MAGNATECH 427A, Operating & Maintenance Instruction Manual, Page: 4 / 113

OPERATING & MAINTENANCE INSTRUCTION MANUAL
MODELS 427A (R-1), 428A (R-2), AND 429A (R-3) WELD HEADS REV. AB
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY
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THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO
OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC
TABLE OF CONTENTS
1.0 TECHNICAL SUPPORT .................................................................................................................................. 1
2.0 MAGNATECH LIMITED WARRANTY FOR MODELS 427A, 428A & 429A .................................................. 2
2.1 Magnatech Product Warranty Registration .................................................................................................................. 3
3.0 REFERENCE DOCUMENTS........................................................................................................................... 4
3.1 Standards .................................................................................................................................................................... 4
3.2 Regulations (Repairs and Maintenance)...................................................................................................................... 4
4.0 SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF ARC WELDING EQUIPMENT ........... 5
4.1 Important Notice........................................................................................................................................................... 5
4.2 Owner/Operator Obligations ........................................................................................................................................ 5
4.2.1 Safety Precautions (General) ................................................................................................................................ 5
4.3 Shock Prevention ......................................................................................................................................................... 6
4.3.1 Installation and Grounding of Electrically Powered Equipment ............................................................................. 6
4.3.2 Torch and Work Cables......................................................................................................................................... 6
4.3.3 Power Source Output Terminals ........................................................................................................................... 6
4.3.4 Service and Maintenance ...................................................................................................................................... 7
4.3.5 Fuse and Circuit Breakers ..................................................................................................................................... 7
4.4 Burn Prevention ........................................................................................................................................................... 7
4.4.1 Protective Clothing ................................................................................................................................................ 7
4.4.1 Eye and Head Protection ...................................................................................................................................... 7
4.4.2 Hazards from Flying Sparks .................................................................................................................................. 7
4.5 Toxic Fume Prevention ................................................................................................................................................ 7
4.5.1 Weldments ............................................................................................................................................................ 8
4.5.2 Coated Weldments ................................................................................................................................................ 8
4.5.3 Vessels that have contained toxic materials ......................................................................................................... 8
4.5.4 Welding Area ......................................................................................................................................................... 8
4.6 Compressed Gas Cylinder Handling............................................................................................................................ 8
4.6.1 Cylinders ............................................................................................................................................................... 8
4.6.2 Pressure Regulators.............................................................................................................................................. 8
4.7 Equipment Warning Labels .......................................................................................................................................... 8
4.8 Inspection .................................................................................................................................................................... 8
4.9 Spares and Expendable Parts ..................................................................................................................................... 9
4.10 Safety Precautions in Normal Operation...................................................................................................................... 9
4.11 Turn Power Off Before Connecting/Disconnecting Cables .......................................................................................... 9
4.12 Always Stop Motors before Reversing ......................................................................................................................... 9
4.13 Abrasive Grinding Dust will Cause Premature Wear ................................................................................................... 9
4.14 Be Cautious About Heat Damage to Head .................................................................................................................. 9
4.15 Do Not Expose System to Rain ................................................................................................................................... 9
4.16 Check to ensure that Weld Head Rotation will not be obstructed ................................................................................ 9
5.0 SAFETY PRECAUTIONS.............................................................................................................................. 10
5.1 Symbol Usage............................................................................................................................................................ 10
5.1.1 Arc Welding Hazards........................................................................................................................................... 10
5.1.2 Electric Shock...................................................................................................................................................... 10
5.1.3 Hot Parts ............................................................................................................................................................. 12
5.1.4 Fumes and Gases ............................................................................................................................................... 12
5.1.5 Arc Rays .............................................................................................................................................................. 12
5.2 Welding ...................................................................................................................................................................... 13
5.2.1 Flying Metal or Dirt .............................................................................................................................................. 13
5.2.2 Buildup of Gas ..................................................................................................................................................... 14