Miller M-180 User manual

October
1969
FORM:
IOM-
114A
Effective
with
serial
No.
N295574
MODEL
STOCK
NO.
M-180
900001
M-180P
900010
M-225
900019
M-225P
900
028
1
Astallation
IfiperatioN
~
E~1
aioteoance
Manual
mIIcr
ELECTRIC
MIGU
CO.
APPLETON,
WISCONSIN,
U.S.A.
54911
-
-
USt.
NWSA
CODE
NO.
4579

SECTION
1-
SAFETY
RULES
FOR
OPERATION
OF
ARC WELDING MACHINE
1.1.
GENERAL
DA.
These
rules
apply
to
ac
and
dc
welding
generators,
ac
transformer
and
ac/dc
welding
machines,
and
dc
transformer
rectifier
welding
machines.
DB.
In
arcwelding
operations,
where
electrically
en
ergized
parts
are
exposed,
observe
the
following
safety
rules
to
insure
maximum
personal
safety
and
protect
nearby
persons.
DC.
Failure
to
observe these
safety
precautions
may
expose
not
only
you,
but
fellow
workers
as
well,
to serious
injuries.
Once
these
rules
are
learned
and
kept
in
mind,
proceed
with maximum
assurance.
WELDING
MACHINE
ciA.
Never
use
welding
cables
at currents
in
excess
of
their
rated
capacity.
It
will
cause
overheating
and
rapid
deterioration
of
the
insulation.
It is
also
uneconomical.
DONT
use worn or
poorly
connected
cables.
DB.
Inspect
the cables
frequently. Immediately
repair
all breaks in the
insulation with rubber and
friction
tapes.
Tighten
all
cable
connections
and
adequately

insulate
any
joints
where
a
connector
may
have
an
exposed
conductive
part.
In addition
to
the
potential
hazard
to
life,
a
hazard
occurs
when
exposed

sections
of
cable
come
in
contact
with
grounded
metallic
objects,
causing
an
arc.
Unprotected
eyes
may
be
injured
and
fire
may
result
if
combustible
materials
such
as
oil
or
grease
are
in the
vicinity.

The
efficiency
and
quality
of
welding
will
be
im
proved
by
elimination
of
these
dangerous
grounds,
and
by keeping
connections
tight.
1.3.
ELECTRODE
HOLDER
DONT
use
electrode
holders with
defective
jaws.
ciA.
Keep
the
jaws
of
the
electrode
holder
tight
and
the
gripping
surfaces
in
good
condition
to
provide
close
contact
with
the
electrodes.
Defective
jaws
will
permit
the
electrode
to
wobble,
making
control
of
the
welding
operations
difficult.
DONT
use
electrode holder
with
loose
cablecon
nections.
Keep
the
connections
of
the
electrode lead to
the
holder
tight
at
all
times.
Use
only fully
insulated
electrode holders
(and
with
out
protruding
screwheads.)
Never
touch
two
electrode
holders
from
two
separate
welding
machines at
the
same
time.
1.4. CODE CONFORMANCE
ciA.
The machine
and its
equipment
must
be
installed
and
maintained in
accordance
with the National
Electrical Code
and
local
requirements.
1.5.
PARALLEL
CONNECTIONS
ciA.
See
diagrams
in
the
instruction manual
applying
to
the
welding
machine
used.
1.6.
POWER
DISCONNECT
SWITCH
DA.
If
the
welding
machine does
not
include
a
power
disconnect
switch,
install
one
at
or
near
the
machine.
1.7. POLARITY
SWITCH
DONT
operate
the
polarity
switch
under
load.
ciA.
The
polarity
switch
(when
supplied)
is
provided
for
changing
the electrode lead
from
positive (reverse
polarity)
to
negative (straight polarity).
Never
move
it while
under the load
of
a
welding
current.
Operate
this switch
only
while the
machine is
idling
and
the
welding
circuit is
open.
The
potential
dangers
of
opening
the
circuit
while
carrying high
current
are:
0(1)
An
arc
will
form
between
the
contact
surfaces
of
the
switch
and
severely
burn
them.
0(2)
The
person
throwing
the switch
may
receive
a
severe
burn
from
this
arcing.
1.8.
RANGE
SWITCH
DONT
operate
the
range
switch
under
load.
ciA.
The
range
switch
(when
supplied)
is
provided
for
obtaining
required
current
settings.
It
must
never
be
operated
while the
machine
is under
the
load of
welding
current.
Operate
the
range
switch
only
while
the machine
is
idling
and
the
welding
circuit
is
open.
Thepotenialdangerofswitchingthe
circuit
while
carrying
high
current
is
the
formation of
an
arc
between
the
contact
surface
which
will
severely
burn
them.
Repeated
occurrences
of
this
arcing
will
eventually
prevent operation
of the
contacts.
1.9.
EXHAUST
GASES
DONT
use
gas
engine
units
in
confined
spaces
without
venting
the exhaust
gases.
ciA.
If
gasoline
or
other fuel
driven
welding
machines
are
operated indoors,
provide
means
to
pipe
the
exhaust
gases
to
the
outside air to
avoid carbon
monoxide
poisoning.
1.2.
WELDING
CABLES
DONT
overload
cables.
DB.
DC.
DD.
I
~1/
,-- I..
-
IOM-114A-
Page
1

