IMPORTANT!!! NOTES: The welding machine has also been designed for use

IMPORTANT!!! NOTES: The welding machine has also been designed for use
INSTRUCTION MANUAL FOR MIG WELDING MACHINE
IMPORTANT!!!
READ THIS MANUAL CAREFULLY BEFORE INSTALLING, USING, OR PERFORMING ANY MAINTENANCE ON
THE MACHINE. PAY SPECIAL ATTENTION TO THE
CHAPTER ON “SAFETY PRECAUTIONS”. CONTACT
YOUR DISTRIBUTOR IF YOU DO NOT FULLY UNDERSTAND THESE INSTRUCTIONS.
1 GENERAL DESCRIPTIONS
1.1 SPECIFICATIONS
This manual has been prepared for the purpose of educating
personnel assigned to install, operate and service the welding
machine.
This equipment is a constant-voltage generator, suitable for
MIG/MAG and OPEN-ARC welding.
Upon receiving the machine, make sure there are no broken
or damaged parts.
The purchaser should address any complaints for losses
or damage to the vector. Please indicate the article and
serial number whenever requesting information about
the welding machine.
NOTES: The welding machine has also been designed for use
in environments with a pollution rating of 3. (See IEC 664).
2 INSTALLATION
2.1 PLACEMENT
Dust, dirt, and any other foreign matter entering the welding
machine can interfere with ventilation and thus with smooth
operation.
Mount the handle, the 2 cylinder supports, the extension
support and pivot support.
Mount the 2 fixed wheels on the wheel support located on top
of the welder. remove the Styrofoam buffer from under the
bottom, at the back of the welding machine. Insert the wheel
support on the bottom, fastening it in place wiyh the screws
provided.
1.2 EXPLANATION OF TECHNICAL SPECIFICATIONS
EN50199 The welding machine is manufactured accordEN60974.1 ing to these international standards.
N°
Serial number, which must be indicated on any
type of request regarding the welding machine.
3a
three-phase transformer-rectifier.
Flat characteristic.
Duwnslope
Suitable for continuous electrode welding.
Suitable for TIG welding.
Suitable for MMA welding.
I2 MAX
Unconventional welding current. This value
represents the maximum limit available during
welding.
U0.
Secondary open-circuit voltage (peak value).
X.
Duty cycle percentage
The duty cycle expresses the percentage of
10 minutes during which the welding machine
may run at a certain current without overheating.
I 2.
Welding current.
Secondary voltage with welding current I2.
U2.
U1.
Rated supply voltage.
3~ 50/60Hz 50- or 60-Hz three-phase power supply.
I 1.
Absorbed current at the corresponding welding
current I2.
IP21
Protection rating for the housing. Grade 1 as the
second digit means that this equipment is
suitable for use outdoors in the rain.
S.
Suitable for use in high-risk environments.
2.2
START-UP
• Only qualified personnel should install this welding machine.
• Connect a plug suitable for the absorbed current to the
power supply cable.
• Connect the yellow-green wire of the machine mains to an
efficient grounding socket.
• Never use water pipes as a grounding conductor.
2.2.1 Connecting the mass clip.
• Connect the power cable terminal to socket AA on the
machine.
• Connect the mass cable clip to the workpiece.
• Make sure the cable is firmly attached to the mass terminal;
check periodically to make sure these connections are tight.
A loose coupling may cause drops in the welding current,
overheating of the cable and mass terminal, leading to a risk
of burns caused by accidental contact.
• The welding circuit must never be deliberately placed in
direct or indirect contact with the safety conductor except on
the workpiece.
• If the workpiece is deliberately grounded by means of the
safety wire, the connection must be as direct as possible, and
made using a wire having a cross-section at least equal to that
of the welding current return wire. It must also be connected
to the workpiece at the same point as the return wire, using the
return wire clamp or a second earth clamp placed immediately
adjacent to it.
2.2.2 Connecting the gas hose.
• Connect the gas hose leaving the rear of the machine, only
after positioning the cylinder.
2.2.3 Connecting the generator and wire feeder.
This generator accepts the wire feeder TR4.
To connect the generator and wire feeder, use the extension
Art. 1182 (5 meters), 1182.20 (10 meters), or 1182.10 (1.3
meters). Performance and operation options are described
in the instructions enclosed with the wire feeder.
