Hobart Welding Products CHAMP 2060 manual Principal Safety Standards, EMF Information

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FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

D Use tongue jack or blocks to support weight.

DProperly install welding generator onto trailer according to instructions supplied with trailer.

READ INSTRUCTIONS.

D Use only genuine MILLER/Hobart replacement parts.

DPerform engine and air compressor (if applica- ble) maintenance and service according to this manual and the engine/air compressor (if appli- cable) manuals.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

DHave only qualified persons familiar with electronic equipment perform this installation.

DThe user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

DIf notified by the FCC about interference, stop using the equipment at once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

DElectromagnetic energy can interfere with sensitive electronic equipment such as micro- processors, computers, and computer-driven equipment such as robots.

DBe sure all equipment in the welding area is electromagnetically compatible.

DTo reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

DLocate welding operation 100 meters from any sensitive elec- tronic equipment.

DBe sure this welding machine is installed and grounded according to this manual.

DIf interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

1-6. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or

in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-7. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

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To reduce magnetic fields in the workplace, use the following procedures:

1.Keep cables close together by twisting or taping them.

2.Arrange cables to one side and away from the operator.

3.Do not coil or drape cables around your body.

4.Keep welding power source and cables as far away from operator as practical.

5.Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

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Contents Description OM-499Processes From Hobart to You Table of Contents Page Marks a special safety message Arc Welding HazardsElectric Shock can kill Fumes and Gases can be hazardousEngine Hazards Compressed Air Hazards Principal Safety Standards EMF InformationSignification des symboles Consignes DE Sécurité Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent Provoquer des brûlures graves’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSpecifications Symbol DefinitionsWeld, Power, And Engine Specifications Welding Weld Output Rated Maximum Generator PowerDimensions, Weights, And Operating Angles Fuel Consumption Kohler-Powered UnitsDo not move or operate unit where it Be damaged or unit could tipFuel Consumption Honda-Powered Units Exceeding duty cycle can damage unit and void warrantyDuty Cycle Continuous WeldingGenerator Power Curves Hz ModelVolt-Ampere Curves MAX MID MINGrounding Generator To Truck Or Trailer Frame InstallationInstalling Welding Generator Grounding Generator When Supplying Building Systems Engine Prestart Checks Kohler-Powered UnitsFuel OilConnect negative cable last Engine Prestart Checks Honda-Powered UnitsConnecting The Battery Electric-Start Models Only Connecting To Weld Output Terminals Selecting Weld Cable Sizes45 m 60 m 70 m 90 m 105 m 120 m Stop engine before50 Hz 60 Hz Controls Kohler-Powered UnitsOperating the Welding Generator 60 Hz 50 Hz Controls Honda-Powered Units See SectionRecoil-Start 2Electric-Start Description Of Controls Honda-Powered Units See Section 120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-499 Generator Power Panel 495 218 USAOperating Auxiliary Equipment Optional Generator Power Panels Generator Power Panel 495Canada-CSA South Africa South America Australia Europe AsiaGenerator Power Panel Ratings It exceeds 5500WMaintenance Maintenance LabelRoutine Maintenance 20 h50 h 100 hOverload Protection Honda-Powered Units Adjusting Engine Speed Kohler-Powered UnitsWeld/Power Speed Adjustment Idle Speed AdjustmentAdjusting Engine Speed Honda-Powered Units Throttle Control Lever Adjustment ScrewPilot Screw Throttle Stop Screw Stop engine. Close fuel valveTroubleshooting TroubleshootingGenerator Power WeldingCheck battery voltage electric-start models only Viscosity oil for operating temperatureEngine Circuit board PC1Electrical Diagrams Circuit Diagram For Welding Generator 1Circuit Diagram For Welding Generator 2 Wiring Diagram For Welding Generator Wiring Diagram For Auxiliary Power Panels 1 Wiring Diagram For Auxiliary Power Panels 2 Generator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Volts 115 Amps Resistive LoadApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesStick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc Tapping Technique Electrode and Amperage Selection ChartStriking an Arc Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 1.6 mm Tack WeldsTroubleshooting Porosity Troubleshooting Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting Excessive Penetration Troubleshooting Incomplete FusionTroubleshooting Lack Of Penetration Troubleshooting Distortion Troubleshooting Burn-ThroughTroubleshooting Waviness Of Bead Parts List Main AssemblyDia Part Dia Part Mkgs Description Quantity Generator Power Panels Item Dia Part Mkgs Description Quantity Service SupportContact your Distributor for Hobart Welding Products