ESAB EMP 255ic User manual

PART # 0463 617 001 © ESAB AB 2018
SERVICE MANUAL
MODEL EMP 255ic & EMP 320ic
Valid for: serial nos. 730-xxx-xxxx, 735-xxx-xxxx
Rights reserved to alter specifications without notice.

(Intentionally Blank)

CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar withthe
principles ofoperation and safepracticesfor arc welding andcutting equip ment, we urge
you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging," Form 52-529. See:
http://www.esabna.com/literature/precautions%20and%20safe%20practices%20for%20a
rc%20welding,%20cutting%20and%20gouging.pdf
Do NOT permit untrained persons to install, operate, ormaintain thisequipment. Do NOT
attempt to install or operate this equipment until you have read andfully understand
these instructions. If you donot fullyunderstand these instructions, contact your supplier
forfurther information. Be sure to read the Safety Precautions before installingor
operating this equipment.
This equipment will perform in conformity with its proper use when installed, operated,
maintained and repaired in accordance with the instructions provided. This equipment
must be checked periodically. Malfunctioning or poorly maintained equipment should not
be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the
manufacturer recommends that a request for service advice be made to the Authorized
Distributor from whom it was purchased. This equipment or any of its parts should not be
altered without the prior written approval of the manufacturer. The user of this
equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, improper repair or alteration by anyone
other than the manufacturer or a service facility designated by the manufacturer.
WARNING
Before use, read and understand the instruction and follow all
labels, employer’s safety practices and Safety Data Sheets.

1-1
SECTION TABLE OF CONTENTS
Paragraph Page
SECTION 1 WELCOME TO ESAB
1.1 HOW TO USE THIS MANUAL............................................................................1-11
1.2 EQUIPMENT IDENTIFICATION..........................................................................1-11
1.3 RECEIPT OF EQUIPMENT .................................................................................1-11
1.4 DESCRIPTION ..................................................................................................1-11
SECTION 2 SAFETY
2.1 MEANING OF SYMBOLS.....................................................................................2-1
2.1.1 SAFETY GUIDANCE AND INFORMATION ............................................................. 2-1
2.1.2 SAFETY PRECAUTIONS ......................................................................................... 2-1
2.1.3 FIRES AND EXPLOSIONS....................................................................................... 2-3
2.1.4 ELECTRICAL SHOCK.............................................................................................. 2-4
2.1.5 ELECTRIC AND MAGNETIC FIELDS ....................................................................... 2-4
2.1.6 FUMES AND GASES.............................................................................................. 2-5
2.1.7 CYLINDER HANDLING........................................................................................... 2-6
2.1.8 MOVING PARTS ................................................................................................... 2-7
2.1.9 MALFUNCTION .................................................................................................... 2-7
2.1.10 EQUIPMENT MAINTENANCE ............................................................................... 2-7
2.1.11 FALLING EQUPMENT ........................................................................................... 2-8
2.1.12 USER RESPONSIBILITY.......................................................................................... 2-9
2.2 ESD (ELECTROSTATIC DISCHARGE)...................................................................2-11
SECTION 3 INTRODUCTION
3.1 KEY FEATURES...................................................................................................3-1
3.2 EQUIPMENT ......................................................................................................3-1
3.2.1 EMP 255IC SERIES:............................................................................................... 3-1
3.2.2 EMP 320IC SERIES:............................................................................................... 3-1
SECTION 4 TECHNICAL SPECIFICATIONS
4.1 EMP 255IC SPECIFICATIONS...............................................................................4-1
4.2 EMP 320IC SPECIFICATIONS...............................................................................4-3
SECTION 5 INSTALLATION
5.1 LOCATION .........................................................................................................5-1
5.2 HIGH FREQUENCY INTERFERENCE .....................................................................5-2
5.3 LIFTING INSTRUCTIONS .....................................................................................5-4
5.4 MAINS SUPPLY ..................................................................................................5-4

