Miller Electric Renegade 180 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 Processes OM-228 042BDescription File Engine DriveFrom Miller to You Table of Contents 10-1 − MaintenanceArc 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 peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Gun SpecificationsOptional Lifting Eye Weight Rating Volt-Ampere CurvesFuel Consumption Power Source Duty CycleGun Duty Cycle And Overheating Generator Power CurveVolts AC AmperesInstalling Welding Generator − InstallationMovement Airflow ClearanceUse ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsEngine Prestart Checks Connecting The Battery Electric Start Models Only+ − OilWork Cable Routing Inside Unit Installing Welding GunChanging Weld Polarity Weld Process/Polarity TableThis unit can provide weld out Connecting Single−Phase, 230 Volt AC Utility Input PowerShown with optional cylinder rack Installing Wire Spool And Adjusting Hub Tension Electrical Service GuideWhen a slight force is needed to turn spool, tension is set AdapterWeld Position Tools Needed 150 mm 030/.035 Groove Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleThreading The Welding Gun Wood Controls See Section − Operating the Welding GeneratorTo Stop Description Of Controls See SectionTo Start Weld Parameter Chart 20 ga 18 ga 16 ga 14 ga Stainless Steel And 100% CO2 Weld Parameters− Operating Auxiliary Equipment Generator Power Panel ReceptaclesGenerator power decreases as weld current increases Power Source Routine Maintenance − MaintenanceWelding Power Source Overload Protection Gun Routine MaintenanceDrive Motor Protection Tip Saver/Short Circuit ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Maintaining Gun Turn off welding power source/wire feederTools Needed 19 mm Replacing Switch And/Or Head TubePrecleaner Paper Element Servicing Air CleanerDo not wash paper element or clean with compressed air Standard Model Shown Stop engineStop engine. Close fuel valve Adjusting Engine SpeedTroubleshooting − TroubleshootingGenerator Power WeldingDoes not run Wire FeederEngine Recommended Spare Parts − Parts ListRecommended Spare Parts OM-217 454 − Electrical Diagrams− MIG Welding Gmaw Guidelines Regulator Flowmeter Wire Feeder Power Source Shielding GasTypical MIG Process Connections Gun Work Clamp WorkpieceThese settings are guidelines only. Material Typical MIG Process Control SettingsWire Suggested Wire Speed Material thickness determines weld parametersHolding And Positioning Welding Gun Nozzle, and tip of wire is posiTioned correctly on seam Groove WeldsGun Angles And Weld Bead Profiles Conditions That Affect Weld Bead ShapeElectrode Extensions Stickout Fillet Weld Electrode Extension StickoutGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive Penetration12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Distortion 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsApproximate 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 Cord Lengths for 120 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsSOCKET/WRENCH Selection Table Standard Metric 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