Miller HG019525 Owner's manual

Miller
Brand
Miller
Model
HG019525
Category
Welding System
Type
Owner's manual

This manual is also suitable for

November
1977
FORM:
OM-214B
STOCK
NO.
ANALOG
300
901
401
901
466
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERî‚’S
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
Effective
With
Serial
No.
HG019525
j
MODEL
BASIC
W/CRATER
OUT
NWSA
CODE
NO.
4579
î‚‘~
~
~
~
î‚‘L~
î‚‘L~~P
~
~P
î‚‘L~
î‚‘L~P
î‚‘l~~P
î‚‘L~P
î‚‘L~
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYî‚—Miller
Electric
Mfg.
Co.,
Apple-
I.
Arc
welders,
power
sources,
and
components
.
..
I
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
î‚—
1
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
days
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
1
year
.
trade
accessories
and
other items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturerî‚’s
warranty
on
the
Mag-Diesel
engine
on
DEL-
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
.
.
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
k.~
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millerî‚’s
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
therefor
shall
be,
at
Millerî‚’s
option,
(I)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
~.s
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
actual
use)
upon
return
of
the
goods
at
Customerî‚’s
risk
and
CX
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
(
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERî‚’
nat
userî‚’s
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERî‚’S
WAR
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
5î‚’
4î‚’
.
__.JI,
4î‚’
7~,
~
,s5L.Jt,
4î‚’
~s,
..Js,
-..~
~
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
-
TROUBLESHOOTING
See
Pages
B
through
H
for
circuits.
Item
Or
Dia.
Part
Replaced
Pg
No.
Mkgs.
No.
With
Description
Quantity
6
T2
000052
046730
TRANSFORMER,
kva
2-30-24-100/115/230
(Eff
W/JA409776)
RECTIFIER,
silicon
diode
(El-f
W/JB489559)
TRANSDUCTOR,
TD-4300
(EffW/HJ136206)
SPRING
(qty
chg)
SUPPRESSOR
(EffW/JB489559)
(El-f
W/JB489559)
RESISTOR,
carbon
2
watt
3900
ohm
(El-f
W/JB489559).
(El-f
W/JB489559)
(El-f
W/JB489559)
(El-f
W/JB489559)
(El-f
W/JB489559)
VARISTOR,
0.63
175
volts
dc
(Eff
W/JB489559)
ANGLE,
mtg
-
suppressor
(El-f
W/JB489559)
(Efl
W/JA409776)
BLOCK,
terminal
20
amp
14
pole
(El-f
W/JA409776)
RELAY,
41
V
-
47V
dropout
11
OV
ac/dc
(El-f
W/JA409776)
13
SRi
037
565
070
672
21
MA7
036
703 036
853
24
010 849
010
849
52
037 473
044
482
53
R15
030
023
Deleted
54
R14
030
959
010
144
030
459
Deleted
55
C9
031
716
010014
Deleted
Deleted
56
SR4
037
463
Deleted
VS1
046
685
046
815
73
020
712
Deleted
74
3T
038
782
038
856
75
CR1 034
601
052
251
76
026
711
Deleted
77
CR2
034
615
059
266
RELAY,
enclosed
120
voltsac
DPDT
(El-f
W/JA409776).
78
CR3
034
612
052
603
RELAY,
enclosed
110
volts
dc
DPDT
(El-f
W/JA409776).
79
91
TD2
603
115
034
715
Deleted
045
799
047
886
047
133
047
883
030
743
BRACKET,
mtg
-
components
(El-f
W/JA409776)
TIMER,
start
delay
(consisting
of)
.
RELAY,
enclosed
120
voltsac
DPDT
.
BRACKET,
mtg
-
timer
.
POTENTIOMETER,
carbon
1
turn
2
watt
50K
ohm
93
4T
038
797
073
873
BLOCK,
terminal
30
amp
14
pole
(El-f
W/JA409776)
95
P1
025
701
025
701
FILTER
(NOTE:
Filter
for
amp
meter
relocated
on
back
of
amp
meter)
(Eff
W/HJ110403)
96
024 274 045
780
BRACKET,
mtg-filter
(El-f
W/JA409776)
102
SR2,7
037 415
035
914
RECTIFIER,
integrated
30
amp
400
volts
(Eff
W/JA409776).