3 DESCRIPTION OF CONTROLS
3.1 CONTROLS ON THE FRONT PANEL.
MODE KEY A.
When the A key is pressed, LED B or C lights for welding in
synergic mode, and LED D or E for welding in manual mode.
After selecting the type of material, type of gas and wire
diameter, synergic mode provides a series of pre-set voltage values (using the knobs B and C on the remote control
of the wire feeder), expressed in VOLTS, and wire speeds
expressed in METERS / MINUTE, suitable for welding.
LED B
2-stage synergic mode.
The machine begins welding when the trigger is pressed,
and stops when it is released.
LED C
4-stage synergic mode.
To begin welding, press the torch trigger; you may release
the trigger once the procedure has begun. Press and release
the trigger again to stop welding. This setting is suitable for
long-term welding, where the welder may tire of holding
down the torch trigger.
LED D
2-stage manual mode
The same operating principle as the 2-stage synergic mode.
LED E
4-stage manual mode
The same operating principle as the 4-stage synergic mode.
MATERIAL KEY F (active only in 2-stage or 4-stage synergic mode)
The LED for the selected material lights whenever this key
is pressed
LED G for iron welding.
LED H for stainless steel welding.
LED I for welding 5% magnesium aluminum.
WIRE KEY L (active only in 2-stage or 4-stage synergic
mode)
The LED for the selected wire diameter lights whenever this
key is pressed
LED M for wire ø 0.8mm.
LED N for wire ø 1mm.
LED O for wire ø 1.2mm.
LED AB for wire ø 1.6mm Art. 508 only).
GAS KEY P (active only in 2-stage or 4-stage synergic
mode)
The LED for the selected gas lights whenever this key is
pressed.
LED Q for ARGON gas.
LED R for CO2 gas.
LED S for ARGON + 2% O2 gas.
LED T for ARGON + 5% CO2 gas.
LED U for ARGON + 18.25% CO2 gas.
Caution not all combinations are available, only those set in
the programs.
• If aluminum is selected as the material, you may select
only diameters 1-1.2-1.6 and only Argon gas.
• If stainless steel is selected as the material, you may select
only diameters 0.8-1-1.2-1.6 and only Ar + 2% O2 gas.
• If iron is selected as the material, you may choose
among diameters 0.8-1-1.2-1.6 and among the gases
CO2 , Ar + 5% CO2 and Ar + 18.25% CO2.
KEIS FOR BUILDING ONE OR MORE SYNERGIC
CURVES V E W.
As specified previously, the programmed synergic curves
do not include all of the wires or gases used
As specified previously, the programmed synergic curves do
not include all of the wires or gases used in welding. If the
operator wishes to create a customized curve for a wire type
or gas other than those programmed, he can do so by following
the instructions below. This function is enabled only in synergic
mode, and a maximum of 5 curves may be memorized.
The first time the program button V is pressed, the LED 1
begins flashing (this is the first free program). To save the
synergic curve to memory, proceed as follows:
• use the knobs on the remote control of the wire feeder
to find the voltage and meters per minute values suitable
for welding
• press the memory key W to save this initial condition,
and at the same time save 3 other pairs of values
• after saving the 4 pairs of values, LED 1 remains
steadily lit, without flashing.
Once the synergic curve has been programmed, to use it
simply set the voltage knob C on the remote control of the
wire feeder to 0, and adjust the parameters using the m/min.
knob B on the wire feeder remote control. Follow the same
procedure to save the other 4 programs available.
To delete a program, select the synergic curve to be deleted
and hold the memory key W down for at least 10 seconds.
After this time has elapsed, the LED will begin flashing again,
and a new program may be stored in this memory position.
It is also possible to save a single voltage/current pair by
pressing the W key 4 times. NOTE: The welding machine
will accept no other commands until the memory procedure has been completed.
INSTRUMENT K (Welding voltage)
This instrument displays the voltage during welding.
In manual mode, the voltage can be adjusted before welding
by turning the potentiometer C on the wire feeder remote
control, and displayed by the instrument.
The Volt meter shows the exact working voltage while
welding; when the operator finishes welding, the last voltage
value remains in the instrument memory until new parameters or functions are selected.
