11. MAINTENANCE & TROUBLESHOOTING
5. HEALTH AND SAFETY INFORMATION
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Sparks and molten metal can pass through gaps. Be aware that fire can start out of sight.
Flammables in a locked cabinet may not be safe.
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Do not weld pressurised containers.
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Do not weld tanks, drums or other vessels until they have been correctly cleaned/prepared for
welding.
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Always have appropriate and fully maintained fire fighting equipment suitable for the materials
used and for use in electrical environments available in close proximity at all times.
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Keep clothing free from oil and grease.
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Wear hat, flame-proof apron, woollen clothing, gloves, long sleeve tops with closed neck,
trousers (without turn-ups) to cover non-slip boots.
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Protective head and shoulder coverings should be worn when overhead welding.
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Avoid taking any fuels with you e.g. cigarette lighters or matches.
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Hot spots and their immediate surroundings should be observed until their temperature has
dropped to normal.
Personal Protection:
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The body should be protected by suitable clothing.
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The use of neck protection may be necessary against reflected radiation.
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Wear safety glasses when chipping, wire brushing, grinding or when near cooling welds as
metal filings or slag can be thrown up. Fully enclosed goggles are advisable.
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Arc machines generate a magnetic field which is detrimental to pacemaker recipients. Consult
your doctor before going near welding equipment/operations.
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The UV and IR radiation generated by welding is highly damaging to the eye, causing burns.
This can also affect the skin. Protect the eyes and face.
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The face and eyes shall be protected by suitable welding shields equipped with appropriate
ocular protection filters.
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Where environments are subject to pedestrians and traffic ensure a protective screen is used
to avoid accidental arc glare.
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Do not weld in the vicinity or children or animals and ensure no one is looking before striking
up.
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In the welding environment, damaging levels of noise can exist. Wear hearing protection if the
process dictates.
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Do not touch hot equipment or metal. Allow the weld time to cool, use the correct tool and
wear protective welding gauntlets.
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Wear flame retardant clothing (leather, wool, etc.).
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Take care when adjusting or maintaining the torch that it has had time to cool sufficiently and
is disconnected.
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The arc generates
• ultra-violet radiation (can damage skin and eyes);
• visible light (can dazzle eyes and impair vision);
• infra-red (heat) radiation (can damage skin and eyes);
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Such radiation can be direct or reflected from surfaces such as bright metals and light
coloured objects.
Trouble
Reason
Remedy
No welding
output
1. Connected power supply
incorrectly.
2. Power switch in off position.
1. Connect power supply according to
manufacturer’s instructions.
2. Place power switch in “on” position.
Trigger not
working
1. Trigger damaged.
2. Gun control wire broken.
3. Control wire plug loosen.
4. Mode switch in incorrect
position.
1. Replace trigger.
2. Connect again or replace if necessary.
3. Connect control wire plug again.
4. Place Mode switch in correct position.
Poor weld
1. Amperage too low
2. Weld time too short.
3. Input power cord did not meet
the requirement.
4. Ground clamp bad contact.
1. Increase amperage setting.
2. Increase time setting.
3. Replace input power cord.
4. Change ground clamp location.
Piercing
workpiece
1. Output amperage too high.
2. Weld time too long.
3. Bad contact of electrode tip or
washer with workpiece .
1. Reduce amperage setting.
2. Reduce weld time.
3. Remove coating from material reduce
added pressure.
Carbon rod
working unstable
1. Carbon rod or workpiece is
dirty.
2. Incorrect amperage and time
setting.
1. Polish carbon rod and workpieces.
2. Set amperage and time according to
workpiece thickness.
Unit stop working
while opration
1. Trigger plug loosen.
2. Gun control wire broken.
3. Over heating .
1. Check gun control wire and trigger
plug.
2. Wait for temperature cool down .
