Lincoln Electric IM723-A User's Manual
Contents
1. BUM ejqiDejr si eui sjeued eunsoj oue y euo uo eui episui pejsed si epoo 1ejnonuaed 104 oyioeds siy Aq seulyoeU jou 104 SI SIUL LON 4616 UNDER COOLER CART LINCOLN E NOTES UNDER COOLER CART LINCOLN NOTES UNDER COOLER CART LINCOLN NOTES UNDER COOLER CART LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektr2. for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form a
3. Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie dicus LES MACHINES SOU
4. up Clean the heat exchanger periodically using a vacuum hose or a low pressure air line Avoid placing the unit near a flux hopper or a flux waste container A clean heat exchanger offers better cooling perfor mance and longer product life In extremely dirty environments it may be necessary to remove the heat exchanger completely from the cooler and clean the fins with soap and water Use care to avoid damaging the fins UNDER COOLER CART LINCOLN D 2 MAINTENANCE D 2 RESERVOIR COOLANT LEVEL The reservoir volume should be checked daily before using the cooler Remove the reservoir fill cap and check the coolant level The reservoir is full when the coolant level is just below the input elbow of the reser voir approximate 2 Gal 7 6 ltrs Keep the reservoir full especially after disconnecting the water lines or changing the accessory being cooled COOLANT TREATMENT RECOMMENDATION This procedure is intended to provide a means of reducing the objectionable amount of fungal and bac terial contamination that has occurred in Under Cooler cart water coolers and cooling systems Limitations This additive should be used with fresh coolants con taining only pure water This additive should not be used with coolants con taining any other substance including antifreeze substances No other additives shall be used with the specified coolant that has been treated with the recommended additive This proce
5. Immersion in water around electrical lines can cause electrical shock Moving parts can injure Never place fingers into openings of Cooler Unplug the cooler and remove water hoses to remove drawer from the cabinet for mainte nance purposes A jumper hose between the coolant in and out connections should be installed to avoid excessive loss of coolant in the system Never operate the cooler with the reservoir fill cap off Hot coolant can burn skin Always be sure coolant is NOT HOT before servicing the cooler Do not pour used ethylene glycol coolant down the drain Do not remove the pump relief valve s 3 4 hex nut or attempt to adjust the relief valve setting See additional warning information at front of this operator s manual GENERAL DESCRIPTION The Under Cooler cart is an internal type re circula tion cooling system designed for use with water cooled TIG torches The coolant IN and OUT con nections are 5 8 18 left hand female threads which match the standard connector nut of domestic water hoses CGA style and water cooled TIG torches The Under Cooler cart can either run with the cooler as needed circuit which operates in conjunction with the TIG machine fan or continuously powered on and off with the TIG machine power switch The overall size and shape of the Under Cooler cart is designed for mounting the Precision TIG 275 375 machine on top The Under Cooler cart plugs into a 115 V powe
6. Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles
7. 59262 62 1 2 Plain Washer 2 25 O D E106A 15 1 2 Lock Washer CF000027 1 2 13 Hex Nut UNDER COOLER CART LINCOLN 5 INSTALLATION 5 FASTENER QUICK REFERENCE FULL SCALE SEE FIGURE A 2 Assembly for fastener placement 9 11 12 10 CONNECTION TIG TORCHES Installation of TIG torches to be used with this Precision TIG Under Cooler cart is explained in the Precision TIG machine literature The torch does not directly attach to the cooler but through a connection box mounted on the TIG machine UNDER COOLER CART LINCOLN 5 1 OPERATION B 1 SAFETY PRECAUTIONS A WARNING e ELECTRIC SHOCK can kill Disconnect input power by remov ing plug from receptacle before working inside Cooler Do not operate with covers removed Use only grounded receptacle Do not remove the power cord ground prong Do not touch electrically hot parts inside Cooler Have qualified personnel do the installation maintenance and troubleshooting work Never operate the cooler with the cooler drawer opened except to temporarily check coolant flow in the reservoir Unplug the cooler before performing general maintenance without removing drawer High voltage typical of welding operations can kill