In synergic mode, the instrument automatically displays the
programmed voltage.
The last welding voltage is always saved, as in manual mode.
INSTRUMENT X (Welding current/meters per minute)
This instrument displays the welding current and the welding
electrode speed in meters per minute.
Before beginning welding in manual mode, the instrument
shows the meters per minute set on the knob B on the wire
feeder remote control; during welding it displays the current.
This remains in the instrument memory after welding, until
new parameters or functions are selected.
In synergic mode, the instrument automatically shows the
programmed meters per minute before welding; it shows the
current during welding, which remains in the instrument’s
memory until new parameters or functions are selected.
LED Y
This LED lights when the thermostat interrupts welding
machine operation when the cooling unit is in use and is
turned off, or the pressure switch signals that coolant fluid is
low, or when the mobile panel of the wire feeder is opened.
LED Z
This LED indicates that the machine is on.
SELECTOR SWITCH J
Turns the machine on and off, and serves to change the supply
voltage. To change the voltage, turn the disc located under the
knob, see Fig. Always make sure that the supply voltage
matches the one shown on the front panel of the machine.
SOCKET AA
Socket for connecting the mass cable terminal.
3.2 CONTROLS ON THE REAR PANEL.
SOCKETSAC
Sockets for connecting the generator/wire feeder connection.
To maximize carbon steel welding, we recommend using the
).
central outlet of the impedance (
To maximize stainless steel welding, we recommend using
the third impedance outlet (
).
To maximize aluminum welding, we recommend using the
third impedance outlet (
).
CONNECTOR AD
This connects to the 14-pin connector on the extension lead
between the power source and the wire feeder art 1444 or
1447.
SOCKET AE
This socket connects to the safety device on the cooling unit.
SOCKET AF (230V).
This socket connects to the cooling unit. Maximum available
power 440W.
KNOB AG
This knob regulates the lenght of the wire that sticks out of
the torch after welding is finished: "BURN-BACK".
CONNECTOR AH
This connects to the 10-pin connector on the extension lead
between the power source and the wire feeder art 1447.
AD
AC
5
AG
6
7
4
3
8
2
9
10
1
50
220V
440V
60
40
70
30
80
20
90
10
100
%
AH
AF
AI
AE
KNOB AI
this knob regulates the wire approch speed before it touches
the workpiece and the welding arc strikes.
This function anables improved are starting and prevents
the wire from stubbing. By turning the knob clokwise the
initial speed increased between a minimum of 10% up to a
maximum of 100% of the set speed.
3) Avoid welding on rusted work pieces or work having spots
of oil and grease present on the surface.
4) The use of a welding torch suitable to the welding currents
that are going to be used.
5) Periodically check that the two handles making up the
ground clamp are not damaged and that the welding cables
(torch cable and the work return lead) do not have any cuts
or burn marks that would reduce their efficiency.
4.3
Welding stainless steels in the 300 series (the austenitic series)
must be done using a shield gas mixture of predominantly Argon
with a small percentage of O2 added to stabilize the arc. The
recommended mixture is AR/O2 in the ratio of 98/2. Do not use CO2
or AR/CO2mixtures as the shield gas.
Do not touch the welding wire with your bare hands.
The filler metal (the wire) must be of a higher quality than the
work to be welded and the weld area must be clean.
4.4
4
WELDING ALUMINIUM
WELDING
4.1 THE MACHINE IS READY TO WELD
• Connect the ground terminal to the part to be welded.
• Put the switch J sulla tensione prescelta.
• Extract the conic gas nozzle by rotating it clockwise.
• Unscrew the current nozzle.
• Press the torch trigger to feed the wire until it comes out
from the torch.
WARNING: Keep your face away from the terminal nozzle
while the wire comes out.
• Screw the current nozzle again, making sure that the hole
diameter be the same as that the wire used.
• Insert the welding conic gas nozzle by rotating it clockwise.
• Open the gas cylinder and adjust flowmeter at 8¸10 l/min.
WARNING: Check that the gas used is compatible with the
material to be welded.
4.2
WELDING STAINLESS STEEL
WELDING CARBON STEELS.
