General Safety Considerations For Arc Welding; Residual Risks - Telwin MASTERMIG 300 Manuel D'instructions

ENGLISH

1. GENERAL SAFETY CONSIDERATIONS FOR ARC WELDING........................ 5

2. INTRODUCTION AND GENERAL DESCRIPTION............................................. 6
2.1 COMPACT WELDING MACHINE ................................................................. 6
2.2 WELDING MACHINE WITH REMOVABLE WIRE PULLER OR SEPARATE . 6
2.3 STANDARD ACCESSORIES ......................................................................... 6
2.4 OPTIONAL ACCESSORIES .......................................................................... 6
3. TECHNICAL DATA .............................................................................................. 6
3.1 DATA PLATE .................................................................................................. 6
3.2 OTHER TECHNICAL DATA ........................................................................... 6
4. DESCRIPTION OF THE WELDING MACHINE .................................................. 6
4.1 CONTROL, ADJUSTMENT AND CONNECTION DEVICES......................... 6
5. INSTALLATION ................................................................................................... 6
5.1 PREPARATION .............................................................................................. 6
5.1.1 Assembling the return cable-clamp ...................................................... 6
5.2 HOW TO LIFT THE WELDING MACHINE ..................................................... 6
5.2.1 CONNECTION TO THE MAIN POWER SUPPLY ................................ 6
5.2.2 PLUG AND OUTLET ............................................................................ 6
5.3 CONNECTION OF THE WELDING CABLES ................................................ 6
CONTINUOUS WIRE WELDING MACHINE FOR MIG/MAG AND FLUX ARC
WELDING DESIGNED FOR INDUSTRIAL AND PROFESSIONAL USE.
Note: In the following text the term "welding machine" will be used.
1. GENERAL SAFETY CONSIDERATIONS FOR ARC
WELDING
The operator should be properly trained to use the welding machine safely and
should be informed about the risks related to arc welding procedures, the
associated protection measures and emergency procedures.
(Refer also to the "IEC TECHNICAL SPECIFICATION or CLC/TS 62081":
INSTALLATION AND USE OF EQUIPMENT FOR ARC WELDING).
- Avoid direct contact with the welding circuit: the no-load voltage supplied by
the welding machine can be dangerous under certain circumstances.
- When the welding cables are being connected or checks and repairs are
carried out the welding machine should be switched off and disconnected
from the power supply outlet.
- Switch off the welding machine and disconnect it from the power supply outlet
before replacing consumable torch parts.
- Make the electrical connections and installation according to the safety rules
and legislation in force.
- The welding machine should be connected only and exclusively to a power
source with the neutral lead connected to earth.
- Make sure that the power supply plug is correctly connected to the earth
protection outlet.
- Do not use the welding machine in damp or wet places and do not weld in the
rain.
- Do not use cables with worn insulation or loose connections.
- If the welding machine has a liquid cooling unit the filling operations should be
carried out with the welding machine switched off and disconnected from the
power supply outlet.
- Do not weld on containers or piping that contains or has contained flammable
liquid or gaseous products.
- Do not operate on materials cleaned with chlorinated solvents or near such
substances.
- Do not weld on containers under pressure.
- Remove all flammable materials (e.g. wood, paper, rags etc.) from the working
area.
- Provide adequate ventilation or facilities for the removal of welding fumes
near the arc; a systematic approach is needed in evaluating the exposure
limits for the welding fumes, which will depend on their composition,
concentration and the length of exposure itself.
- Keep the gas bottle (if used) away from heat sources, including direct
sunlight.
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* )
- Use adequate electrical insulation with regard to the electrode, the work piece
and any (accessible) earthed metal parts in the vicinity.
This is normally achieved by wearing gloves, shoes, head coverings and
clothing designed for this purpose and by using insulating platforms or mats.
- Always protect your eyes using masks or helmets with special actinic glass.
Use special fire-resistant protective clothing and do not allow the skin to be
exposed to the ultraviolet and infrared rays produced by the arc; other people
in the vicinity of the arc should be protected by shields of non-reflecting
curtains.
- Noise level: If particularly intensive welding operations cause a personal daily
exposure level (LEPd) that is greater than or equal to 85db(A), the use of
suitable personal protectors is compulsory.
- The flow of the welding current generates electromagnetic fields (EMF) around
the welding circuit.
Electromagnetic fields can interfere with certain medical equipment (e.g. Pace-
makers, respiratory equipment, metallic prostheses etc.).
Adequate protective measures must be adopted for persons with these types of
medical apparatus. For example, they must be forbidden access to the area in
which welding machines are in operation.
This welding machine conforms to technical product standards for exclusive use
