MIG Welding User Guide: Difference between revisions

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'''Procedure Number'''
'''Procedure Number'''


UG 130-03, Rev. 0
UG 130-03, Rev. 2
|width="33%"|
|width="33%"|
'''Date'''
'''Date'''


DRAFT
8/17/2022
|}
|}


 


= GENERAL =
= GENERAL =


The Millermatic 211 is both a stick welder and a MIG welder, see sister Stick Welding Guide UG 130-02 and Maintenance Guide MT 130-02
The MIG welder is used for fusing steel and aluminum. We have Lincoln 350MP MIG welders.
[[File:Lincoln 350MP.jpg|thumb]]
 


[[File:Millermatic 211 Stick and MIG Welder.png]]


= SAFETY =
= SAFETY =


* Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
* Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.
* Non-slip footwear or anti-skid floor strips are recommended.
* Wear approved welding gloves and jacket.
* Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
* Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.  
* Closed toe shoes are required when working in a shop area.
* Closed toe shoes are required when working in a shop area.
* Do not touch live electrical parts.
* Turn off all equipment when not in use.  
* Wear dry, hole-free insulating gloves and body protection.
* Do not use worn, damaged, undersized, or poorly spliced cables.  
* Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.
* Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged.
* Turn off all equipment when not in use.
* Do not use worn, damaged, undersized, or poorly spliced cables.
* Do not drape cables over your body.
* Do not drape cables over your body.
* If earth grounding of the workpiece is required, ground it directly with a separate cable.
* Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.  
* Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
* Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.
* Keep all panels and covers securely in place.
* Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
* Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
* Do not connect more than one electrode or work cable to any single weld output terminal.
* Do not connect more than one electrode or work cable to any single weld output terminal.
* Keep your head out of the fumes. Do not breathe the fumes.
* Do not touch hot parts bare handed.
* Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.
* Allow cooling period before working on gun or torch.
* The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
* Keep your head out of the fumes. Do not breathe the fumes.  Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
* Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
* Do 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
* Wear approved safety glasses with side shields under your helmet.
* 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.  
* Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
* Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
* Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
* Shut off shielding gas supply when not in use.
* Do not touch hot parts bare handed.
* Allow cooling period before working on gun or torch.
* To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.


= REFERENCE =
= REFERENCE =


* [https://www.youtube.com/watch?v=v62lm7FGhNc MIG welding basics]
* Millermatic 211 Manual (https://www.millerwelds.com/files/owners-manuals/o239988d_mil.pdf)
* The Millermatic 211 is both a stick welder and a MIG welder, see sister Stick Welding Guide UG 130-02 and Maintenance Guide MT 130-02
* MIG welding basics video (https://www.youtube.com/watch?v=v62lm7FGhNc)
* [[:File:350mp_manual.pdf| Lincoln 350MP User Manual ]]
* MIG welding settings chart (https://weldguru.com/wp-content/uploads/wire-selection-settings-chart-large.jpg)
*


= PROCEDURE =
= PROCEDURE =


'''<u>Voltage Control</u>'''
# Power on welder.
# Open MIG gas bottle and ensure correct flow rate at the regulator.
# Set wire speed to Automatic for 0.030" wire, as this is the wire diameter that should be loaded.
# Set voltage dial according to the material thickness being welded.
# Connect ground clamp to workpiece or work surface.
# Ensure proper PPE is in use and safe surroundings.
# Weld
# When finished, store welding cables properly
# Turn off welder
# Close gas bottle
 
= TROUBLESHOOTING =


* Set Voltage control.
[[File:8-8 MIG Troubleshooting − Excessive Spatter.png]]
* Turn control clockwise to increase voltage.


'''<u>Wire Speed Control</u>'''
[[File:8-9 MIG Troubleshooting − Porosity.png]]


* Set Wire Speed control.
[[File:8-10 MIG Troubleshooting − Excessive Penetration.png]]
* Increase or decrease wire speed to obtain desired bead profile and travel speed.


'''<u>Power Switch</u>'''
[[File:8-11 MIG Troubleshooting − Lack Of Penetration.png]]


* This switch energizes the main transformer and control circuitry.
[[File:8-12 MIG Troubleshooting − Incomplete Fusion.png]]


<u>'''Shielding Gas Bottle'''</u> – make sure it is always chained up, either to the machine or somewhere in the shop. If it falls over with a regulator on it, the gas will try to escape and the gas stream could potentially hurt someone. To prevent the escape of gas when not in use, remove the regulator and fasten a threaded protector cap to the top of the bottle to keep the valve system safe and help prevent a rupture.
[[File:8-13 - 14 MIG Troubleshooting − Burn-Through and Waviness.png]]


 
[[File:8-15 MIG Troubleshooting − Distortion.png]]


= TROUBLESHOOTING =


'''THIS IS THE END OF THE PROCEDURE'''
                                                      '''END OF THE PROCEDURE'''

Latest revision as of 08:09, 1 May 2025

Shop Area: Metal Shop

Tool: MIG Welding

Requires in-person training: Yes 

Procedure Number

UG 130-03, Rev. 2

Date

8/17/2022


GENERAL

The MIG welder is used for fusing steel and aluminum. We have Lincoln 350MP MIG welders.


SAFETY

  • Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.
  • Wear approved welding gloves and jacket.
  • Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
  • Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
  • Closed toe shoes are required when working in a shop area.
  • Turn off all equipment when not in use.
  • Do not use worn, damaged, undersized, or poorly spliced cables.
  • Do not drape cables over your body.
  • Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
  • Do not connect more than one electrode or work cable to any single weld output terminal.
  • Do not touch hot parts bare handed.
  • Allow cooling period before working on gun or torch.
  • Keep your head out of the fumes. Do not breathe the fumes. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
  • Do 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
  • 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.
  • Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

REFERENCE

PROCEDURE

  1. Power on welder.
  2. Open MIG gas bottle and ensure correct flow rate at the regulator.
  3. Set wire speed to Automatic for 0.030" wire, as this is the wire diameter that should be loaded.
  4. Set voltage dial according to the material thickness being welded.
  5. Connect ground clamp to workpiece or work surface.
  6. Ensure proper PPE is in use and safe surroundings.
  7. Weld
  8. When finished, store welding cables properly
  9. Turn off welder
  10. Close gas bottle

TROUBLESHOOTING


                                                      END OF THE PROCEDURE
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