107
Q1,2
024
207 037
236
TRANSISTOR,
l5ampl00volts(El-fW/JA409776)
108
039
696
Deleted
-
112
SR6
037
568
035
914
RECTIFIER,
integrated
30
amp
400
volts
(El-f
W/JA409776).
113,114
Deleted
(El-f
W/JA409776)
115
Ri
030
617
Deleted
(El-f
W/JA409776)
231
C2
031
601
î‚•
081
291
059
887
081
282
007
532
CAPACITOR,
HF(Efî‚’fW/S/NHK232542)
.
CAPACITOR,
metal
film
10
uf
220
volts
.
STRIP,
mounting
-
capacitor
.
CLAMP,
capacitor
1
inch
dia
232
014
159
Deleted
(El-f
W/S/N
HK232542)
260
RC5O,51
039 794
073
730
CONNECTOR,
edge
22
pin
Page
10
039
798
009
546
KEY,
polarizing
271
CR58,59
034794
034794
RELAY(qtychg)(EffW/S/NHJ11O4O3)
273
039664 039664
SOCKET(qtychg)(EffW/S/NHJ11O4O3)
Page
ii
039
774
Deleted
1
1
1
3
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
4
7-2-82
OM-2148
Page
A
ItemOr
Dia.
Part
Replaced
Pg
No.
Mkgs.
No.
With
Description
Quantity
Page
12
A51
036
296
079
744
CIRCUIT
CARD
ASSEMBLY,
operational
amplifier
(con
sisting
of)
1
Cl
052
141
.
CAPACITOR,
ceramic
33
uf
1000
volts
IC1
079 734
.
AMPLIFIER,
operational
8
pin
1
Ri
035
848
.
POTENTIOMETER,
cermet
trimmer
25
turn
0.5
watt
10K
ohm
1
Page
12
R77
030
001
030
707
RESISTOR,
carbon
1
watt
47
ohm
1
Page
12
027
043
Deleted
Page
13
A51
036
296
079
744
CIRCUIT
CARD
ASSEMBLY,
operational
amplifier
(con
sisting
of)
1
Cl
052
141
.
CAPACITOR,
cerarnic33
uf
1000
volts
1
Ci
079
734
.
AMPLIFIER,
operational
8
pin
1
Ri
035
848
.
POTENTIOMETER,
cermet
trimmer
25
turn
0.5
watt
10K
ohm
1
Page
13
R77
030
001
030 707
.
RESISTOR,
carbon
1
watt
47
ohm
1
Page
13
027 043
Deleted
C9
031
737
CAPACITOR,
ceramic
0.02
uf
1000
volts
dc
(Elf
W/JC630159)
1
t072
910
REGULATOR,
current
booster
(Elf
W/JA409776)
1
072 904
CIRCUIT
CARD,
transistor
(Elf
W/JA409776)
(consisting
of)
1
D7
037
577
.
DIODE,
zener47
volts
10
watt
1
R5
030 004
.
RESISTOR,
carbon0.5
watt
10K
ohm
1
R6,7
030
009
.
RESISTOR,WWfusible5watt0.82
ohm
2
073
344
GROMMET,
1/2
ID
x
5/8
mtg
-
hole
1
+047
497
LABEL,
general
precautionary
1
tltems
105,
107
in
manual
are
now
part
of
regulator.
+
When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-214B
Page
B
:~
Figure
7-2.
Circuit
Diagram
For
Basic
Models
Effective
With
Serial
No.
HJ110403
Thru
JA409775
CD
3
0~
m
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C-)
C)
C
0
0;
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Circuit
Diagram
No.
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401-1E
_
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H
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Figure
7-2.
Circuit
Diagram
For
Basic
Models
Effective
With
Serial
No.
JB489559
Thru
JC630158
Circuit
Diagram
No.
D-070
245
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i
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Circuit
Diagram
No.
D-087
195
Figure
7-2.
Circuit
Diagram
For
Basic
Models
Effective
With
Serial
No.
JC630159
And
Following
0
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w
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Figure
7-3.