8. a Precision TIG machine Assembly 1 Lift the Precision TIG machine approximately 24 610mm off the floor using the lift bale Lower onto the Under Cooler cart aligning holes in the TIG base with the two pins on each side of the Under Cooler cart roof 2 Fasten the case sides of the Under Cooler cart to the TIG machine base using items 4 through 7 in the 4 locations shown Washer lock washer and nut in that order are to be inside machine base flange with the head of the bolt on the outside of the Under Cooler cart case side 3 Remove 4 5 16 18 X 625 long screws from the front of the machine and discard Mount handle with the 4 remaining item 4 screws 4 Lay the upper cylinder support and hook assembly on top of the rear baffle and filler rod holder aligning the top holes Fasten in 4 places with item 8 screws as shown 5 Add items 9 through 12 to the lift bale as shown to prevent use of the lift bale with when gas bottles have been loaded See figure A 2 below UO 8 FIGURE 2 K1828 1 Under Cooler Cart Installation Instructions Description Req d Under Cooler Cart M19767 Upper Cylinder Support and Hook Assembly L11682 9225 47 Handle 5 16 18 x 1 50 Thread Forming Screw CF000029 5 16 18 Hex Nut E106A 14 5 16 Lock Washer 59262 121 5 16 Plain Washer 9225 68 1 4 20 x 50 Thread Forming Screw CF000030 1 2 13 x 1 25 Hex Head Cap Screw
9. are identified in equipment instruc tion manuals refer to specific Power Source machine manual and Under Cooler cart IM723 Drain the cooling system of contaminated coolant Do not reuse this coolant e f system contained an antifreeze based coolant rinse the cooling system until it is clear of antifreeze solution Service the cooler Always unplug the cooler and remove hoses con nected to the TIG machine Remove the cooler drawer for thorough cleaning and disinfecting of sys tem Independently flush out the welding accessories of debris if necessary Mechanically clean out the cooler including reser voir of debris if necessary Power washing may be useful Clean or replace the pump s inlet strainer as required UNDER COOLER CART LINCOLN D 3 MAINTENANCE D 3 Disinfect the cooling system Prepare the disinfectant Make a quantity of only is needed to avoid an excess Bulk preparation for coolers serviced in quantity 2 325 gals 8 775 liters of pure fresh water per cooler 1 625 ml of additive per cooler Example for 100 coolers add 162 5 ml to 232 5 gals of pure fresh water Pour 2 0 gals 7 55 liters of disinfectant into the empty reservoir Recap the reservoir tape over the air vent in the cap roll disinfectant around the inside the reservoir to thoroughly coat all of its surfaces Remove the tape from the reservoir cap Prime the cooling system and circulate disinfec
10. ening strainers 7 8 acorn nut Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head See figure 3A c Inspect strainer for damage or excessive clogging Replace or Gently rinse strainer under running water to thoroughly clean it d Use a mirror to inspect inside of pump for contami nation If hardened debris is present and interferes with filter seating carefully remove it with dental pick without scratching inside of the pump Use care not to drop debris into pump e Reinstall strainer and acorn nut tighten to 75 in Ibs 8 5N m of torque Hold pump head to apply counter torque when loosening strainers 7 8 acorn nut f Wipe dry all areas wetted by coolant Dispose of towels in an environmentally responsible manner Add coolant Add 2 Gal 7 6 ltrs of coolant either the recom mendations off the water cooled accessory or if none see the design specification summary listed in this manual ADDITIONAL SERVICE NOTES Always use a back up wrench on pump head when loosening or tightening pump fittings Never run the pump dry Always use ed coolant otherwise pump damage may result Flush coolant from system and replace with fresh recommended coolant at least once a year More frequent flushing may be necessary depending upon the user s particular system or its usage especially if it is prone to clogging from biological growth in
11. illai aui Qui al gll Gail ag ls LINCOLN B e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
12. plug the unit into 115V NEMA electrical receptacle for start up operation Be certain that the power input into the unit matches the Cooler s rated input The following should always be observed when operating the Under Cooler Cart Check the coolant reservoir level daily Keep the reservoir full especially after changing any water lines The cooler should turn on as soon as an arc 15 struck and remain on approximately 8 min after welding is stopped Be certain that the cooler is ON by checking the flow under the fill cap e Never operate the cooler with the reservoir fill cap removed after checking the flow Avoid placing the Under Cooler Cart and Welder near a flux hopper or an area where dust build up is extreme Avoid kinking or putting sharp bends in any water lines Keep all water lines clean and free of any block age Do not operate cooler without coolant in reser voir Never run pump dry Never lift the Precision by its lift bale once the under cooler cart has been installed Never lift the Precision TIG and Under Cooler cart by its handle You will be able to hear the fan running and feel air flow out of the back of the unit when the cooler is operating The cooler will run continuously unless it is plugged into the switched receptacle on the power source bottom 115V receptacle The coolant FLOW INDICATOR is accessed by removal of the fill cap Actual retu
13. Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret
14. CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU e Fat ie es zzv 24758 else SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine
15. DER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93
16. IBITORS OR LEAK STOP PERS When adding coolant to the Under Cooler cart UNPLUG THE COOLER BEFORE FILLING THE COOLANT RESERVOIR ADDING COOLANT Carefully add 2 gallons 7 6 liters of coolant through a funnel into the coolant reservoir fill hole AVOID SPILLING COOLANT INTO THE DRAWER OR ONTO THE PUMP MOTOR UNDER COOLER CART LINCOLN 3 INSTALLATION A 3 A CAUTION NOTE DO NOT ADD MORE THAN 2 GALLONS 7 6 LITERS OF COOLANT INTO THE RESER VOIR The fill cap contains a pressure release air hole which must not be blocked by overfilling the reservoir with coolant Be certain to replace the reservoir fill cap when the reservoir is full Simply press on the inside center of the fill cap until the cap snaps into place Operation of the cooler without the fill cap in place can cause poor cooling efficiency evaporation loss of coolant and reduced product life COOLANT CONNECTIONS The fittings located on the back center of the cooler drawer are two female 5 8 18 left hand threaded fit tings CGA Style The hoses provided with this unit are color coded with red hot and blue cold tape that should be matched up with the decals also color coded on both the cooler and the TIG machine Recommended torque value for the 5 8 18 LH fittings is 12 15 ft lbs If a torque wrench is not available snug the fittings and check for leaks Refer to Figure A 1 for decal located adjacent to water connections FIGURE A 1 CO
17. OLANT lt COOLANT OUT 525134 CAUTION Be certain that no leaks exist when the cooler is turned on A leak will deplete reservoir volume causing poor cooling performance and reducing torch life Note Be certain that only 5 8 18 left handed male nuts with clean and smooth threads are used on your water hoses Poor connections cause coolant to leak at the fittings and will deplete the coolant in the reservoir If you have hose to make replacement hose assem blies but need to order the fittings and hardware see below for the correct part numbers to mate with the Under Cooler cart and the Precision TIG Machine Then follow the given instructions 2 T15007 2 Connector Nuts 2 T15008 Nipples for 3 16 1 0 hose 2 S10888 35 Hose Clamps Remove the connector nut from the INLET hose by making a straight cut 1 4 1 2 6 12mm away from the end of the nipple located inside of the hose Take the nipple and the connector nut ordered above and insert the nipple into the connector nut so that the threaded end of the connector nut points away from the barbed end of the nipple Twist the barbed end of the nipple into the hose until the shoulder of the nipple is flush with the end of the hose Secure the hose onto the nipple with the hose clamp to insure that the con nection is watertight No water can leak from the con nection if it is properly attached Repeat the procedure for the OUTLET hose When complete fol
18. RETURN TO MAIN MENU IMT23 A UNDER COOLER CART For use with machines having Code Numbers 10808 11068 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful IP 21S NTRL C m OPERATOR S MANUAL 150 9001 lt 4 X Desig a Q inc LINCOLN fo Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ABS Quality Eval to 150 9001 Re 5 CERTIFICATE NUMBER 30273 l WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Abov
19. Save the instruction manual and service directory sup plied with the Under Cooler cart for parts orders and future maintenance service FILLING COOLANT RESERVOIR See Section A 1 for recommended coolant To avoid freeze damage and water leakage in ship ment the Under Cooler cart is delivered empty with no coolant in the system To fill the unit locate the plastic reservoir fill cap at the front middle of the cool er drawer Clean tap water distilled water de ionized water a 50 50 mix of pure ethylene glycol and water can be added into the coolant reservoir The reservoir fill hole mates with most coolant containers but to avoid spillage of coolant a funnel should be placed into the reservoir hole when filling NOTE Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphazardly discarded especially by pouring liquids down the drain Contact the local EPA office for responsible dis posal methods or for recycling information For best results when using the Under Cooler cart with Lincoln torches use distilled or de ionized water although if not available tap water can be used If pro tection from freezing is desired use a 50 water and 50 pure ethylene glycol mixture and should be ordered from a local welding distributor WARNING When using the Under Cooler cart DO NOT USE OIL BASED COOLANTS OR COOLANTS THAT CONTAIN RUST INH