To weld carbon steels the following things are necessary:
1) The use of a binary shielding gas which is most commonly
Argon and Carbon dioxide, in a ratio of 75¸80 % Argon and
25¸20% Carbon dioxide. Some applications, however, may
require a mix of three gases: Argon, Carbon dioxide (CO2), and
dioxide (O2). These gas mixtures generate heat during welding
and as a result the weld bead will be well filleted and neat in
appearance. The penetration, however, will not be deep.
The use of Carbon dioxide as the shield gas results in a
narrow weld bead with deep penetration but the ionization of
the gas will have an influence on arc stability.
2) The use of a filler wire of the same quality as the steel to be
welded. It is recommended that high quality wires be used and that
welding with rusted wires be avoided because they can give rise
to defects in the weld bead. Generally, the current range within
which a wire can be used is calculated in the following manner:
Ø of wire x 100= minimum number of Amperes.
Ø of wire x 200= maximum number of Amperes.
Practical example: 1.2 Ø wire= 120 Amps minimum and 240
Amps maximum. These amperages are based on the use of
an Argon/CO2mixture as the shield gas and welding in the
Short Arc transfer mode.
The following is required for aluminium welding:
1) 100% Argon as welding protection gas.
2) A torch wire of composition suitable for the basic material
to be welded.
For ALUMAN welding wire 3.5% silicon.
For ANTICORODAL welding wire 3.5% silicon.
For PERALUMAN welding wire 5% magnesium.
For ERGAL welding wire 5% magnesium.
3) A torch prepared for aluminium welding.
If you only have a torch for steel wires, the same shall be
modified in the following way:
- Make sure that lenght of torch cable does not exceed 118
inches (it is advisable not to use longer torches).
- Remove the brass sheath-holding nut, the gas and the
current nozzles, then slip the sheath off.
- Insert the teflon sheath for aluminium and ensure it
protrudesfrom both ends.
- Screw the current nozzle so that the sheath adheres to it.
- Insert the sheath holding nipple, the O-Ring in the free end of the
sheath and secure with the nut without tightening too much.
- Slip the brass tube on the sheath and insert both into the
adapter (after removing the iron tube which was fitted inside
the adaptor).
- Cut the sheath diagonally so that it stays as close as
possible to the wire slide roller.
4) Use drive rolls that are suitable for aluminium wire. The drive
rolls, when being installed, must be tightened as tight as
possible.
5) Use contact tips that are suitable for aluminium wire and
make sure that the diameter of the contact tip hole
corresponds to the wire diameter that is going to be used.
6) Use abrasive grinders and tool brushes specifically designed
for aluminium. Never use these tools on other materials.
REMEMBER that cleanliness equals quality.
The wire spools must be stored in plastic bags with a
dehumidifier.
5
WELDING DEFECTS
1- DEFECT- Porosity (in, or on the surface of the weld
bead)
CAUSES • Bad wire (rust on the surface).
• Insufficient gas shielding due to:
- Inadequate gas flow due to a block in the gas line.
- Defective flowmeter.
- Gas regulator covered with frost because a
gas heater was not used to heat the CO2
shielding gas.
- Failure of gas valve solenoid.
- Gas nozzle plugged up with spatter.
- Gas flow holes plugged up.
- Air drafts in the welding area.
2- DEFECT- Shrinkage Cracks
CAUSES • Welding wire or work to be welded dirty or rusty.
• Weld bead too small.
• Weld bead too concave.
• Too much weld bead penetration.
3- DEFECT- Lateral cracking
CAUSES • Welding speed too fast.
• Low current and high arc voltages.
4- DEFECT Too much Spatter
CAUSES • Voltage too high
• Insufficient impedance
• No gas heater used for CO2 shielding gas.
6 MACHINE MAINTENANCE
Gas nozzle . Periodically clean the nozzle of all weld spatter
that may have accumulated during welding operations. If the
nozzle should become distorted or oval in shape then it must
be replaced.
Contact tip . A good contact between the contact tip and the
wire ensures a stable arc and optimal current output. Therefore,
following steps must be followed:
A) The contact tip hole must be kept free of dirt or oxidation.
B) After lengthy welds, spatter can easily accumulate on the
contact tip and prevent the wire from being fed. The contact tip
must be cleaned regularly and if necessary it must be replaced.
C) The contact tip must always be screwed tightly on to the
body of the torch. The thermal cycles which the torch
undergoes during operation may loosen the contact tip
which, in turn, may cause the torch body and nozzle to
overheat or cause unsteady wire feed.
