen,
and
inert
gases,
open fully
to
seal
stem
against possible
leak.
For
fuel
gas,
open
to
less than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(availabe
from
your
supplier)
for
safe
and
efficient,
recommended
pressure settings
on
regulators.
Check
for leaks
on
first
pressurization
and
regularly
there-after.
Brush with
soap
solution
(capfull
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
indi
cate
leak.
Clean
off
soapy
water
afterlest;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
bum.
*Trademark
of Proctor
&
Gamble.
OM-317
Page
3

1-3.
ARC WELDING
Comply
with
precautions
in
1-1, 1-2,
and
this
section.
Arc
Welding,
property
done,
is
a
safe
process,
but
a
careless
operator
invites trouble.
The
equipment
carnes
high
currents at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and in
frared
energy
radiates,
weidments
are
hot,
and
com
pressed
gases
may
be
used.
The wise
operator
avoids
unnecessary
risks
and
protects
himself
and others
from
accidents.
Precautions
are
described here
and
in
stan
dards referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
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
more
severe
and
painful.
~ONT
GET
BURNED;
COMPLY
WITH
PRECAUTlOI~IS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and shoes
(1 -2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-re
sistant
leggings.
Avoid
outer
garments
of untreated
cot
ton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button collar
to
protect
chest and
neck and
button
pock
ets to
prevent entry
of
sparks.
2.
Eye
and Head Protection
Protect
eyes
from
exposure
to
arc.
NEVER look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face before
striking
arc.
Protect filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when bro
ken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes (particularly
a
high intensity
gas-shielded arc)
can
cause
a
retinal
bum
that
may
leave
a
permanent
dark
area
in
the
field
of vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
sepa
rate
room
or
enclosed
bay
is
best.
in
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow for
free
air
circulation,
par
ticularly
at
floor level.
Viewing
the
weld. Provide face shields
for
all
persons
who
will
be
looking
directly
at
the weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B. Toxic
Fume Prevention
Comply
with
precautions
in
1
-2B.
Generator
engine
exhaust
must
be
vented
to
the outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
ExplosIon
Prevention
Comply
with
precautions
in
1
-2C.
Equipments
rated
capacity.
Do
not
overload
arc
weld
ing
equipment.
It
may
overheat cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on a
cylinder
or
other
pressure
ves
sel.
It
creates
a
brittle
area
that
can
cause
a
violent
rup
ture
or
lead
to
such
a
rupture
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
E.
Shock
Prevention
Exposed
hot conductors
or
other bare
metal
in
the
weld
ing
circuit,
or
in
ungrounded, electrically-HOT
equip
ment
can
fatally
shock
a
person
whose
body
becomes
a
conductor. DO NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface
when
welding,
without suitable
protection.
To
protect
against
shock:
Wear
dry
insulating
gloves
and
body
protection.
Keep
body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces the
electrical
resistance,
and
could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
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.
1.
Grounding
the
Equipment
Arc
welding
equipment
must
be
grounded
according
to
the
National
Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each unit
such
as
welding
power
source,
control,
worktable,
and
water
ci
r
culatorto the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-317
Page
4