20. TATING FAN BLADES ARE HAZARDOUS Do not put your hands near an oper ating fan Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from fans and all other moving parts when starting oper ating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the great est care when working near moving parts UNPACKING The packaging of the Under Cooler cart is designed to withstand shipping abuse and contains a cardboard liner that surrounds the unit If any shipping damage has occurred contact your certified Lincoln distributor or service center When unpacking the unit avoid thrusting sharp objects through the carton liner which may damage the heat exchanger or scratch the case Below is the recommended procedure for unpacking the Cooler Cut banding securing carton and remove carton Remove banding that holds the cart to the skid Remove screws securing rear bottle tray to skid Dislodge front notched 2 X 4 that secures front cast ers and remove Roll Under Cooler Cart forward off of skid Cut banding securing drawers and remove and unwrap handle upper cylinder support assembly hoses and hardware package located in the storage drawer of the unit
21. anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE e HMDS AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE SHAE e 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai ge dul ale f cs Sarin e os uui BALL cal ue pha J e cuts Fi gall l y e Ll gt LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CUCRITEOSSXSUEIL HS 85 ET REL BE RU Rr de OE D o 0 SAAD FAIS HHR ele BEHE TT Saal
22. dure is no permanent substitute for a peri odic maintenance schedule for the specified coolers 1 quart bottle of additive is sufficient to disinfect and treat about 720 coolers Check with the manufacturer of your guns torches to be sure that this procedure is compat ible with your equipment a Additive Poly Algaecide 30X containing 30 of active ingredient Poly oxyethylene dimethylimino ethylene dimethylimino ethylene dichloride b Cooler Lincoln part number see Parts Pages of this manual c Cooling system the entire system including cool er and accessories torch all connecting hoses etc d Disinfectant A user prepared mixture of fresh pure water and additive concentrated to 200 ppm maximum e ppm parts per million f Treated coolant A user prepared mixture of fresh pure water and additive concentrated to a nominal of 30 ppm Preparation Always switch off the Precision TIG machine power Always disconnect the Under Cooler cart from the TIG machine receptacle Be sure that the coolant presently in the system is at room temperature to avoid being burned Personal safety equipment chemical safety glasses rubber gloves See applicable MSDS for additional information Contact the additive manufacturer local EPA office or applicable environmental agency for responsible disposal methods of both used treated coolant and used disinfectant Safety hazards
23. e For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 m MAGNETIC FIELDS i may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine par
24. e unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed UNDER COOLER CART LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION Cooler does not operate 1 Input cord unplugged 2 Power harness damaged 3 Water lines blocked or crimped 4 Leak in gun or water hoses 5 Coolant reservoir empty 6 The system needs to be primed Internal water leak 1 Hose clamp loose on one of internal hoses 2 Internal hose punctured 3 Heat exchanger leaking 4 Pump seal is leaking If all recommended possible areas Torch or gun runs hot 1 Unit placed by area of extreme of misadjustment have been heat checked and the problem persists 2 Low coolant flow Contact your local Lincoln 3 No coolant flow Authorized Field Service Facility 4 Fan not operating 5 Heat exchanger clogged 6 Pump seal is leaking Fan operates but there is low 1 Leak in torch gun or hoses coolant flow 2 Torch gun or hoses partially obstructed 3 Reservoir empty or very low 4 Pump Strainer is dirty Fan operates but there is no 1 Pump or pump motor failure coolant flow 2 Pump strainer is blocked Pump operates but fan does not 1 Loose or disconnected fan lead 2 Obstruction in fan blade 3 Fan m