The Wire Liner is an important part that must often be checked
since, during normal operations, the wire can deposit copper
dust or tiny metal shavings in the lining. Periodically clean the
liner and the gas line with a jet of dry, compressed air. Wire
liners are exposed to continual wear and therefore they must
be replaced after a certain period of time.
Wire feed motor. Periodically clean the wire feed assembly
and the drive rolls from any rust or metal shavings due to the
feeding of the wire. A periodic check of all the components
of the wire feed assembly, spool holder, drive rolls, wire liner
and the contact tip is recommended.
7 TROUBLESHOOTING
Note: All repair work must be done by qualified personnel.
Disconnect the power input cable from the mains supply
before replacing cables or before removing the unit covers.
The machine is equipped with a thermostat that shuts the
machine down when the power source overheats. After the
thermostat intervenes, let the power source cool down for
several minutes before resuming welding operations.
The troubleshooting table lists troubles, causes and remedies
for those troubles that occur most commonly.
TROUBLE
PROBABLE CAUSE
REMEDY
Limited electric
output.
A phase is missing.
Check the phase of the feed
line and/or the remove
control switch contacts.
A line fuse is burnt.
Replace it.
Loosened torch or ground
connections.
Tighten all connections.
trasformer wire interrupted on
the commutator
Unscrew the commutator
contact, remove the wire
insulation and put it under
the contact
Welding with a lot Wrong adjustment of the
of metal spatter
welding parameters.
Wire not
advancyng or
advancyng
unproperly
The wire jams or
entangles between
the drive rolls and
the torch infeed
wire guide
Select the correct parameters
through the welding-voltage
switch and the wire-speed
adjustment potentiometer.
Insufficient grounding.
Check grounding
connections.
Wire advancing unproperly.
Uncorrect sheath diam.
Wire roller with too wide
groove.
Replace roller.
Obstructed or clogged liner.
Extract it and clean.
Loose wire pressing roller.
Tighten it.
Coil reel friction too tight.
Loosen and adjust it.
Current nozzle clogged.
Replace it.
Wrong current nozzle
diameter.
Replace it.
Wrong roller groove
alignment
Align it
Obstructed or clogged sheath Remove and clean
8
WELDING MACHINE SERVICING
Experience has shown that many fatal accidents originated
from servicing improperly executed. For this reason, a
careful and thorough inspection on a serviced welding
machine is just as important as one carried out on a new
welding machine.
Furthermore, in this way producers can be protected from
being held responsible for defects stemming from repairs
not carried out by the manufacturer.
8.1 Prescriptions to follow for servicing
● After rewinding the transformer or the inductance, the
welding machine must pass the applied-voltage test in
accordance with indications in table 2 of 6.1.3 of the EN
60974.1 standard (CEI 26.13).
Conformity must be checked as specified in 6.1.3.
● If no rewinding is done, a welding machine which has
been cleaned and/or reconditioned must pass an
applied-voltage test with voltage values equal to 50% of
the values given in table 2 of 6.1.3. Conformity must be
checked as specified in 6.1.3.
● After rewinding and/or the replacement the no-load
voltage shall not exceed the values given given in 10.1
of EN 60974.1.
● If the servicing is not done by the manufacturers, the
repaired welding machines which underwent replacements or
modifications of any component, shall be marked in a way
such that the identity of the person having serviced it is clear.
● After making repairs, take care to re-order the cables so
that there is sure to be insulation between the primary and
secondary sides of the machine. Make sure that the wires
cannot come into contact with moving parts or parts that
heat during operation. Replace all clamps in their original
positions on the machine, to prevent a connection between
the primary and secondary circuits if a conductor accidentally
breaks or disconnects.
9 SAFETY PRECAUTIONS
9.1 ELECTRIC SHOCK
•Disconnect the power cord from the mains
before working on the cables or opening the
machine.
• Never touch live parts
• Never use the machine without the safety guards.
• Insulate yourself from the part to be cut/welded and from
the earth by wearing insulating gloves and clothing.
• Keep all clothing (gloves, shoes, headgear) and your body
dry at all times.
