Miller Electric 250 manual California Proposition 65 Warnings, Principal Safety Standards

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H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

DHave only qualified persons familiar with electronic equipment perform this installation.

DThe user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

DIf notified by the FCC about interference, stop using the equipment at once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

DElectromagnetic energy can interfere with sensitive electronic equipment such as micro- processors, computers, and computer-driven equipment such as robots.

DBe sure all equipment in the welding area is electromagnetically compatible.

DTo reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

DLocate welding operation 100 meters from any sensitive elec- tronic equipment.

DBe sure this welding machine is installed and grounded according to this manual.

DIf interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproduc- tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Mississauga,

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web- site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1.Keep cables close together by twisting or taping them, or using a cable cover.

2.Arrange cables to one side and away from the operator.

3.Do not coil or drape cables around your body.

4.Keep welding power source and cables as far away from operator as practical.

5.Connect work clamp to workpiece as close to the weld as possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recom- mended.

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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 spécifiquesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion 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, Weights, and Operating Angles Dimensions For Units With Optional Running GearDimensions 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 − Operating Optional Battery Charger Battery Charge ControlsDetermining Battery Charging Current 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-bindingMaking Engine Speed Adjustments Adjusting Idle SpeedAdjusting Weld/Power 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 VoltsStick Mode Volt-Ampere Curves DC Amps CC/AC Stick Mode AC VoltsAC Amps DC Amps MIG Mode Volt-Ampere Curve− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame 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 Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping 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 − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro Service Your distributor also givesSupport 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