25. e when working near moving parts ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves e MOVING PARTS can injure D Do not operate with doors open or guards off Keep away from moving parts Observe all Safety Guidelines detailed throughout this manual Be sure to disconnect the Under Cooler cart from the Power Source before performing any maintenance procedures ROUTINE Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a low pressure air hose or removing it with a vacuum hose PERIODIC In dirty or dusty environments or if biological growth occurs in the coolant it may be necessary to flush the coolant reservoir Dump the old coolant rinse the inside of the reservoir and circulate rinsing solution through coolant system Add new coolant when cleaning is finished It is recommended to flush the coolant at least once a year A cooling system free from debris offers increased cooling efficiency and longer pump and torch life See the coolant treatment recommendation in Section D 2 NOTE Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphazardly discarded especially by pouring liquids down the drain Contact the local EPA office for res
26. ety PreCautions CA HR ler deb ie D 1 ROUDE EPOR DEEP TERT TRE D 1 P TIOQIC peed D 1 airs D 1 PUMP de D 1 Heat Exchanger iii D 1 R servoir Coolant Er RR D 2 Coolant Treatment Recommendation D 2 D 3 Pump Inlet FINE E D 3 POCO CUI Red dE ets D 3 Additional Service Notes D 4 Troubleshooting e unn aderant Section E EACUS E 1 How to Use Troubleshooting Guide E 1 Troubleshooting 2 Diagrams C Section Wiring 1 EIE RH 2 Dimension rf usb F 3 Parts CETERORUM 402 INSTALLATION TECHNICAL SPECIFICATIONS UNDER WATER COOLER Model Make Under Cooler Cart K1828 1 Input Rated Current Draw 100 120 VAC 50 60 Hz 1 Phase 60 Hz 2 8 3 5 Amps 50 Hz 3 5 5 3 Amps Operating Pressure 60 psig 413 kPa 4 1 bar Pump Hydraulic Rating No Flow Discharge Pressure gage Relief Valve Setting 60 PSIG 414 kPa 4 14 bar Max No Pressure Flow Rate 1 66 gal min 6 28
27. following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover p plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of
28. liter min Max Pump Hydraulic Rating Typical Operation Discharge Pressure gage 53 57 PSIG 365 393 kPa Flow Rate 45 60 gal min 1 7 2 3 liter min Reservoir Capacity 2 0 Gallons 7 6 Liters Recommended Coolant For Use Above Freezing Clean tap distilled or de ionized water For Use Below Freezing 50 water and 50 pure ethylene glycol mixture DO NOT USE Automotive anti freeze that contains rust inhibitors or leak stoppers These coolants will damage the pump and block the small internal passageways of the heat exchanger affecting cooling performance To acquire the proper coolant contact a local welding distributor DO NOT USE Pre packaged welding industry coolants These coolants may contain oil based substances which attack the plastic components of the cooler Once added to the cooler these substances are virtually impossible to purge from the water lines and heat exchanger Weight Shipping 252 Ibs 114 kg Reservoir Full Water 267 lbs 121 kg Dimensions Length 41 in 1041 mm Width 27 in 686 mm Height Top Face 21 in 533mm Height TIG Interface 19 in 483 mm UNDER COOLER CART LINCOLN 2 INSTALLATION A 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK Can Kill Only qualified persons should per form this installation HOT COOLANT CAN BURN SKIN e Always be sure coolant is not hot before doing any work on cooler parts RO
29. ll Disconnect input before servicing Do not touch electrically live parts Do not touch live parts Only qualified persons should perform this installation This Undercarriage is designed to handle up to two gas Cylinders e After Installation check all mounting hardware to assure tightness Never use Lift Bale when Undercarriage and Upper Cylinders Supports are attached all Gas Cylinders placed on Cylinder Platform tightly chained to Upper Cylinder Support CYLINDER may explode if damaged under pressure is explosive Always keep gas cylinders in an gt upright position and always keep chained to undercarriage or stationary support Cylinders should be located 1 Away from areas where they may be struck or subjected to physical damage 2 A safe distance from arc welding or cut ting operations and any other source of heat sparks or flame Never lift a welder with a cylinder attached Never allow welding electrode to touch cylinder e Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Associate 1235 Jefferson Davis Highway Arlington VA 22202 Assembly of the Under Cooler cart to the Precision TIG machine is actually quite simple Read carefully the prior warnings and precautions to assembling to
