Miller Electric 250 manual Symbol Usage, Arc Welding Hazards, Electric Shock can kill

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

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Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equip- ment is a hazard.

DDo not touch live electrical parts.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

DDo not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

DUse AC output ONLY if required for the welding process.

DIf AC output is required, use remote output control if present on unit.

DAdditional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoid- able or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

DDisconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

DProperly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

DAlways verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

DWhen making input connections, attach proper grounding conduc- tor first − double-check connections.

DKeep cords dry, free of oil and grease, and protected from hot metal and sparks.

DFrequently inspect input power cord for damage or bare wiring — replace cord immediately if damaged — bare wiring can kill.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DIf earth grounding of the workpiece is required, ground it directly with a separate cable.

DDo not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

DUse only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

DDo not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

DClamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

DInsulate work clamp when not connected to workpiece to prevent contact with any metal object.

DDo not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop- ping engine.

DStop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

D Allow cooling period before working on equip- ment.

DTo handle hot parts, use proper tools and/or wear heavy, insu- lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

DWelding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

DWear approved safety glasses with side shields even under your welding helmet.

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Contents File Engine Drive OM-217 455HVisit our website at 2007−05−21From Miller to You Table of Contents 13-3 13-213-4 13-5Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicauxSymbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsDimensions Dimensions, Weights, and Operating AnglesDimensions For Units With Optional Running Gear Installing Welding Generator − InstallationVehicle frame. Always connect a ground wire MountingConnecting the Battery Installing Exhaust Pipe+ − Stop engine and let coolOverview And Engine Prestart Checks Starting engine for the first time Engine Left Side Engine Right SideRun-in period first 100 hours Daily pre-start checksCorrect Installation Connecting to Weld Output TerminalsWork Weld Output Terminal Tools Needed Do not placeSelecting Weld Cable Sizes Place switch in Run position to operate most MIG equipment Engine Control Switches− Operating the Welding Generator Do not use glow plugs longer than 20 secondsWeld Output Controls Typical Settings For 7018 1/8 Electrode Typical Stick Welding Connections And Control SettingsStop engine Work Clamp Electrode HolderSet Weld Process Selector switch to Wire + Dcep position Typical MIG Welding Connections And SettingsSet Weld Process Selector switch to Wire + position Set Weld Process Selector switch to Wire − position DcenTools Needed 3/4 Work Not Used To Work Left Side View − Operating Auxiliary Equipment Generator Power ReceptaclesAt least once a month, run engine at To verify Gfci is working properlySimultaneous Weld And Power Determining Battery Charging Current − Operating Optional Battery ChargerBattery Charge Controls Battery Charge Cable Connections Minutes Battery Charging ProcedureStart Your Professional Welding Career Now Routine Maintenance − Maintenance and TroubleshootingStop engine and let cool Oil And Fuel Maintenance Label And Engine Maintenance Activities804 197-A / Ref 803 111-A / 227 Ment is not covered by the warranty Cleaner or with dirty element. EngineAir cleaner primary element can Damage when determining whetherAdjusting Fuel Solenoid Position Adjusting Engine SpeedStop screw is factory-set and should not be adjusted Checking Fuel SolenoidChecking Throttle Solenoid Adjusting Throttle Solenoid16 mm Check for non-bindingAdjusting Weld/Power Speed Making Engine Speed AdjustmentsAdjusting Idle Speed Component Panel Stop engine Overload ProtectionFuse F1 Supplementary Protector CB8Generator Power Troubleshooting TablesWelding Trouble RemedyEngine Maintenance Display ActionRecommended Spare Parts − Parts ListRecommended Spare Parts Current transformer CT1, and throttle solenoid TS1Circuit Diagram For Welding Generator − Electrical Diagrams228 719-B OM-217 455 231 607-B Run-In And Wetstacking − RUN-IN and WetstackingFuel Consumption Curves − Performance DataUS Gal./Hr IdleDuty Cycle Generator Power CurveVolts AC Amperes At 120 VoltsAC Amps Stick Mode Volt-Ampere CurvesDC Amps CC/AC Stick Mode AC Volts DC Amps MIG Mode Volt-Ampere CurveGrounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated in electrical codes Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Support ServiceYour distributor also gives Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s
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