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Mig Welding Handbook

Mig Welding Handbook

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Published by Momentumm
Mig Welding Handbook
Mig Welding Handbook

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Published by: Momentumm on May 18, 2010
Copyright:Attribution Non-commercial

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09/06/2014

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Processes
MIG (GMAW) Welding
154 557 A
2007
02
Guidelines ForGas Metal ArcWelding (GMAW)
Visit our website at
www.MillerWelds.com
 
TABLE OF CONTENTS
 
154 557 Page 1
SECTION 1
SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1.Symbol Usage
Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.
Y
Marks a special safety message.
.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.
1-2.Arc Welding Hazards
Y
The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section1-5. Read and follow allSafety Standards.
Y
Only qualified persons should install, operate, maintain, andrepair this unit.
Y
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.
D
Do not touch live electrical parts.
D
Wear dry, hole-free insulating gloves and body protection.
D
Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.
D
Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
D
Use AC output ONLY if required for the welding process.
D
If AC output is required, use remote output control if present onunit.
D
 Additional safety precautions are required when any of the follow-ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic 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 welderis recommended. And, do not work alone!
D
Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).
D
Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.
D
 Always verify the supply ground
check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.
D
When making input connections, attach proper grounding conduc-tor first
double-check connections.
D
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged
bare wiring can kill.
D
Turn off all equipment when not in use.
D
Do not use worn, damaged, undersized, or poorly spliced cables.
D
Do not drape cables over your body.
D
If earth grounding of the workpiece is required, ground it directlywith a separate cable.
D
Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.
D
Do not touch electrode holders connected to two welding ma-chines at the same time since double open-circuit voltage will bepresent.
D
Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.
D
Wear a safety harness if working above floor level.
D
Keep all panels and covers securely in place.
D
Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.
D
Insulate work clamp when not connected to workpiece to preventcontact with any metal object.
D
Do not connect more than one electrode or work cable to anysingle weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-typewelding power sources after removal of inputpower.
D
Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.
FUMES AND GASES can be hazardous.
D
Keep your head out of the fumes. Do not breathe the fumes.
D
If inside, ventilate the area and/or use local forced ventilation at thearc to remove welding fumes and gases.
D
If ventilation is poor, wear an approved air-supplied respirator.
D
Read and understand the Material Safety Data Sheets (MSDSs)and the manufacturer’s instructions for metals, consumables,coatings, cleaners, and degreasers.
D
Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.
D
Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.
D
Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

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