30. low the con nection procedure detailed above for connecting the hoses to the cooler drawer fittings The connector and nipple listed fit tightly onto 5 32 4 0mm to 3 16 4 8mm inner diameter hose but if clamped tightly to the hose can fit up to a 25 6 4mm inner diameter hose NOTE Hoses have been provided with this product and any replacement hoses purchased or made should not deviate from their length To replace the ses hoses from Lincoln Electric ORDER 1 S18453 19 HOT AND 1 S18453 20 COLD Hoses too long may be pinched when replacing the gas bottles and hoses too short may be damaged opening the cooler drawer UNDER COOLER CART LINCOLN A 4 INSTALLATION A 4 INPUT POWER CONNECTION Plug the input power cord on the Under Cooler cart into the standard bottom 115V NEMA circuit breaker protected receptacle located on the back of the Precision TIG machine Using this receptacle is taking advantage of the cooler as needed circuit incorporat ed into the TIG machine and will prolong the life of the cooler The lower or bottom receptacle is clearly marked for this application If you wish to use the top 115 V NEMA receptacle located on the back of the machine for cooler opera tion the cooler will run 100 of the time that the Precision TIG machine is powered ON ASSEMBLY OF PRECISION TIG SAFETY PRECAUTIONS A WARNING Protect yourself and others from serious injury ELECTRIC SHOCK Can Ki
31. nd submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page luci m Section A Technical Specificatioris 22 2 cL eeu e Lodel epa ie A 1 Safety Precautions L A 2 Unpacking EI M A 2 Filling Coolant Reservoir sise A 2 Coolant Connections RE A 3 Mc DER 4 Assembly of Precision Tigres niiehn ssnetentanet ereemesnieestoetteineneennse A 4 Fastener Quick Reference siens 5 Gonnection of Tig Em 5 clc e E Section B Ii B 1 General Description B 1 Recommended Processes siens B 1 Recommended Equipment B 1 Turning the System MES B 2 Cooling Efficiency isd asta iste edict kode B 2 Maintenance sc Section D Saf
32. oden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR 7 amp nf dchsn zucct e E GUB MU S Oa EERTE ecu S422 Xe uc Bp e Weal AMI d ous uil el jad oa Y O ay gl uit slt All usu DA daas ule Y Jio moe Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM IEEE IIS eis A Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF ez 119 59 s ESSAI dise ule Lily vues al ad ne t daag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
33. on for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode 22238 if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e
34. otor failure A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed UNDER COOLER CART LINCOLN 5 T I WIRING DIAGRAM 1 Jequunu epoo ou SAIN 104 si au sjeued y euo uo eui episui pejsed si epoo e Jenueui siy Aq 20 eq jou 51 SIUL 310 G L86 LIN N33H9 9 3 LIHM HOLON 3 CULIN ZH 09 08 MOV S 8 3009 YOLOW LS LIN INANI Ld l 216919 dad SIOEWAS 1VOTH LOd T3 NOILOANNOO GQNNOYS ANO HS NV 29 NOILOANNOO GNNOWD 3SV8 14V9 831003 8 30 UNDER COOLER CART LINCOLN E 2 VCL6LIN HIOAH3S3H LNV1009 DIAGRAM LNV 1002 LNO LNVIOOD MO 191009 Meg L 9C98 LM F 2 UNDER COOLER CART LINCOLN E DIMENSION PRINT F 3 Jequunu epoo y BAIN e 104 eorues
35. overnor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions 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 if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the
36. ponsible disposal methods or for recycling information PUMP The pump head has a built in strainer on the inlet side of the pump It is recommended to clean or replace the pump s inlet strainer at least annually as follows Drain the coolant reservoir and all coolant lines Dispose of the coolant properly as specified above Hold the pump head firmly to apply a counter torque when loosing the strainers 7 8 acorn nut located on the bottom Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from the pump head Gently rinse the strainer under running water to thoroughly clean it Use a mirror to inspect the inside of the pump for contamination Carefully remove hardened debris with a dental pick if necessary without scratching the inside of the pump Reinstall the strainer and 7 8 acorn nut tighten to 75 in Ibs 8 5N m of torque Wipe dry all area wetted with coolant Dispose of coolant soaked towels properly as specified above PUMP MOTOR The Under Cooler cart is rated for continuous operation It is recommended to re oil the pump motor bearings once a year as follows Remove the plastic plugs located on the top of both the inboard and outboard bearing end caps Re oil each bearing with 30 35 drops of SAE 20 oil then reinstall both plugs HEAT EXCHANGER To maintain maximum cooler efficiency the heat exchanger should be kept free of dust and dirt build