• Do not work in damp or humid environments
• Should you notice even the slightest sensation of electric
shock, stop cutting/welding immediately. Do not use the
equipment again until the problem has been identified and
resolved.
• Include an automatic wall switch of adequate capacity
placed near the equipment, to allow it to be shut off
immediately in case of emergency.
• Inspect the power cord, torch cable, grounding cable and
the torch itself often. Never use the machine if any of these
parts are damaged.
• Make sure the power supply line is fitted with an efficient
grounding socket.
• Plasma cutting equipment requires dangerous voltages to
strike the arc (approximately 250/350 V DC). It is therefore
recommended to take the following precautions during use.
• Never disable the safety devices on the torch and machine.
• If using the system for plasma cutting, always turn off the
machine before replacing the nozzle, isolating diffuser,
electrode or nozzle holder.
• Only screw the nozzle holder onto the head with the
electrode, the isolating diffuser and the nozzle mounted.
If these parts are not present, the machine will not
function properly and operator safety will be endangered.
9.2 RADIATION
• The ultraviolet radiation emitted by the arc may
harm eyes and burn the skin; it is therefore
recommended to wear the appropriate safety
garments and masks.
• Protect anyone around the cutting/welding area. The arc is
hazardous to a distance of up to 15 meters.
• Never look at the arc with your bare eyes!
• Prepare the cutting/welding area to reduce the reflection
and transmission of ultraviolet radiation by painting the walls
and other exposed surfaces black to decrease reflections,
and installing protective screens or curtains to reduce
transmitting ultraviolet rays.
• Do not wear contact lenses! The intense heat issued by the
arc could melt them to the cornea.
The shields and helmet masks provided are in compliance
with the European directive 89/686/CEE and satisfy European
requirements and standards. For your protection, read all of
the enclosed information carefully before using the screens
and masks. This information forms an integral part of
directive 89/686/CEE, enclosed in paragraph 1.4.
Make sure that the shield filter strength is appropriate to the
tasks to be carried out. This filter strength is indicated by a
progressive number that must be chosen based on the task
to be carried out.
9.3 FUMES
Cutting and welding produce hazardous fumes and
metal dust that may be hazardous to your health.
Therefore:
• Work only in adequately ventilated areas.
• Keep your head away from fumes.
• Use adequate ventilation systems in closed areas.
• Use approved respirators if the ventilation is not deemed
adequate.
• Clean the material to be cut/welded if any solvents or
halogen degreasers are present that may create toxic gases
during cutting/welding. Some chlorinated solvents may decompose in the presence of the radiation emitted by the arc,
and generate phosgene gases.
• Never cut/weld where solvent fumes are present or if the
radiant energy can penetrate atmospheres containing even
the slightest traces of trichloroethylene or perchloroethylene.
• Never cut/weld coated metals or those containing lead,
graphite, cadmium, zinc, chrome, mercury or beryllium if you
are not using an adequate respirator.
• The electric arc generates ozone. Prolonged exposure to
atmospheres containing high concentrations of ozone may
cause headaches, nasal, throat, and eye irritation, serious
congestion and chest pains.
Current (A)
Arc process
0,5
2,5
1
10
20
5
15
Manual metal arc welding
40
80
30
60
9
10
125
100
10
MIG (heavy metal*)
MIG (light metal)
10
TIG
9
10
11
10
MAG
11
Arc gouging
150
11
11
5
6
7
8
9
10
* The term "heavy metal" covers e.g. stainless steel and copper alloys.
11
12
275
250
350
300
12
12
11
12
12
12
13
13
14
13
11
11
4
225
200
10
Plasma cutting
Plasma welding
175
12
13
12
450
400
13
13
14
14
14
15
14
13
13
14
500
14
15
15
15
• IMPORTANT: NEVER USE OXYGEN FOR VENTILATION
PURPOSES.
9.4 FIRE
Avoid producing fire due to sparks and hot
scraps or incandescent pieces.
• Make sure that appropriate fire-fighting
devices are available near the cutting/welding area.
• Remove all flammable and combustible materials from the
cutting/welding area and its vicinity (at least 10 meters).
• Do not cut/weld on fuel and lubricate containers, even if
empty. They must be cleaned thoroughly before being cut/
welded.
• Let the cut/welded material cool before touching it or
placing it in contact with combustible or flammable material.