1-2
SECTION TABLE OF CONTENTS
Paragraph Page
5.5 RECOMMENDED ELECTRICAL-SUPPLY SPECIFICATIONS .....................................5-6
5.6 SUPPLY FROM POWER GENERATORS ................................................................5-6
SECTION 6 OPERATION
6.1 USER CONNECTIONS AND CONTROLS................................................................6-2
6.2 CONNECTION OF WELDING AND RETURNCABLES .............................................6-3
6.2.1 FOR MIG/MMA PROCESS .................................................................................... 6-3
6.2.2 FOR TIG PROCESS................................................................................................. 6-3
6.3 POLARITY CHANGE ............................................................................................6-4
6.4 SHIELDING GAS..................................................................................................6-4
6.5 VOLT-AMPERE CURVES .....................................................................................6-4
6.5.1 MAW (Stick) 400 V............................................................................................... 6-5
6.5.2 GMAW (MIG) 400 V............................................................................................. 6-5
6.5.3 GTAW (TIG) 400 V................................................................................................ 6-6
6.6 DUTY CYCLE.......................................................................................................6-6
6.7 REMOVING/INSTALLING BOBBIN ......................................................................6-8
6.8 REMOVING/INSTALLINGWIRE.........................................................................6-10
6.8.1 REMOVING WIRE............................................................................................... 6-11
6.8.2 INSTALLLING WIRE............................................................................................. 6-14
6.9 WELDING WITH ALUMINUM WIRE..................................................................6-14
6.10 SETTING WIRE-FEEDPRESSURE........................................................................6-15
6.11 REMOVING/INSTALLING WIRE-FEEDROLLERS .................................................6-17
6.11.1 REMOVING WIRE-FEED ROLLERS ...................................................................... 6-17
6.11.2 INSTALLING WIRE-FEED ROLLERS...................................................................... 6-19
6.12 REMOVING/INSTALLING/ADJUSTING WIRE-GUIDES........................................6-20
6.12.1 OUTPUT WIRE-GUIDE REMOVAL/INSTALLATION.............................................. 6-22
6.12.2 CENTER WIRE-GUIDE REMOVAL/INSTALLATION............................................... 6-23
6.12.3 ADJUSTING WIRE GUIDES.................................................................................. 6-23
6.13 OVERHEATING PROTECTION............................................................................6-25
6.14 SHORT CIRCUIT PROTECTION WHILE WELDING ...............................................6-25
SECTION 7 CONTROL PANEL
7.1 HOW TO NAVIGATE...........................................................................................7-1
7.2 MAIN MENU......................................................................................................7-1
7.3 SMIG MODE: BASIC ...........................................................................................7-2
7.4 SMIG MODE: ADVANCED ..................................................................................7-2
7.5 MANUAL MIG MODE: BASIC..............................................................................7-2
7.6 MANUAL MIG MODE: ADVANCED.....................................................................7-3

1-3
SECTION TABLE OF CONTENTS
Paragraph Page
7.7 FLUX CORED WIRE MODE: BASIC.......................................................................7-3
7.8 FLUX CORED WIRE MODE: ADVANCED..............................................................7-3
7.9 MMA MODE: BASIC...........................................................................................7-4
7.10 MMA MODE: ADVANCED..................................................................................7-4
7.11 LIFT-TIG MODE: BASIC.......................................................................................7-4
7.12 LIFT-TIG MODE: ADVANCED ..............................................................................7-5
7.13 SETTINGS...........................................................................................................7-5
7.14 USER MANUAL INFORMATION..........................................................................7-5
7.15 ICON REFERENCE GUIDE ....................................................................................7-6
SECTION 8 MAINTENANCE
8.1 ROUTINE MAINTENANCE...................................................................................8-2
8.2 WIRE-SIDE MAINTENANCE................................................................................8-3
8.2.1 WIRE-FEEDER ASSEMBLY CLEANING ................................................................... 8-3
8.3 EMP-UNIT POWER-SIDE MAINTENANCE............................................................8-6
8.4 TORCH LINER MAINTENANCE............................................................................8-6
8.4.1 TORCH LINER CLEANING...................................................................................... 8-7
SECTION 9 TROUBLESHOOTING
9.1 PRELIMINARY CHECKS.......................................................................................9-1
9.2 USING GENERATORS OR EXTENSION CORDS .....................................................9-3
9.3 INTERCONNECTIONS .........................................................................................9-3
9.4 WIRE-FEED PROBLEMS ......................................................................................9-3
9.5 USER INTERFACE (UI) SOFTWARE-DISPLAYED FAULT CODES..............................9-4
9.6 THE POWER SOURCE SIDE .................................................................................9-6
9.7 DESIGN OF THE POWER SOURCE .......................................................................9-6
9.7.1 UI.......................................................................................................................... 9-7
9.7.2 Main Power Switch............................................................................................ 9-10
9.7.3 EMI Filter Board................................................................................................. 9-11
9.7.4 Main Power Board............................................................................................. 9-13
9.7.5 Internal Power Supply (IPS) Board .................................................................... 9-18
9.7.6 Control Board .................................................................................................... 9-21
9.7.6.1 DIP Switch Settings ......................................................................................... 9-23
9.7.7 Main Transformer.............................................................................................. 9-26
9.7.8 Output Diode Assembly..................................................................................... 9-28
9.7.9 Output Inductor................................................................................................. 9-30
9.7.10 Current Sensor................................................................................................... 9-32
9.7.11 Cooling Fans....................................................................................................... 9-33