Circuit
Diagram
For
Crater-Out
Models
Effective
With
Serial
No.
JA409776
Thru
JB489558
______
-
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Circuit
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146
Figure
7-3.
Circuit
Diagram
For
Crater-Out
Models
Effective
With
Serial
No.
JB489559
And
Following
~~9)~î‚’
~
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L~1~I(~~
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___
____
__TI
CERTIFICATE
NAME
OF
EQUIPMENT:________________________
MODEL
NO~
SERIAL
NO.~~____________________________
DATE
This
equipment
has
been
type-tested
under
standardized
field
test
conditions
as
recommended
by
the
Joint
Industry
Committee
on
High
Frequency
Stabilized
Arc
Welding
Machines
found
to
rad
late
less
than
10
microvolts
per
meter
at
a
distance
of
one
mile,
the
maximum
allowable
limit
established
by
the
Federal
Communications
Commission
for
equipment
of
this
type.
Installations
using
this
equipment
on
the
basis
of
these
tests,
may
reasonably
be
expected
to
meet
the
radiation
limitations
established
by
the
Federal
Communications
Commission,
only
when
in
stalled,
operated
and
maintained
as
specified
in
the
instruction
book
provided.
USERî‚’S
CERTIFICATION
The
welding
equipment
identified
above
has
been
installed
in
accordance
with
the
specific
in
structions
applicable
to
this
model
as
outlined
in
the
instruction
book
furnished,
It
is
being
used
only
for
the
purpose
for
which
it
was
intended
and
is
being
maintained
and
operated
in
accord-
once
with
the
manufacturerî‚’s
instructions.
Date
lnstolled
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
î‚—
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1-3.
ArcWelding
3
1
4.
Standards
Booklet
Index
4
SECTION
2
î‚—
INTRODUCTION
2-1.
General
5
2-
2.
Receiving-Handling
5
2-
3.
Description
5
2-4.
Safety
5
SECTION
3
î‚—
INSTALLATION
3-1.
Location
5
3
-
2.
Electrical
Input
Connections
6
3-
3.
Secondary
Welding
Connections
7
3
-
4.
Remote
Current
Control
Connections
7
3
-
5.
Contactor
Control
Connections
7
3
-
6.
Water
Valve
Connections
7
3-
7.
Shielding
Gas
Valve
Connections
7
3
-
8.
Crater-Out
Connections
7
SECTION
4
î‚—
FUNCTION
OF
CONTROLS
4
-
1.
Power
Switch
8
4
-
2.
Current
Control
8
4-
3.
Current
Control
Receptacle
&
Switch
8
4
-
4.
Starting
Current
Selector
Switch
9
4
-
5.
Contactor
Control
Receptacle
9
4
-
6.
High-Frequency
Switch
9
4-
7.
Crater-Out
Adjustment
9
4-8.
Post-FlowTimer
9
4-9.
Meters
9
4-10.
Volt-Ampere
Curves
10
SECTION
5
î‚—
SEQUENCE
OF
OPERATION
5-
1.
Gas
Tungsten-Arc
Welding
General
Notes
10
5
-
2.
Gas
Tungsten-Arc
Welding
11
5-
3.
Shutting
Down
11
SECTION
6î‚—
MAINTENANCE
6-1.
Fan
Motor
11
6
-
2.
Transformer
11
6
-
3.
Rectifier
11
6-4.
Spark
Gap
11
6-
5.
Circuit
Protection
12
6
-
6.
Theory
Of
Operation:
Closed
Loop
Feedback
System
12
6
-
7.
Integrator
î‚—
Pre-Amp
Board
Calibration
13
Section
No.
Page
No.
SECTION
7
î‚—
TROUBLESHOOTING
SECTION
8
î‚—
CERTIFICATION
FQR
HIGH
FREQUENCY
ARC
WELDING
EQUIPMENT
8-1.
General
17
8
-
2.
General
Information
17
8-
3.
Power
Service
17
8-
4.
Welding
Machine
18
8-5.
Welding
Leads
18
8-
6.
Wiring
In
The
Vicinity
Of
The
Welding
Area
18
8-7.
GrQunds
18
8-
8.