• Do not operate in atmospheres having high concentrations
of combustible fumes or flammable gases and dusts.
• Always check the work area half an hour after cutting to
make sure no fires have started.
• Never keep combustible items such as cigarette lighters or
matches in your pocket.
9.5 BURNS
• Protect your skin against burns from the ultraviolet radiation
emitted by the arc, sparks and scraps of molten metal by
wearing fireproof clothing that covers all exposed body
surfaces.
• Wear protective welder's garments/gloves, headgear and
high-top shoes with reinforced toes. Button your shirt collar
and pocket flaps, and wear trousers without cuffs to prevent
scraps and sparks from falling in them.
• Avoid oily or greasy garments. A single spark could set
them on fire.
• Incandescent metal parts such as pieces of electrode and
the workpiece must always be handled with gloves.
• First aid equipment and a qualified person must be
available for each working shift, unless there are health
facilities nearby for the emergency treatment of eye or skin
burns.
• Use earplugs when working overhead or in a small space.
Use a helmet when others are working above you.
• People getting ready to weld/cut must not use flammable
hair products.
• Wait for the torch to cool, then turn the machine off before
touching the front part of the torch.
• Plasma cutting machines have a pilot arc, thus the arc
strikes as soon as the torch trigger is pressed, even when
the earth cable is disconnected. You must therefore avoid
aiming the jet towards your body or towards the people
present in the cutting area.
• When you are finished cutting, always hang the torch on the
hook provided and turn off the machine to avoid accidentally
striking the plasma arc.
9.6 EXPLOSIONS
• Never cut/weld above or near containers under
pressure.
• Never cut/weld in atmospheres containing
explosive dust, gases or fumes.
• Plasma cutting machines run on compressed air. Take the
appropriate precautions if the air is drawn from cylinders.
Welding/cutting machines use gases such as CO2, ARGON,
or blends of ARGON + CO2 to protect the arc; you must
therefore take the utmost care with:
9.6.1 Cylinders
• Large gas leaks may dangerously affect the concentration
of oxygen.
• Never connect the cylinder directly to the machine: use a
pressure regulator.
• The intake pressure must never exceed 6 bar (0.6 MPa) for
plasma cutting machines, and 4 bar (0.4 MPa) for cutting/
welding machines.
• Always observe current regulations when handling or using
cylinders under pressure.
• Never use cylinders that leak or have been physically
damaged.
• Always fasten the cylinders in place.
• Never move cylinders without protecting the valve.
• Use only cylinders whose contents have been clearly
identified.
• Never use oil or grease to lubricate cylinder valves.
• Never place the plasma or welding arc in electrical contact
with the cylinder.
• Never expose the cylinders to excessive heat (greater than
50°C), sparks, molten scraps or flames.
• Never tamper with the cylinder valves.
• Never try to release jammed valves with hammers, wrenches
or other means.
• Never erase or alter the name, number or other markings
on the cylinders. This is both illegal and dangerous.
• Never lift the cylinders off the ground by grasping the valve
or cap, or by using chains, harnesses or magnets.
• Refill the cylinders at authorized centers only.
• The cylinder fittings must never be changed or switched.
9.6.2 Pressure regulators
• Keep pressure regulators in good condition.
• Never use a regulator that leaks or appears physically
damaged.
• Never use oil or grease to lubricate a regulator.
9.6.3 Air/gas hoses
• Replace any hoses that appear damaged.
• Keep hoses stretched taut to avoid creasing.
• Keep any excess hose coiled and away from the work area
to prevent it from being damaged.
9.7 MOVING PARTS
• Moving parts such as the fan may cut fingers and hands
and snag clothing.
• Only qualified personnel may remove guards and coverings
for maintenance, after first disconnecting the power cable.
• Replace all coverings and guards and close the doors when
the task is complete, and before starting the machine.
9.8 NOISE
This machine does not in itself produce noise
above 80 dB. The plasma cutting/welding procedure may produce noise levels above that limit; users
must therefore take all precautions required by law.
9.9 PACEMAKERS
Magnetic fields caused by high currents may affect the
operation of pacemakers. Wearers of any vital electronic
equipment (pacemakers) must consult their physician before
performing arc welding, cutting, deseaming or spot welding.