1-4
SECTION TABLE OF CONTENTS
Paragraph Page
9.7.12 OKC Capacitor Board ......................................................................................... 9-34
9.7.13 Gas Valves.......................................................................................................... 9-35
9.8 TESTING PROCEDURES ....................................................................................9-36
9.8.1 Initial Set up conditions..................................................................................... 9-36
9.8.2 Power-UP Procedure ......................................................................................... 9-37
9.9 POWER UP FAULTS..........................................................................................9-39
9.9.1 Mains Power fuses blow/ breaker trips when SW1 is turned on:..................... 9-39
9.9.2 Unit is completely inactive, front panel display is off, no output voltage. ....... 9-39
9.10 SMAW PROCESS TEST......................................................................................9-41
9.10.1 SMAW Process Test: LED status ........................................................................ 9-41
9.10.2 SMAW Process Test Problems........................................................................... 9-42
9.11 GTAW LIFT TIG PROCESS TEST .........................................................................9-43
9.11.1 GTAW LIFT TIG Process Test: LED status ........................................................... 9-43
9.11.2 GTAW LIFT TIG Process Test Problems.............................................................. 9-44
9.12 GMAW MIG PROCESS TEST .............................................................................9-45
9.12.1 GMAW Process Test: LED status ....................................................................... 9-45
9.12.2 GMAW Process Test Problems.......................................................................... 9-45
9.13 COMPONENT, SUB-ASSEMBLY TESTS ..............................................................9-48
9.13.1 Power Cord/Plug, Power Switch, and EMI Board Test...................................... 9-48
9.13.2 Primary Rectifier Test ........................................................................................ 9-49
9.13.2.1 BR1, BR2 Test Procedure................................................................................ 9-51
9.13.3 IPS Board Test.................................................................................................... 9-53
9.13.4 Main Power Board Test ..................................................................................... 9-54
9.13.5 Control Board Test............................................................................................. 9-58
9.13.6 UI Board Test ..................................................................................................... 9-60
9.13.7 Output Diode Board Test................................................................................... 9-61
9.13.8 Current Sensor Test........................................................................................... 9-62
9.13.9 Remote Control Trigger Test ............................................................................. 9-63
9.14 CALIBRATION ..................................................................................................9-64
SECTION 10 ORDERING SPARE PARTS
10.1 SPARE PARTS...................................................................................................10-1
10.2 WEAR PARTS...................................................................................................10-3
10.3 ACCESSORIES...................................................................................................10-4
10.4 REPLACEMENTS PARTS....................................................................................10-5

