Miller Electric DVI-2 R manual Symbol Usage, Arc Welding Hazards, Electric Shock can kill

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _2007−04

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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.

1-2. Arc Welding Hazards

.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.

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 1-5.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 equipment 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.

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

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

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 inverter-type welding power sources after removal of input power.

DTurn Off inverter, disconnect input power, 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.

DAllow cooling period before working on gun or

torch.

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

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Contents Processes OM-232 386BDescription File MIG GmawFrom Miller to You Table of Contents Typical MIG Process Connections − Parts List− MIG Welding Gmaw Guidelines Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-232 386 Symbols And Definitions − InstallationSpecifications − Definitions40% duty cycle at 150 amps Minutes Welding Minutes Resting Duty Cycle And OverheatingOverheating MinutesCorrect Installation Connecting To Weld Output TerminalsVolt-Ampere Curves Range Range 4 RangeSetting Gun Polarity For Wire Type Installing Work Cable And ClampPolarity Changeover Label Information 11/16Tools Needed 8, 5/8 Installing Gas SupplyRear Panel Installing 1 Or 2 lb Wire Spool Installing MIG Wire Spool and Adjusting Hub TensionUse compression spring With 8 in 200 mm spools To turn spool, tension is set230 VAC =GND/PE Earth Ground Connecting 1-Phase Input Power For 230 VACExtension Cord Data Electrical Service Guide For 230 VACHz Single Phase 18 in 457 mm of space for airflow Selecting a Location And Connecting Input PowerDo not move or operate unit where it could tip Pressure Threading Welding WireScale Remove gun nozzle and contact tipTurn Off unit, and disconnect input power Connecting An Optional Spool Gun Voltage Control − OperationControls Voltage Chart Settings Weld Parameter ChartInput Line Parameter226 652-A Routine Maintenance − Maintenance &TROUBLESHOOTINGChanging Drive Roll and Wire Inlet Guide Unit OverloadTroubleshooting Aligning Drive Rolls and Wire GuideTurn Off power Welding Trouble RemedyWire Drive/Gun Trouble Remedy OM-232 386 Welding Power Source Circuit Diagram − Electrical Diagram229 598-B Typical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsAmperage Select VoltageGroove Welds Holding And Positioning Welding GunPush Conditions That Affect Weld Bead ShapePerpendicular Drag Short Normal LongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Weld bead Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Problem Probable Cause Remedy Troubleshooting Guide For Semiautomatic Welding EquipmentCommon MIG Shielding Gases ApplicationReadjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessaryDrive Roll And Wire Guide Kits − Parts ListSupport 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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