Miller Electric CBI 801D manual User Responsibilities, Leaving Equipment Unattended

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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 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 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 (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 (capfull of Ivory Liquid* or equivalent per gallon of water). Bubbles indi- cate 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.

*Trademark of Proctor & Gamble.

OM-166 941 Page 3

Image 8 Contents
OM-166 941C ProcessesDescription Per NsprWarranty Page Table of Contents − Maintenance − Troubleshooting− Electrical Diagrams − Parts List− Safety Rules for Operation of ARC Welding Power Source General PrecautionsIntroduction Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index − Safety Precautions and Signal Words General Information and SafetySafety Safety Alert Symbol and Signal Words− Specifications OCVDescription − Installation or RelocationDuty Cycle Exhaust Extension Installation Connecting the BatteryLifting Of Equipment Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote 9 Receptacle Information And Connections Figures 4-2 Remote Control ConnectionsRemote Feeder AMPERAGE/VOLTAGE Output Contactor Wire remote control cord directly to terminal strip Tion CWithin unit according to Section B Remote Terminal Strip 3T InformationAIR Compressor Connections Ether Starting AID OptionalPosure to Ether can seriously harm Your health− Auxiliary Power Power Output Electric Sparks can cause fireLOW Voltage and Frequency can dam- age electrical equipment General− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Battery Magnetic Shutdown SwitchBroken Cooling Belt Shutdown Switch Fuel− Sequence of Operation ARC Rays can burn eyes and skin Noise can damage hearingFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAuxiliary Power Operation AIR Carbon ARC Cutting and Gouging CAC-A TableAIR Compressor Operation Tables 7-2 Starting the EngineStopping the Engine Flow Of Free Air CFM Through Orifices Of Various DiametersMiscellaneous − Maintenance Deutz F4L912 Diesel Engine AIR Cleaner Service Table Air Cleaner ServiceBattery Replacement Procedure FUEL/WATER Separator and Sludge Drain PlugFuel/Water Separator Sludge Drain PlugGovernor MAINTENANCE-FREE Battery CHARG- INGEngine Speed Adjustments Figure Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureMoving Parts can cause severe injury RUN-IN ProcedureRun-In Procedure Using Load Bank Diagram Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gramBooster Battery Jump Starting − TroubleshootingDiagram 8-2. Resistance Grid Connections Overload Protection Figure Moving Parts can cause serious personal injuryIncorrect Fuse can damage unit Circuit Breaker CB1 FigureTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Auxiliary Power Troubleshooting Auxiliary Power Probable Cause Remedy TroubleEngine Troubleshooting Air Compressor TroubleshootingOM-166 941 − Electrical Diagrams Diagram 10-1. Circuit Diagram For Welding GeneratorSC-168 908-B 66 Fig − Parts List11-2 1A. Main Assembly 073 FITTING, brs barbed M 3/16tbg x 1/4NPT 0456660009309 1B. Main Assembly 811 6563 62 21 22 15 141532480009309 18 17 16 Includes Item Panel, Front w/ComponentsPanel, Front w/Components -1A Item Panel, Lower Front w/Components Panel, Lower Front w/Components 1A Item Control Box -1A Item Generator -1B Item