1-5
SECTION LIST OF FIGURES
Figure Page
Figure 2-1. Danger and Warning Symbols............................................................................... 2-1
Figure 5-1. Minimum Safe Clearances .................................................................................... 5-1
Figure 5-2. Lifting lustrated..................................................................................................... 5-4
Figure 5-3. Sloping Ground ..................................................................................................... 5-4
Figure 5-4. Rating plate (1) with supply connection data....................................................... 5-6
Figure 6-1. Front & Rear Views: Model EMP255ic & EMP320ic ............................................. 6-2
Figure 6-2. Function of User Interface Control Dials .............................................................. 6-3
Figure 6-3. SMAW (Stick) V-A Curve ....................................................................................... 6-5
Figure 6-4. GMAW (MIG) V-A Curve ....................................................................................... 6-5
Figure 6-5. GTAW (TIG) V-A Curve .......................................................................................... 6-6
Figure 6-6. Example of 40% Duty Cycle................................................................................... 6-7
Figure 6-7. Plotting Duty Cycle Selection ................................................................................ 6-7
Figure 6-8. Tightening the Bobbin Locking Nut (A) for 100 mm (4 in.) Spool......................... 6-8
Figure 6-9. Tightening the Bobbin Locking Nut (A) for 200 mm (8 in.), 300 mm (12 in.) ....... 6-9
Figure 6-10. View of Wire-Bobbin-Side................................................................................. 6-10
Figure 6-11. Wire-Bobbin Side Exposed View....................................................................... 6-11
Figure 6-12. Tension Scale on Tension Arm of Wire-Feed Assembly.................................... 6-12
Figure 6-13. Wire-Feed Mechanism...................................................................................... 6-12
Figure 6-14. Checking Feed-Roller Slip.................................................................................. 6-16
Figure 6-15. Checking Feed-Roller Pressure ......................................................................... 6-16
Figure 6-16. Drive Gear with Woodruff Key on Motor Shaft................................................ 6-18
Figure 6-17. Feed Roller Removal and Installation ............................................................... 6-18
Figure 6-18. Wire-Feed Rollers Offered in Multiple Sizes..................................................... 6-19
Figure 6-19. Wire Guides....................................................................................................... 6-21
Figure 6-20. Location of Guides and Set Screws................................................................... 6-22
Figure 6-21. Verify Clearance of Both Guide Tubes.............................................................. 6-24
Figure 8-1. Relevant Wire-Feed Assembly Parts Location ...................................................... 8-3
Figure 8-2. Wire-Feed & Pressure-Roller Locations................................................................ 8-4
Figure 8-3. Tension Scale on Tension Arm of Wire-Feed Assembly........................................ 8-4
Figure 9-1. Power Side Functional Diagram............................................................................ 9-6
Figure 9-2. Power Side Exposed.............................................................................................. 9-7
Figure 9-3. User Interface (UI)................................................................................................. 9-8

1-6
SECTION LIST OF FIGURES
Figure Page
Figure 9-4. Connector Location on UI board........................................................................... 9-8
Figure 9-5. UI Structure........................................................................................................... 9-9
Figure 9-6. Location of Mounting Screws for UI ..................................................................... 9-9
Figure 9-7. Main Power Switch Functional Location............................................................. 9-10
Figure 9-8. Main Power Switch Connection Labels............................................................... 9-10
Figure 9-9. Main Power Switch ............................................................................................. 9-11
Figure 9-10. Location of EMI Filter Board ............................................................................. 9-11
Figure 9-11. EMI Filter Board Map........................................................................................ 9-12
Figure 9-12. EMI Filter Functional Location .......................................................................... 9-12
Figure 9-13. EMI Board Disassembly..................................................................................... 9-13
Figure 9-14. Location of Main Power Board ......................................................................... 9-14
Figure 9-15. Location of Primary Rectifier, BR1, BR2............................................................ 9-14
Figure 9-16. Main Power Board Map.................................................................................... 9-15
Figure 9-17. Main Power Board Functional Location............................................................ 9-16
Figure 9-18. Heat Sink Support Bracket ................................................................................ 9-17
Figure 9-19. Main Power Supply Board Disassembly............................................................ 9-17
Figure 9-20. Location of Internal Power Supply (IPS) Board................................................. 9-18
Figure 9-21. Internal Power Supply (IPS) Board Map ........................................................... 9-19
Figure 9-22. ISP Board Functional Location .......................................................................... 9-20
Figure 9-23. IPS Board Disassembly ...................................................................................... 9-20
Figure 9-24. Location of Control Board................................................................................. 9-21
Figure 9-25. Control Board LED Locations............................................................................. 9-22
Figure 9-26. DIP Switch Settings on Control Board............................................................... 9-23
Figure 9-27. Control Board Functional Location ................................................................... 9-24
Figure 9-28. Control Board Connector Locations.................................................................. 9-25
Figure 9-29. Control Board Disassembly............................................................................... 9-26
Figure 9-30. Location of Main Transformer .......................................................................... 9-27
Figure 9-31. Main Transformer Functional Location ............................................................ 9-27
Figure 9-32. Location of Output Diode Assembly ................................................................. 9-28
Figure 9-33. Map of Output Diode Board ............................................................................. 9-29
Figure 9-34. Output Diode Assembly Functional Location ................................................... 9-29
Figure 9-35. Output Diode Board Disassembly..................................................................... 9-30