9.10 ELECTROMAGNETIC COMPATIBILITY
9.10.1General notes
This machine has been built in conformity with the instructions
of harmonized standard EN50199.
In this standard, the limits for electromagnetic emissions are
based on practical experience. However, the machine's
ability to function compatibly with other radio and electronic
systems depends largely on how it is used. The limits set
forth in the above standard may not be adequate to fully
eliminate interference when a receiving apparatus is located
in the immediate vicinity, or is highly sensitive. In these
cases it may be necessary to adopt special measures to
further reduce interference.
This machine must be used solely for professional purposes
in an industrial environment. Keep in mind that it is potentially
difficult to ensure electromagnetic compatibility in nonindustrial environments.
9.10.2Installation and use
The user is responsible for installing and using the cutting/
welding equipment according to the manufacturer's
instructions. If electromagnetic disturbances are detected,
then it shall be the responsibility of the user of the cutting/
welding equipment to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial
action may be as simple as grounding the cutting/welding
circuit, (see NOTE). In other cases, it could involve
constructing an electromagnetic screen enclosing the cutting/
welding power source and the work complete with associated
input filters. In all cases, electromagnetic disturbances shall
be reduced to the point where they are no longer troublesome.
Note: The cutting/welding circuit may or may not be grounded
for safety reasons. Changing the grounding arrangements
should only be authorized by a person who is competent to
assess whether the changes will increase the risk of injury,
e.g. by allowing parallel cutting/welding current return paths
which may damage the grounding circuits of other equipment.
Further guidance is given in IEC 974-13 "Arc welding
equipment - Installation and use" (under preparation).
9.10.3Assessing the area
Before installing cutting/welding equipment, the user shall
make an assessment of potential electromagnetic problems
in the surrounding area. The following shall be taken into
account:
a) other supply cables, control cables, signaling and telephone
cables located above, below and adjacent to the cutting/
welding equipment.
b) radio and television transmitters and receivers.
c) computer and other control equipment.
d) safety critical equipment, e.g. guarding of industrial
equipment.
e) the health of the people around, e.g. the use of pacemakers
and hearing aids.
f) equipment used for calibration or measurement.
g) the immunity of other equipment in the environment.
The user shall ensure that other equipment being used in the
environment is compatible. This may require additional
protection measures.
h) the time of day that cutting/welding or other activities are
to be carried out.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
9.10.4Methods of reducing emissions
- Mains power supply
The machine must be connected to the mains power supply
according to the manufacturer's instructions. If interference
occurs, it may be necessary to take additional precautions
such as filtering the mains power supply. Consideration
should also be given to shielding the supply cable in a
metallic conduit or equivalent. Shielding should be electrically
continuous throughout its length. The shielding must be
connected to the cutting/welding power source so that good
electrical contact is maintained between the conduit and the
cutting/welding power source enclosure.
- Maintenance of the cutting/welding equipment
The cutting/welding equipment should be routinely maintained
according to the manufacturer's recommendations. All access
and service doors and covers should be closed and properly
fastened while the machine is in operation. The cutting/
welding machine should not be modified in any way, except
for those changes and adjustments described in the
manufacturer's instructions. In particular, the spark gaps of
arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer's
recommendations.
- Welding and cutting cables
The cutting/welding cables must be kept as short as possible
and should be positioned close together, running at or close
to floor level.
- Equipotential bonding
Bonding of all metallic components in and adjacent to the
cutting/welding installation should be considered. However,
metallic components bonded to the workpiece will increase
the operator's risk of electric shock by touching these
metallic components and the electrode at the same time.
The operator should therefore be insulated from all such
bounded metallic components.
- Grounding the workpiece
If the workpiece is not grounded for electrical safety or due
to its size and position (for example, ship hulls or building
steel-work), a connection bonding the workpiece to earth
may reduce emissions in some but not all instances. Care
should be taken to prevent the grounding of the workpiece
from increasing the risk of injury to users, or damage to other
electrical equipment. Where necessary, the workpiece must
be grounded by means of a direct connection, while in some
countries where direct connections are not permitted, the
bonding may be achieved by suitable capacitance selected
according to national regulations.
- Shielding
Selective shielding of other cables and equipment present in
the surrounding area may alleviate problems of interference.
You may consider shielding the entire cutting/welding
installation for special applications.
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