INDEX
pag.
5.3.1 Connection to the gas bottle................................................................. 6
5.3.2 Connecting the welding current return cable ........................................ 6
5.3.3 Connecting the torch ............................................................................ 6
5.3.4 Connection to the wire feeder (for model with
external wire feeder) ............................................................................. 6
5.3.5 Warnings............................................................................................... 6
5.3.6 Connection of G.R.A. -water-cooling unit -(only for R.A. version)......... 6
5.4 LOADING THE WIRE REEL .......................................................................... 6
6. WELDING: DESCRIPTION OF THE PROCEDURE............................................ 7
6.1 PRELIMINARY OPERATIONS....................................................................... 7
6.2 WELDING ..................................................................................................... 7
6.3 ALUMINIUM WELDING ................................................................................. 7
6.4 SPOT WELDING ........................................................................................... 7
6.5 RIVET WELDING .......................................................................................... 7
6.6 METAL SHEET HARDENING ....................................................................... 7
7. MAINTENANCE .................................................................................................. 7
7.1 ROUTINE MAINTENANCE............................................................................ 7
7.1.1 Torch ..................................................................................................... 7
7.1.2 Wire feeder ........................................................................................... 7
7.2 EXTRAORDINARY MAINTENANCE ............................................................. 7
in an industrial environment for professional purposes. It does not assure
compliance with the basic limits relative to human exposure to electromagnetic
fields in the domestic environment.
The operator must adopt the following procedures in order to reduce exposure to
electromagnetic fields:
- Fasten the two welding cables as close together as possible.
- Keep head and trunk as far away as possible from the welding circuit.
- Never wind welding cables around the body.
- Avoid welding with the body within the welding circuit. Keep both cables on the
same side of the body.
- Connect the welding current return cable to the piece being welded, as close
as possible to the welding joint.
- Do not weld while close to, sitting on or leaning against the welding machine
(keep at least 50 cm away from it).
- Do not leave objects in ferromagnetic material in proximity of the welding
circuit.
- Minimum distance d: 20 cm (Fig. N).
- Class A equipment:
This welding machine conforms to technical product standards for exclusive use
in an industrial environment and for professional purposes. It does not assure
compliance with electromagnetic compatibility in domestic dwellings and in
premises directly connected to a low-voltage power supply system feeding
buildings for domestic use.
EXTRA PRECAUTIONS
WELDING OPERATIONS:
- In environments with increased riskof electric shock;
- In confined spaces;
- In the presence of flammable or explosive materials;
MUST BE evaluated in advance by an "Expert supervisor" and must always be
carried out in the presence of other people trained to intervene in
emergencies.
Technical protection measures MUST BE taken as described in 5.10; A.7; A.9.
of the "IEC TECHNICAL SPECIFICATION or CLC/TS 62081".
- Welding MUST NOT be allowed if the welding machine or wire feeder is
supported by the operator (e.g. using belts).
- The operator MUST NOT BE ALLOWED to weld in raised positions unless
safety platforms are used.
- VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES: working with
more than one welding machine on a single piece or on pieces that are
connected electrically may generate a dangerous accumulation of no-load
voltage between two different electrode holders or torches, the value of which
may reach double the allowed limit.
An expert coordinator must use measuring instruments to determine the
existence of a risk and should take suitable protection measures as detailed in
5.9 of the "IEC TECHNICAL SPECIFICATION or CLC/TS 62081".

RESIDUAL RISKS

- OVERTURNING: position the welding machine on a horizontal surface that
is able to support the weight: otherwise (e.g. inclined or uneven floors etc.)
there is danger of overturning.
- IMPROPER USE: it is hazardous to use the welding machine for any work other
than that for which it was designed (e.g. de-icing mains water pipes).
- MOVING THE WELDING MACHINE: Always secure the gas bottle, taking
suitable precautions so that it cannot fall accidentally.
The safety guards and moving parts of the covering of the welding machine and
of the wire feeder should be in their proper positions before connecting the
welding machine to the power supply.
WARNING! Any manual operation carried out on the moving parts of the wire
feeder, for example:
- Replacing rollers and/or the wire guide;
- Inserting wire in the rollers;
- Loading the wire reel;
- Cleaning the rollers, the gears and the area underneath them;
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