1-7
SECTION LIST OF FIGURES
Figure Page
Figure 9-36. Location of Output Inductor ............................................................................. 9-31
Figure 9-37. Output Inductor Functional Location ............................................................... 9-31
Figure 9-38. Location of Current Sensor ............................................................................... 9-32
Figure 9-39. Current Sensor Functional Location ................................................................. 9-32
Figure 9-40. Location of Cooling Fans ................................................................................... 9-33
Figure 9-41. Cooling Fans Functional Location ..................................................................... 9-33
Figure 9-42. Location of OKC Filter Cap Board...................................................................... 9-34
Figure 9-43. OKC Cap Board Functional Location ................................................................. 9-34
Figure 9-44. Gas Valves ......................................................................................................... 9-35
Figure 9-45. Power-Side Cover Removal............................................................................... 9-36
Figure 9-46. Control Board LED Locations............................................................................. 9-38
Figure 9-47. Test Points for Control Board CN10.................................................................. 9-46
Figure 9-48. Test Points for Control Board CN13.................................................................. 9-46
Figure 9-49 Test Points on IPS Board for Continuity to Plug Blades .................................... 9-48
Figure 9-50. Test Point Schematic for Continuity ................................................................. 9-49
Figure 9-51. Location of BR 1 and BR 2 on Main Power Board............................................. 9-49
Figure 9-52. Pin Identification for BR1, BR2.......................................................................... 9-50
Figure 9-53. Schematic of BR1 or BR2................................................................................... 9-51
Figure 9-54. Terminal Identification of BR 1, BR 2................................................................ 9-52
Figure 9-55. IPS Board Test Points ........................................................................................ 9-53
Figure 9-56. Location of VR1 on Main Power Board............................................................. 9-54
Figure 9-57. Test Points for Rl79, RY1................................................................................... 9-55
Figure 9-58. Test Points for C70, C72, C400.......................................................................... 9-56
Figure 9-59. Test Points for Q3, Q4, Q6, Q7.......................................................................... 9-57
Figure 9-60. SW2 Switch Positions........................................................................................ 9-58
Figure 9-61. Test Points for Control Board CN19.................................................................. 9-58
Figure 9-62. Test Points for Control Board CN13.................................................................. 9-59
Figure 9-63. CN10 Test Points............................................................................................... 9-59
Figure 9-64. UI to Control Board Connection Locations ....................................................... 9-61
Figure 9-65. Diode Output Test Procedure Illustrated ......................................................... 9-62
Figure 9-66. CN18 Test Points ............................................................................................... 9-62
Figure 9-67. Remote Control Connector, J1 Pinout Diagram................................................ 9-63

1-8
SECTION LIST OF FIGURES
Figure Page
Figure 10-1. Unit-Part Example............................................................................................. 10-2
Figure 10-2. Wire-Feed Assembly, Wear-Parts..................................................................... 10-3

