Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL User manual

t~e
0~
096~
OWN
ERS
MANUAL
November1983
FORM:
OM-1537B
Effective
With
Serial
No.
J0668503
MODEL
SYSTEM
9
GAS
CONTROL
HUB
&
SPINDLE
WIRE REEL
ITIIIIER
MILLER
ELECTRIC
MFG.
CO.
778
S.
BOUNDS
SI,
P.O.
Box
1079
APPLETON,
WI
54912
USA
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.

LIMITED
WARRANTY
EFFECTIVE: JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex~
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
,~j
LIMITED
WARRANTY-Subject
to
the
terms
and conditions
As
a
matter
of
general
policy
only,
Miller
may
honor claims
t4
hereof,
Miller
Electric
Mfg.
Co..
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller. No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
Ill
repair
or
12)
replacement
cessories
or
other items
manufactured
by
others.
Such
or,
where
auttronzed
in
writing
by
Miller
in
appropriate
cases,
13)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
141
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their manufacturer for
one
year
from
price
Iless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk arid
expense.
Upon
receipt
of notice
of
apparent
defect
or
failure,
Miller shall
instruct
the clai
Except
as
specified
below,
Millers
warranty
does
not
apply
.
mant
on
the
warranty
claim
procedures
to
be
followed.
S
to
components
having
normal useful
life
of
less
than
one
1)
year,
such
as
spot
welder
tips, relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,

Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
-
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the date
of
delivery
of
Equip-
FITNESS
FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO
~
ment
to
the
original
user:
ANY
AND ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3years
EXCEPT AS
EXPRESSLY
PROV1DED
BY
MILLER
IN
(!abor
-1
year
only)
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIALi
INDUSTRIAL
4.
All
other Millermatic Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive of
labor
.
60
days
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
(
6.
Batteries
6months
WELDING
EQUIPMENT
AND
Nor
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
~
provided
that
Miller
is
notified
iii
writing
within
thirty
(301
days
TO,
AND
NO
RESELLER IS
AUTHORIZED
TO EXTEND
of
the
date
of
such
failure.
.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~-~

ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later In
this
manual.
AMENDMENT
TO
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
Amend
Figure
7-1.
Circuit
Diagram
For Weld
Control
(see
Page
2
on
this
Errata
Sheet)
Add
Figure
7-9. Circuit
Diagram
For
Voltage Regulator
Board
PC12
Circuit
Diagram
No.
A-123 556
Figure
7-9.
CircuIt
Diagram
For
Voltage
Regulator
Board
PC12
AMENDMENT
TO
PARTS
LIST
(see
Page
3
on
this Errata
Sheet)

-I
I
~
_=
I
___
_
C
_
a

~
~T
~
_________
0
0
~
rnGa
1
.C.I(D,
*
I
c31C1
flIt
I
Li~–ft~11ff~+~
~:~~~Ev
–
1~
.

p
~I
Sin
2
p

-~
14C1
p
~
Si~22-#
:o~
~
~
_______________
t.____...J0p....JZ.a~__.4
~
Ofi
0t
TO
a~..
TO
PTGfl0
Circuit
Diagram
No.
C-097
891-B
Figure
7-1.
CIrcuit
Diagram
For
Weld
Control
Effective
With
Serial
No.
JF947217
~1
Ti
L;
~
(f.
j~i
:

1
r
:Ui~
;fziii:1~
~
~
~~Jiii~
~
U
Li
:L:
TO
LT,i1
2_au:
~
]
~
~

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 6
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
SECTION
3
-
INSTALLATION
3-1. Location
7
3
-
2.
Shielding
Gas Connections
8
3 -3.
Water
Connections
8
3
-
4.
Limit Switch Connections
3
-
5.
AuxiliaryOutput
Connections
10
3
-
6. Weld
Control
Interconnections
10
3
-
7.
Field Installation Of MHA-2
11
3
-
8.
Hub
And
Spindle Assembly
Installation
13
3
-
9. Installation Of
Spool-Type
Wire
13
3-10. Installation
Of
Reel-Type
Wire
13
3
-11.
Installation Of Wire
Reel
14
3-12.
Adjusting
Hub
Tension
14
SECTION
.4
-
DEFINITIONS OF
PROGRAM
TERMS
4
-
1.
Program
Definitions
14
4
-
2.
Alpha
Numeric
Display
Definitions
15
SECTION
5
-
OPERATOR CONTROLS
5
-
1.
Power
Emergency
Stop
Button
16
5 -2.
Run/Set
Up
Switch
16
5 -3.
Jogging
Controls
17
5 -4.
Auxiliary
Output
Indicators
17
5
-
5.
Alpha-Numeric
Display
17
5
-
6. Weld
Program
Indicators
17
5
-
7.
Voltage
Reset Button
18
5
-
8.
Purge
Push
Button
18
5
-
9.
Program
Select
Push Button
18
5-10.
Program
Run
Push Button
18
5-11.
Sequence
Advance Push Button
19
5-12. Halt/Resume Push Button
19
SECTION
6
-
PROGRAMMING
6
-
1.
Mini-Cassette
Tape
Operation
19
6
-
2.
Programming
Module
Operation
20
6
-
3.
Programming
Examples
21
6
-
4.
Running
A
Program
22
SECTION
7
-
MAINTENANCE &
TROUBLESHOOTING
7
-
1.
Running
The
Diagnostic
Program
33
7
-
2.
Inspection
And
Upkeep
33
7
-
3.
Memory
Batteries 33
7
-
4.
Troubleshooting
33

