REEL QUALITY DX CABLE LEAD REELS SAFETY INFORMATION AND INSTALLATION INSTRUCTIONS Thank You for choosing Reel Quality Products, Inc. Please read the following important safety and installation instructions before mounting and using your new reels. Important Safety Information WARNING! LIVE WELDING CABLE LEAD REELS CAN BE EXTREMELY DANGEROUS! Improper installation and / or use can result in equipment damage, serious injury to yourself and others, or even death. Only properly trained individuals with a thorough knowledge of welding and welding safety practices should install, operate and maintain your reels. Prior to using your new reels, you must carefully read and understand the following instructions and safety warnings. Live welding lead reels and all welding equipment should be installed and maintained in accordance with OSHA 1926 Sub part J and the National Electric Code (NFPA 70) and in addition must always be installed and operated in accordance with all local laws, codes, ordinances and workplace safety regulations. This may include, but is not limited to: *Applying suitable compliant insulation to exposed areas of your reels to prevent accidental shorting, grounding and/or electrical shock *Informing passers by to stay clear of your equipment and workspace with appropriate highly visible warning signs and/or audible warning alarms. *Maintaining your reels and equipment in good safe working order. *Covering your reels when not in use and keeping them clean and dry at all times *Periodically performing visual inspections of your equipment and welding cable paying special attention to exposed insulation of the cable, spool and lock pin assemblies for possible chipping, cracking and / or tearing and repairing or replacing any damaged cable following guidelines as defined in OSHA 1926 Sub part J. *Periodically checking all fasteners as to being secure and tight. *Never attempting to service your reels and equipment with the power on. Avoiding contact with electrically charged parts and always wearing appropriate compliant welding gloves in good condition and all other appropriate compliant Personal Protective Equipment (PPE) when operating your equipment. Generally speaking, with the power on, the entire spool assemblies should be understood and considered to be ELECTRICALLY LIVE and treated as such. Mounting and connecting you reels 1. Make sure all power is off and locate a suitable area away from other equipment and potential grounding hazards. 2. If fastening your reel to the mounting surface use four steel bolts of at least 3/8 diameter with lock washers. If welding, mounting base is 1018 steel. 3. Find the input cable lug located at the end of the spindle of your Grounding spool. Using a 5/16 Allen wrench, remove the lug. Attach your welding cable to the lug by crimping or soldering following standard industry guidelines and reattach the lug to the spindle. 4. Similarly, attach your output cable to the lug located along the spool hub. 5. Connect your other stinger spool, input and additional cable as per above. 6. After mounting, complete a continuity test both, reel-to-reel and reel-to-ground to insure proper isolation. Adjusting the reel tension 1. Using a 1/4 hex key wrench, loosen the set screw located at the center of the hand adjusting nut. Loosen or tighten the adjusting nut to desired reel tension. 2. Once the desired tension has been achieved, re-tighten the set screw to lock in place. Operating Tips It is good practice to always deploy all your welding lead cable before welding. Especially with higher amperage long duration welds. Long lengths of coiled cable promote Joule and/or induction heating and inhibit heat dissipation. In tests, even though Reel Quality reels remained much cooler than other reels even when fully loaded, there was still a significantly higher rise in reel temperature with the cable rolled up vs. fully deployed. When in doubt, deploy the cable. When rolling up tension is the key to a nice and neat finish. Try to roll up the full weight of the cable, when possible, so it will track nicely onto the spool. It is a good idea to cover your reels when not in use. keeping them clean, dry and covered will help insure optimal performance, prevent corrosion and allow your reels to preserve that like new look.