1-9
SECTION LIST OF TABLES
Table Page
Table 4-1. Specifications for EMP 255ic.................................................................................. 4-1
Table 4-2. Specifications for EMP 320ic.................................................................................. 4-3
Table 5-1. Recommended Electrical-Supply Specifications: 400V ± 10%, 3 ɸ, 50/60 Hz ....... 5-6
Table 8-1. Maintenance Schedule During Normal Conditions................................................ 8-2
Table 9-1. Table of Faults ........................................................................................................ 9-1
Table 9-2. UI Fault Codes ........................................................................................................ 9-4
Table 9-3. Control Board LED Meanings ............................................................................... 9-23
Table 9-4. BR1, BR2 Test Procedure...................................................................................... 9-52
Table 10-1. Unit Part Numbers ............................................................................................. 10-2
Table 10-2. Reference for Figure 9-2 Wire-Feed Assembly, Wear-Parts.............................. 10-3
Table 10-3. Accessories......................................................................................................... 10-4
Table 10-4. Replacement Parts ............................................................................................. 10-5

1-10
APPENDIX TABLE OF CONTENTS
Paragraph Page
DIAGRAMS
A.1 FUNCTIONAL BLOCK DIAGRAM ........................................................................ A-1
SCHEMATIC
B.1 255, 320 SCHEMATIC, PAGE 1 OF 2...................ERROR! BOOKMARK NOT DEFINED.
B.2 255, 320 SCHEMATIC, PAGE 2 OF 2...................ERROR! BOOKMARK NOT DEFINED.
Lift-TIG Welding
C.1 2-STROKE AND 4-STROKE WELDING PROCESS ILLUSTRATED..............................C-1
Roller & Wire-Guide Selection
D.1 ROLLER SELECTION........................................................................................... D-1
D.2 WIRE-GUIDE SELECTION ................................................................................... D-1
GLOSSARY

1-11
SECTION 1 WELCOME TO ESAB
1.1 HOW TO USE THIS MANUAL
To ensure safe operation, read the entire manual, including the section on safety instructions
and warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay attention
to the information provided under these headings.
1.2 EQUIPMENT IDENTIFICATION
The unit's identification number (specification or part number), model, and serial number
usually appear on a data tag attached to the rear panel. Equipment which does not have a data
tag such as torch and cable assemblies are identified only by the specification or part number
printed on a loosely attached card or the shipping container. Record these numbers on this
book for future reference.
1.3 RECEIPT OF EQUIPMENT
When you receive the equipment, check it against the invoice to make sure it is complete and
inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim.
1.4 DESCRIPTION
The ESAB EMP 255ic and the EMP 320ic are 400V, 3 ɸ, 50/60 Hz, constant current welding
capable of performing SMAW (STICK), GTAW (HF TIG) and GTAW (LIFT TIG) welding processes
and constant voltage welding capable of performing GMAW (MIG) welding processes. The unit
is equipped with amperage and voltage meters which display on its User Interface during
welding. A host of other features display to satisfy the broad operating needs of the user.
The ESAB EMP 255ic and the EMP 320ic provide excellent welding performance across a broad
range of applications when used with the correct welding consumables and procedures. The
following instructions detail how to correctly and safely set up the machine and give guidelines
on gaining the best efficiency and quality from the Power Source. Please read these instructions
thoroughly before using the unit.
Additional copies of this manual may be purchased by contacting ESAB. Include the Owner's
Manual number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by
going to the ESAB web site: http://www.esab.com.

SAFETY
2-1
SECTION 2 SAFETY
2.1 MEANING OF SYMBOLS
As used throughout this manual: Means Attention! Be Alert!
Figure 2-1. Danger and Warning Symbols
2.1.1 SAFETY GUIDANCE AND INFORMATION
These Safety Precautions are for your protection. They summarize precautionary information
listed throughout this manual. Before performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below as well as all other manuals,
material safety data sheets, labels, etc. Failure to observe the Safety Precautions could result in
injury or death.
2.1.2 SAFETY PRECAUTIONS
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must
DANGER
Means immediate hazards which, if not avoided,
will result in immediate, serious personal injury or
loss of life.
WARNING
Means potential hazards which could result in
personal injury or loss of life.
CAUTION
Means hazards which could result in minor
personal injury.
WARNING
Before use, read and understand the instruction and follow all
labels, employer’s safety practices and Safety Data Sheets.

