Miller Electric Metro 250D manual Safety Precautions − Read Before Using, Symbol Usage

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1.Safety Precautions − Read Before Using

1.1Symbol Usage

OM-402B -4/97, safety_rom 4/97

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

Y Marks a special safety message.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

 

. Means “Note”; not safety related.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1.2Arc Welding Hazards

YThe 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.

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

YDuring operation, keep everybody, especially children, away.

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.

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.

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.

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.

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 − do not use work clamp or work cable.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

DWear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

DWear approved safety glasses with side shields under your helmet.

DUse protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant mate- rial (wool and leather) and foot protection.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

DIf ventilation is poor, use an approved air-supplied respirator.

DRead the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe.

DDo not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

DDo not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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Contents Description OM-402BProcesses From Miller to You Metro 250D Table of ContentsPage Arc Welding Hazards Safety Precautions − Read Before UsingSymbol Usage Engine Hazards Moving Parts can cause injury Battery Explosion can BlindEngine Exhaust Gases can kill Engine Heat can cause fireEMF Information Principal Safety StandardsRadiation can cause interference ARC Welding can cause interferenceConsignes de sécurité − lire avant utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserInformation sur les champs électromagnétiques Principales normes de sécuritéÉlectrostatiques peuvent endommager les circuits imprimés UNE Remorque QUI Bascule peut entraîner des blessuresDefinitions Symbols and DefinitionsGeneral Precautionary Label Fan and Moving Parts Label Battery Charging LabelDiesel Fuel Label Hot Muffler Label− 50 h Std Falling Equipment LabelActivation Tag Manufacturer’s Rating Label Do Not Use Ether LabelWeld, Power, and Engine Specifications SpecificationsDimensions, Weights, and Operating Angles Volt-Ampere CurveDuty Cycle and Overheating Fuel ConsumptionAC Auxiliary Power Curve InstallationInstalling Welding Generator Location GroundingEngine Prestart Checks Connecting Battery and Installing Exhaust PipeStop engine Connect negative − cable lastSelecting Weld Cable Sizes Connecting to Weld Output Terminals100 ft 30 m or Less 10 − 60% 60 − 100% Duty 10 − 100% Duty CycleSocket Information Remote 14 Receptacle RC1 InformationRef. ST-158 Operating the Welding Generator Using Idle Lock SwitchFront Panel Controls PlugRemote Amperage and Contactor Control Operating Auxiliary Equipment Auxiliary Power ReceptaclesMaintenance & Troubleshooting 100 Hrs Maintenance Changing Engine Oil and Oil Filter To Clean air filter Servicing Air CleanerDo not clean housing with air hose Changing Fuel FiltersWeld/Power Speed Adjustment Adjusting Engine SpeedIdle Speed Adjustment Remote Control Circuit Weld And Auxiliary Power CircuitsOverload Protection Engine Control CircuitStop engine and let cool. Reinstall cleanout plug Welding TroubleshootingServicing Optional Spark Arrestor Trouble RemedyEngine Troubleshooting Auxiliary Power TroubleshootingUle OM-402 Circuit Diagram for Welding Generator Electrical DiagramSC-181 Heavy loading during first Run-In ProcedureWetstacking Load Bank Run-In Procedure Using Load BankRun-In Procedure Using Resistance Grid Grounding Generator to Truck or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Amperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Approximate 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 = Starting Amperage VoltsTypical Connections to Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleMain Assembly Parts ListST-801 488-A PC6 11.1CB9 Panel, Front w/Components .1 Item CB5 11.2Generator .1 Item Diode Board Control Box w/Components .1 ItemOM-402 Page OM-402 Page Metro 250D Options and AccessoriesCall Miller for your local Miller distributor Miller Electric Mfg. Co Owner’s Record