SECTION 1
-
SAFETY
RULES
FOR OPERATION OFARC WELDING
POWER
SOURCE
1-i.
INTRODUCTION
-
We learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in this
manual.
Research,
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
reason
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
serious
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
cutting;
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
process..,
slectrode
alloy.,
and
fluxes
can
produce
different
fumes,
gases
and
radiation levels.
In
addition
to
the
Information
in
this
manual,
be
sure
to
consult
flux
and elec
trode manufacturers
for
specific
technical
data
and
precautionary
measures
concerning
their
matenal.
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
or
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
1
-3A.2.
Avoid
oily
or
greasy
cjothing.
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
available
for
each
shift unless
medical
facilities
are
cjose
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
dep(etion
that
welding
(or
cutting)
may
produce.
Prevent them
with
adequate
ventilation
as
described
in
ANSI
Stan
dard
Z49.
1
listed
1
in
Standards index. NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when welded
(or cut)
may
produce
harmful concentrations
of
toxic
fumes.
Ade
quate
local
exhaust ventilation
must
be
used,
or
each
person
in the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated
with
or
containing
materials that emit
toxic
fumes
should
not
be heated
unless
coating
is
removed from the
work
surface,
the
area
is well
ven
tilated,
or
the
operator
wears
an
air-supplied respirator.
Work
in
a
confined
space
only
while
it is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
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
accidently
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
OM-1537
Page
1

highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The ultraviolet
(radiant)
energy
of
the
arc can
also
decompose
trichioroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO NOT
WELD
or
cut
where solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
per
chioroethylene.
C.
Fire
and
Explosion
Prevention
Causes of fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
material;
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
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
yen
tilators.
If
the
work
cannot
be
moved,
move
corn-
bustibles
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
ex
tin~uishing
equipment
during
and for
some
time
after
welding
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
or
visible)
in
floors~
or
walls
within
35
feet
may expose
com
bustibles
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
OM-1537
Page
2
never
be
welded
on or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
3
in
Standards
index.
This
includes:
a
thorough
steam or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
com
bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should be
cleaned
(see
paragraph
above).
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
~ut
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,
PRECAUTIONS
FOR SAFE
HANDLING Of
COMPRESSED GASES
IN
CYLINDERS,
listed 6
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
symptoms
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
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
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
in
cluding
third
rails,
electrical
wires,
or
welding
cir
cuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1
-3C.)

Coil
excess
hose
to
prevent
kinks
and
tangles.
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an assurance
of
safety
when the
cylinder
is
properly
handled.
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
cylinder
or
its
contents
for
other
than its
intended
use,
NEVER
as a
support
or
roller.
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
allow
contents
to
exceed
130F. Cool
with
water
spray
where
such
exposure
exists.
Project
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.
Neler
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
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
use
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.
VVipe
with
a
clean lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
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
and
regulator,
if
one
is
required.
Use two
wrenches to
tighten
adapter
marked RIGHT
and
LEFT
HAND threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
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
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage regulators.
3.
Hose
Stand
to
side of
regulator
while
opening
cylinder
valve.
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
generalhose
identification
rule
is:
red
for fuel
gas,
green
for
oxygen,
and
black for
inert
gases.
Use
ferrules
or
clamps
designed
for
the hose
(not
or
dinary
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
io
keep
it from
being
run
over,
stepped
on,
or
otherwise
damaged.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
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
(available
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
(capful
of
Ivory
OM-15Z17
Page
3

Protect filter
plate
with
a
clear
cover
plate.
Liquid
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean off
soapy
water
after
test;
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
burn.
1-3.
ARC WELDING
-
Comply
with
precautions
in
1-1,
1-2.
and
this section.
Arc
Welding,
properly
done,
is.a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and others
from
accidents.
Precautions
are
described here
and
in
standards referenced
in index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is intense
and
visibly
bright,
Its
radia
tion
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.
DONT GET
BURNED;
COMPLY
WITH
PRECAU
TIONS.
,1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and shoes
(1-2A).
As
necessary,
use
additional
protective clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest and neck
and
button
pockets
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.
lrademark of
Proctor &
Gamble.
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
broken,
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
burn
that
may
leave
a
permanent
dark
area
in
the field of vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production welding,
a
separate
room or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens or
panels.
Allow
for free air
circula
tion,
particularly
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
welding
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
vessel.
It
creates
a
brittle
area
that
can cause
a
vuo~ent
rupture
or
lead to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-20.
OM-1537
Page
4