DONT
use
welding
machine
without
grounding
frame
or
case.
I
_
I
DA.
Ground the
ground
cable
of
every
power
circuit
to
prevent
accidental
shock
by stray
current.
The
potential
danger
is
that
development
of
a
stray
cur
rent
may
give
a
fatal
shock
should
a
person,
for
example,
place
one
hand
on
thewelding
machine
and
the other
on
the
switch
box,
or
other
grounded
equipment.
Do
not
ground
to
pipelines
carrying
gases
or
flammable
liquids
and
conduits
carrying
electrical
conductors.
Be
sure
conductors
can
safely
carry
the
ground
current.
When
con
necting
the
welding
machine,
properly ground
the
machine
frame
or
case.
WELDING
OPERATIONS
1.11.
CONTAINERS
WHICH
HELD COMBUSTIBLES
DONT
weld
on
containers
which
have held
com
bustible
or
flammable
materials
or
materials
which,
when
heated,
give
off flammable
or
toxic
vapors
without
proper
cleaning,
purging,
or
inerting.
DA.
Welding
on
containers
which
have
heldflammable or
combustible
materials
may
be
extremely
danger
ous.
To
prevent
afireorexplosionof
the
container,
follow
the
recommendations
of
the
American
Weld
ing
Society
Pamphlet
A6.O
Welding
or
Cutting
Con
tainers
Which
Have Held
Combustibles.
DONT
depend
on
your
eyes
or
nose
to
decide
if
it is
safe
to
weld
on a
closed
container.
DB.
Find
out
what
was
in
the
container
or use
an
explosimeter.
A
very
small
amount
of
residual
flammable
gas
or
liquid
can cause
a
serious
explosion.
NEVER
use
oxygen
to
ventilate
a
container.
DC.
When
you
know
the
container
held
a
gas
or
liquid
which
will
readily
dissolve
in water:
D(1)
Flush
out
with water
several
times
and
then
fill
with
water
as
far
as
work
permits,
posi
tioning
container
to
permit
introduction
of
as
much water
as
possible.
D(2)
Before
welding
be
sure
there
is
a
vent
or
opening
to
provide
for release
of
air
pressure.
EW.
When
you
know
the
container
held
a
gas
or
liquid
which
will
not
readily
dissolve
in
water.
D(1)
Clean
out
thoroughly
with steam
or a
cleans
ing
agent
and
purge
all air
or
inert
with
a
gas
such
as
carbon dioxide
or
nitrogen
before
re
pairing.
Carbon dioxide
is
heavier
than
air
and
will
tend
to
remain
in the container
if
the
open
ing
is
at
the
top.
D(2)
Use steam
to
clean
out
light
material.
D(3)
Use
a
strong
caustic
soda
solution
to
clean
out
heavy
oils
or
grease.
0(4)
Be
sure
to
purge
all air
or
inert
with
a
gas,
such
as
nitrogen
or
carbon
dioxide,
no
matter
how
well
you
have
cleaned.
There
may
still
be
traces
of
oil,
grease,
or
other
readily
oxidizable
material under
the
seams.
DE.
Be
careful
when
cleaning
with steam
or
caustic
soda
wear
goggles
and
gloves.
DONT clean
where
there
is
poor
ventilation.
OF.
Ventilation
is
necessary
to
carry
away
harmful
or
explosive
vapors.
DONT clean where there
are
open
flames.
0G.
When
scraping
or
hammering
to
remove
heavy
sludge
or
scale,
use
a
spark
resistivetool
and
keep
it wet to
avoid
sparks.
OH.
Keep
your
head and
arms as
far
away
from
your
work
as
possible.
1.12.
HOLLOW CASTINGS
DONT
weld
on
hollow
(cored)
castings
that have
not
been
properly
vented.
The
casting
may
explode.
NEVER
weld
in
or
near
explosive
atmospheres,
Such
atmospheres
can
be created
by
flammable
gas
leaks
or
by
vapors
from
flammable
liquids
(gasoline,
alcohol,
etc.)
or
by
combustible
dusts.
1.14.
VENTILATION
DONT
weld
in
confined
spaces
without
adequate
ventilation.
DA.
When
welding
in
confined
spaces,
provide
ventilation
in accordance
with
United States
of
America Stand
ard
Z49.1,
1967.
Always
provide
adequate
ventila
tion
by
blowers,
air
lines,
or
other
acceptable
means.
Never
use
compressed
oxygen.
The
depletion
of
the
oxygen
supply,
the
heat
of
welding,
and
the
fumes
given
off
may
cause
severe
dis
comfort
or a
serious
illness.
OB.
When
toxic
fumes from
lead
or
cadmium
bearing
materials
or
any
other
substances
are
present
in
harmful
concentrations,
always
use
an
air
supplied
respirator.
L
--