Metal
Building
18
8
-
9.
Individual
Installation
Certification
19
8-10.
Check
List
19
PAR
TS.LIS.T
î‚—SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety
through
personal
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
weld
ing
and
cutting
are
described
in
this
manual.
Research,
devel
opment,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
operation,
and
servicing
practices.
Acci
dents
occur
when
equipment
is
improperly
used
or
main
tained.
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
attempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
particular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
in
jury
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
procedures
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
in
spection
requirements
also
provide
a
basis
for
equipment
in
stallation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
A.
Burn
Prevention
Wear
protective
clothing
-
leather
(Or
asbestos)
gauntlet
gloves,
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
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
available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
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
persons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Adequate
ventilation.
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
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.
Adequate
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
used.
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
ventilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ventilated
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
concentration
danger
ously.
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
down
stream
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
flamel
to
form
PHOSGENE,
a
highly
toxic
gas.
and
other
lung
and
eye
irritating
products.
The
ultra
violet
(radiantl
energy
of
the
arc
can
also
decompose
tn
chloroethylene
and
perchloroethylene
vapors
to
form
phos
gene.
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
trichloroethylene
or
perchloroethylene.
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,
ventilators.
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
ex
tinguishing
equipment
during
and
for
some
time
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construc
tion)
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
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
supervisorî‚’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
pro
duce
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
3
in
Standards
index.
OM-214
Page
1
This
includes:
a
thorough
steam
or
Caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
combustibleî‚’s
solubility(
followed
by
purging
and
iperting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recom
mended
in
A6.0.
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
t
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
gaso
line).
0.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precaution~
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
PRECAU
TIONS
FOR
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLINDERS,
listed
6
in
Standardt
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regula
tor
from
ciî‚’erpressure;
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
~as
other
than
that
for
which
the
regulator
w~
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
~top
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturerî‚’s
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handlei
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
Contact
with
cyliqders
including
third
rails,
electrical
wires,
or
welding
cjrcuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1-3C.(
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
cylipders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
con
tent.
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
support
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
mag
nets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130î‚°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
exchanged.
3.
Hose
Prohibited
use.
Never
use
hose
other than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fittings
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
other
wise
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
connec
tions.
Immerse
pressured
hose
in
water;
bubbles
indicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
Out
and
splicing
(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.
Wipe
with
a
clean
lint-
less
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
CON
NECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
connections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connec
tion
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
supplier)
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
before
opening
cylinder
(Or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
excessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressur
ization.
Leave
adjusting
screw
engaged
slightly
cn
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
regu
lator
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.
Page
2
2.
Electrode
Holders
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
Units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
Wire
Electrode
wire
becomes
electrically
HOT
when
the
power
switch
of
gas
metal-arc
welding
equipment
is
ON
and
welding
gun
trigger
is
pressed.
Keep
hands
and
body
clear
of
wire
and
other
HOT
parts.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
Out.
Before
installation,
inspection,
or
service,
of
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Discon
nect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency
it
must
be
disconnected,
guard
against
shock
burns.
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
dis
connect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
Source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
~
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
2501
NW
7th
St.,
Miami,
Fl~.
33125.
2.
ANSI
Standard
Z87.1,
SAFE
PRACTICE
FOR
OCCUPA
TION
AND
EDUCATIONAL
EYE
AND
FACE
PROTEC
TION,
obtainable
from
American
National
Standards
Institute.
1430
Broadway,
New
York,
N.Y.
10018.
3.
American
Welding
Society
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUSTIBLES,
obtainable
same
as
item
1.
4.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING,
obtainable
from
the
National
Fire
Protection
Association,
470
Atlant)c
Avenue,
Boston,
Mass.
02210.
5.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PRO
CESSES,
obtainable
same
as
item
4,
6.
CGA
Pamphlet
P-i.
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
N. V.
10036.
7.
OSHA
Standard
29
CFR,
Part
1910,
Subpart
0,
WELD
ING,
CUTTING
AND
BRAZING.
Page
4
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Miller HG019525 Owner's manual

Miller
Brand
Miller
Model
HG019525
Category
Welding System
Type
Owner's manual
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