Miller Electric OM-234 016D 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.

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.

OM-234 016 Page 1

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Contents OM-234 016D File Wire FeederProcesses DescriptionFrom Miller to You Table of Contents Page 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-234 016 Removing MIG Gun From Welding Power Source SpecificationsOperation Connecting Spool Gun To Millermatic 140/180 ModelsTurn Off unit, and disconnect input power Polarity Changeover Terminal Block Close door Connecting Spool Gun To Millermatic 140/180Correct Connecting Spool Gun To Millermatic Passport PlusIncorrect Connecting Spool Gun To Renegade Installing Wire Spool And Threading Welding Wire Spool Gun Operation On Millermatic 140/180 Models Controls For Millermatic 140/180 ModelsExample .030 diameter wire, welding 18 ga. material Weld Parameter Chart For Millermatic 140 Model w/Auto−SetEExample 4 Refer to chart below to select Voltage and Wire Speed basedNumber on right Slash is Wire Selecting Wire, Gas and Control Settings for Aluminum With optional Spool Gun. Order part no 035 0.9 mm 030 0.8 mm225 229−E #220179#220179 #202926 OM-234 016 Spool Gun Operation On Millermatic Passport Plus Model Controls For Millermatic Passport Plus Model115/230V Weld Parameter Chart For Millermatic Passport Plus ModelAr / 2.5% CO 0350.9 mm Min/15 100 100 10/80 10/60 10/90230V 235557−ASpool Gun Operation On Renegade 180 Model Controls For Renegade 180 ModelAluminum 4043 Dcep 030 10/100 Weld Parameters For Renegade 180 Model035 10/90 Aluminum 4043 Dcep 030 10/75= Check = Change ~ = Clean = Replace Routine MaintenanceChanging Drive Rolls Turn Off power at welding power source firstChanging Push Roll Changing Lower Drive RollChanging Liner TroubleshootingBefore You Start Welding Gmaw MIG Aluminum Welding HintsWelding Techniques Direction Of WeldingGas Nozzle Contact Tip To Work Contact Tube Recessed 1/8 Common Problems/Troubleshooting− Electrical Diagrams Circuit Diagram For Millermatic 140/180 234 419-B − Parts List Optional Page Page Page 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

OM-234 016D specifications

Miller Electric OM-234 016D is a versatile and powerful machine designed for various welding applications. Known for its reliability and efficiency, this model integrates advanced technologies to cater to both professionals and hobbyists in the welding industry.

One of the standout features of the OM-234 016D is its inverter technology, which allows for a more compact and lightweight design compared to traditional welding machines. This technology not only enhances portability but also provides exceptional control over the welding process. The inverter system ensures stable arcs and precise welding performance, contributing to clean and consistent welds across different materials.

The OM-234 016D offers multiple welding modes, including TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas), making it ideal for aluminum, steel, and other metals. The machine is capable of handling a wide range of thicknesses, making it suitable for various applications such as automotive repairs, fabrication, and light industrial work. The dual functionality allows welders to switch between modes effortlessly, adapting to specific project requirements with ease.

Another key characteristic of this model is its intuitive digital display, which provides real-time feedback on welding parameters such as voltage and amperage. This feature offers users greater control over their settings, enabling them to make precise adjustments on the fly. The machine also includes advanced arc stability features that minimize spatter and enhance overall weld quality.

Safety is a priority with the OM-234 016D, equipped with multiple safety features including thermal overload protection and input power monitoring. These functions safeguard the machine against potential damage and ensure optimal performance even under heavy-duty use.

Additionally, this welding machine is designed with user comfort in mind. Its ergonomic handle and compact footprint allow for easy transportation and operation in different environments. Whether working in a garage or on a job site, the OM-234 016D combines convenience with high-performance capabilities.

In summary, the Miller Electric OM-234 016D stands out as a robust option for those seeking a reliable welding solution. Its inverter technology, dual welding modes, user-friendly interface, and safety features make it an excellent choice for a wide range of welding tasks. This machine is a testament to Miller Electric’s commitment to innovation and quality in the welding industry, proving to be an invaluable asset for anyone looking to achieve professional results in their welding projects.