Hobart Welding Products 4500 manual Symbol Usage, Arc Welding Hazards, Electric Shock can kill

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

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Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equip- ment is a hazard.

DDo not touch live electrical parts.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

DDo not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

DUse AC output ONLY if required for the welding process.

DIf AC output is required, use remote output control if present on unit.

DAdditional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoid- able or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

DDisconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

DProperly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

DAlways verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

DWhen making input connections, attach proper grounding conduc- tor first − double-check connections.

DKeep cords dry, free of oil and grease, and protected from hot metal and sparks.

DFrequently inspect input power cord for damage or bare wiring — replace cord immediately if damaged — bare wiring can kill.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DIf earth grounding of the workpiece is required, ground it directly with a separate cable.

DDo not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

DUse only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

DDo not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

DClamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

DInsulate work clamp when not connected to workpiece to prevent contact with any metal object.

DDo not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop- ping engine.

DStop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

D Allow cooling period before working on equip- ment.

DTo handle hot parts, use proper tools and/or wear heavy, insu- lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

DWelding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

DWear approved safety glasses with side shields even under your welding helmet.

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Contents Description OM-4418210 597KProcesses From Hobart to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peu- vent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peut Rendre AveugleRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique’EMPLOI Excessif peut UNE Remorque QUI Bascule peut entraîner des blessuresPrincipales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF En ce qui concerne les implants médicauxSymbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsAux Power Gal./Hr Weld Power In KW Dimensions, Weights, And Operating AnglesFuel Consumption Weld Amps At Rated Duty CycleAC Power Volts Generator Power CurveAC Power Amperes Duty CycleAC Amps Volt-Ampere CurvesVolts Max Amp Min Amp Installing Welding Generator − InstallationRating Label Location MovementGrounding Generator To Truck Or Trailer Frame Grounding Generator When Supplying Building SystemsOil Engine Prestart Checks13 mm Full Gasoline Open/On Closed/Off Connecting To Weld Output Terminals Selecting Weld Cable Sizes Connecting to weld150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mMaterial Thickness Reference Chart Controls See Section − Operating the Welding GeneratorAmperage Selection Table For Stick Smaw Electrodes To Stop turn engine switch to OffDescription Of Controls See Section − Operating Auxiliary Equipment Generator Power Panel ReceptaclesUse GFCI-protected extension cord X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418Routine Maintenance − MaintenanceStop engine Servicing Air CleanerTroubleshooting − TroubleshootingGenerator Power WeldingStarting difficult With proper viscosity oil for operating temperatureEngine Circuit Diagram For Welding Generator − Electrical DiagramsSelecting Equipment − Generator Power GuidelinesHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse #10 AWG or larger insulated Resistive Load Volts 115 AmpsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Main Assembly − Parts ListSR1 Start Your Professional Welding Career Now Assistance ServiceSupport Hobart Welding Products Contact your Distributor for
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