J
--
1.10.
POWER
CIRCUIT GROUND
1
_--I
1.13.
EXPLOSION
HAZARDS
Page
2

1.15.
SOLVENTS
DA.
Do
not
weld
where
chlorinated
hydrocarbon
vapors
from
degreasing, cleaning,
or
spraying
may
reach
or
he
drawn
into air
surrounding
the
welding
operation.
The
heat
of
the
arc can
decompose
solvent
vapors
to
form
phosgene,
a
highly
toxic
gas
and other
irritating
decomposition products.
OB.
Do
not weld
where
ultraviolet
lightfrom
the
electric
arc
can
penetrate
air
containing
even
minute
amounts
of
vapors
from
solvents
such
as
trichlo
roethylene
or
perchloroethylene.
Ultraviolet
light
can
decompose
the
vapors
to
form
phosgene,
a
highly
toxic
gas,
and
other
irritating
products.
1.16.
FIRE
HAZARDS
DONT
weld
near
flammable
or
combustible
materials.
DA.
Fires
can
be caused
by
the
arc,
by
contact with
the heated
metal,
by
slag,
or
sparks. Keep
com
bustibles
at
least 35
feet from
the
arc
or
suitably
protected.
If
welding
must
be
done
in
a
particular
area,
move
the combustibles
away.
If
they
cannot
be
moved,
cover
them
completely
with
fire
resistive
screens.
Cover
cracks
or
openings
in
floors
or
walls;
sweep
floor
free
of
combustibles
and wet
down,
if
wood,
being
sure
welder
wears
insulation
shoe
coverings.
Avoid
welding
on
partition
walls
in contact
with
combustibles.
Heated metal
on
the
other side
of
partition
wall
being
welded
upon
can
ignite
combustibles
in contact
with the
partition.
Where
other
than
a
minor
fire
might develop,
have
a
fire
watcher
stand
by
with suitable fire
extin
guishing
equipment
for
at
least
one-half
hour
after
the
welding
is
completed.
1.17.
ELECTRICAL
SHOCK-VOLTAGE
OPEN
power
circuits
before
checking
machines.
DA.
Before
working
on
the
wiring,
switches,
controls,
etc.,
open
the
power
line
disconnect
switch.
In
most
welding
shops
the
power
supply
used
for
arc
welding
machines
is
230
or
460
volts.
Open
circuit
voltages
are
usually
less
than
100 volts
and
welding
or arc
voltage
drops
are
still
lower.
How
ever,
all
of
these
voltages
are
capable
of
developing
a
harmful
or
fatal current
to
the
body.
DONT
touch
electrically
hot
parts.
DB.
Never
touch
any
exposed
or
non-insulated
part
of
the
cables,
cable
connectors,
clamps,
electrode
holders,
electrodes~
or
the
power
supply
equipment
to
prevent
harmful
or
fatal
electric
shock
or
burns.
1.18.
ELECTR
ICAL
SHOCK-DAMPNESS
NEVER
work
in
a
damp
area
without
suitable
in
sulation
against
shock.
Keep
hands,
feet,
and
clothing
dry
at all
times.
DA.
To
pievent