SAFETY
2-2
meet the requirements that apply to this type of equipment. The following recommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. INCORRECT OPERATION OF THE EQUIPMENT MAY LEAD TO HAZARDOUS
SITUATIONS WHICH CAN RESULT IN INJURY TO THE OPERATOR AND DAMAGE TO THE
EQUIPMENT.
1. Anyone who uses the equipment must be familiar with:
its operation
location of emergency stops
its function
relevant safety precautions
welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
no unauthorized person is stationed within the working area of the equipment when
it is started up
no-one is unprotected when the arc is struck, or work is started with the equipment
3. The workplace must:
be suitable for the purpose
be free from drafts
4. Personal safety equipment:
Always wear recommended personal safety equipment, such as safety glasses, flame-
proof clothing, safety gloves
Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns
5. General precautions:
Use side shields in any work area, even if welding helmets, face shields and/or goggles
are also required.
Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuff-less pants, high-
topped shoes, and a welding helmet or cap for personal protection. A flameproof
apron may also be desirable as additional protection against radiated heat and
sparks.

SAFETY
2-3
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned (closed) and open pockets should be
eliminated from the front of the clothing.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains. Post warning signs advising others not to watch the welding
arc or be in direct exposure to the active arc without proper protection.
Use goggles or face shields over safety glasses when chipping slag or grinding.
Chipped slag may be hot and can fly for long distances. Bystanders should also wear
goggles over safety glasses.
2.1.3 FIRES AND EXPLOSIONS
Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Remove all combustible materials well away from the work area or cover the
materials with an approved protective non-flammable covering. Combustible
materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints, and
coating paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that
such openings are protected from hot sparks and metal.
4. Follow the "hot work" procedures for the location. This can include a fire watch
person who monitors the sparks during the work, the requirement for a formal work
permit and the surveillance of the scene for an extended period of time to ensure no
smoldering fires are developing.
5. Do not weld, cut, or perform other hot work until the work piece has been
completely cleaned so that there are no substances on or in the work piece which
might produce flammable or toxic vapors. Do not perform hot work on closed
containers, they may explode.
6. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
7. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
FIRE HAZARD - Sparks (spatter) can cause fire.

SAFETY
2-4
8. After completing work, inspect the work area to make sure there are no hot sparks
or hot metal that could cause a fire later. Use fire watchers when necessary.
2.1.4 ELECTRICAL SHOCK
Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the
input power. All ground points should be verified with periodic testing by an
electrician.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder
and power source.
6. Make sure that all parts of your body are insulated from both the work piece and
from the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a
damp area; stand on an effective insulation layer, such as dry boards, an insulating
platform, and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power, before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for an earth cable.
2.1.5 ELECTRIC AND MAGNETIC FIELDS
Therefore:
ELECTRIC SHOCK - Can kill
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

SAFETY
2-5
1. Welders with medical pacemakers fitted should consult their doctor before welding.
EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
a. Route the electrode and work cables together. Secure them with tape when
possible.
b. Never coil the torch or work cable around your body.
c. Do not place your body between the torch and work cables. Route cables
together on the same side of your body.
d. Connect the work cable to the workpiece as close as possible to the area being
welded.
e. Keep the welding power source and cables as far away from your body as
possible.
2.1.6 FUMES AND GASES
Therefore:
1. Keep your head out of the fumes, smoke, and vapors. Do not breathe the smoke,
fumes, and gases that are generated by welding processes. Always provide
adequate ventilation in the work area by natural or mechanical means.
2. Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
3. Orient the ventilation to draw smoke, fumes, and vapors in a direction away from
the welding operator. Position ventilation suction to pull welding fumes and smoke
from the far side of the work area if possible.
4. Provide general ventilation for the surrounding work area if there is a risk of workers
or other persons beyond the immediate work area getting exposed to significant
welding fumes. Monitor the fugitive fumes and smoke for potential collateral
exposures. Install appropriate ventilation controls or cease surrounding activity if
fumes become an exposure issue outside of the immediate work area
FUMES AND GASES - Can be dangerous to health