harmful
body
shocks,
keep
hands,
feet
and
clothing
dry.
Never
stand
or
lie
in
puddles
of
water,
damp
ground,
or
against grounded
metal
when
welding
without
suitable insulation
against
shock.
Always
find
a
dry
board
or
rubber
mat
to stand
on
when
water,
moisture,
or
perspiration
cannot
be
avoided.
Dampness
between
the
body
and
an
en
ergized
or
grounded
metallic
part
lowers
the
resistance
to
the
passage
of
current to
the
body
which
may
produce
a
harmful
or
fatal
shock.
Salt
in
perspiration
or
sea
water
dangerously
1ower~
contact
resistances.
1.19. STARTING
UNDER LOAD
DONT
leave
an
uninsulated
electrode
holder,
or
a
live
electrode
on
the
table
topor
in
contact
with
a
grounded
metallic
surface.
When
it is
not
in
use,
never
place
an
electrode
holder
in
contact
with the
table
top
or
other
metallic
surface
in
contact
with
welding
ground.
Provide
an
insulated
hook
or
holder
for
the
electrode
holder.
A
potential
danger
is
that
a
holder
in contact
with
the
ground
circuit
provides
a
dead
short
circuit
on
the
welding
machine.
If
the
machine
should
be
started
up,
this
short
circuit
would
cause
an ex
cessive
load
on
the
machine
and
may
damage
the
insulation.
1.20.
FACE
PROTECTION
DONT
use
cracked
or
defective
helmets
or
shields.
Keep
the
helmet,
hand
shields,
or
face
shield
in
good
condition,
If
cracks
occur
in
the
fibre
material,
replace
the
shield,
since
the
leakage
of
arc
rays
may
cause
serious
burns.
1.21.
EYE
PROTECTION
NEVER
under
any
circumstances,
look
at
an
electric
arc
without
eye
protection.
CAUTION
Make
sure
that
flash
goggles
are
used
under
the

welding
helmet
at
all
times,
particularly
while
gas
shielded-arc
welding.
DA.
In
some
type
of
arc
welding,
such
as
gas
shielded-
arc
welding.ultraviolet
and
infrared
radiation
from
the
arc
is
particularly
intense
and
requires
constant
attention
to
avoid
arc
flashes
to
the
welder
when
striking
an
arc
and
to
avoid
exposure
to
other
welders.
NEVEB
strike
an
arc
without
ascertaining
that
nearby
persons
either
have
the
necessary
pro
tective
equipment
or
are
looking
in
the
opposite
direction.
DB.
For
welding
operations
in
open
areas,
provide
portable,
nonreflecting
screens
to
shield
persons
nearby
from the
rays
of
the
arc.
Eye
burns
from
the
arc, though
not
generally
permanent
injuries,
are
exceedingly
painful.
Such
burns
frequently
referred
to
as
flashes,
feel
like hot
sand
In
the
eye.
For
eye
burns
consult
your
first
aid
station
or doctor.
IOM-114A-Page
3