37. r receptacle in the rear of the machine and is rated for both 50 or 60 HZ Adding coolant to the reservoir is simple and connecting to the coolant IN and OUT connections are easily made with an adjustable wrench The Under Cooler cart coolant flow is circulated through a heat exchanger to remove heat energy from the coolant The coolant flow is then deposited into the coolant reservoir The pump draws its coolant sup ply from the coolant reservoir and delivers coolant to the welding torch Refer to Flow Diagram Section F CAUTION DO NOT USE A WATER SOLENOID VALVE with the Under Cooler Cart RECOMMENDED PROCESSES The Under Cooler Cart is designed for use with the Precision TIG 275 and Precision TIG 375 machines The recommended 115 V power receptacle is labeled cooler as needed This receptacle shuts on and off in conjunction with the TIG machine fan By using this receptacle the duty cycle of the cooler is greatly reduced and lets the cooler run only when needed RECOMMENDED EQUIPMENT The Under Cooler cart is designed for use with the Precision TIG 275 and Precision TIG 375 and any water cooled TIG Torches applicable Although the cooler could operate as a standalone unit the cart has been designed specifically to mount these two TIG machines only UNDER COOLER CART LINCOLN 2 OPERATION B 2 TURNING THE SYSTEM ON A CAUTION After connecting the Precision Tig and Tig Torches per Installation Section
38. rn flow is directly vis ible via the fill opening of the reservoir with the draw er open SHUT THE COOLER DRAWER DURING NORMAL OPERATION When first starting the unit check all of the coolant hoses to insure that no water leaks are present Water leakage causes poor welding performance poor cooling performance low welding component life and potential electrical safety hazards COOLING EFFICIENCY The high cooling efficiency of the Under Cooler cart offers a cooler more comfortable weld than conven tional air cooled procedures as well as leading com petitors water cooled systems The Under Cooler cart effectively removes the heat of the arc away from the torch handle and places it into the exiting air flow at the back of the Cooler Ambient air temperature affects the coolant temperature of the cooler Unlike other water coolers that depend on bulky reser voir size the high efficiency components of the Under Cooler cart allows the reservoir size to be small The result is a lightweight unit in a drawer with additional storage space for welding accessories UNDER COOLER CART LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the mainte nance requiring their removal is complete Always use the greatest car
39. rstand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparati
40. s PROCEDURE Preparation Always switch off the Precision TIG machine power Always disconnect the Under Cooler cart from the Tig machine receptacle Always allow the coolant in the system to cool enough to avoid burn injuries Avoid contact with contaminated coolant Wear waterproof gloves and protective eyewear Do not remove the pump relief valves 3 4 in acorn hex nut or attempt to adjust the relief valve setting Inspect condition of coolant a If coolant is contaminated or old Drain the system of coolant and dispose of it in an environmentally responsible manner Flush system of old coolant Fill with fresh tap or distilled water run for ten min utes and drain Proceed to adding coolant b If coolant is clean and fresh f clean dedicated coolant handling equipment including a clean siphon pump and a clean holding tank are available then proceed to servicing the pump inlet strainer Removing Coolant a Drain coolant from the reservoir using clean siphoning equipment b Coolant level should be drained below the filter s pressure fitting This prevents coolant from streaming out of unit when filter nut is removed UNDER COOLER CART LINCOLN 0 4 MAINTENANCE Service the pump s inlet strainer a Place absorbent towels underneath pump head to prevent stray coolant from wetting cooler s electrical components b Hold pump head to apply counter torque when loos
41. tant through it for 10 to 15 minutes Drain disinfectant from the cooling system Do not reuse this solution Add new fresh coolant to the cooling system Add 0 325 gals 1 225 liters of fresh disinfectant to the system by pouring it into the reservoir then reduce the concentration to the nominal 30 ppm Add the balance 1 675 gals 6 325 liters of fresh pure water to the reservoir to create the treated coolant concentration Prime the cooling system Check coolant level Add more fresh pure water if required without adding more than 0 125 gal 0 475 liters of pure water to prevent diluting the coolant additive Additive The recommended additive can be purchased at local pool supply stores An example is Maintain Pool Pro 30 Non Foam Algaecide PUMP INLET FILTER Poor cooler performance can usually be traced to a partially or completely blocked pump inlet filter This is user serviceable item and can be cleaned and reused or replaced Continued pump operation with a blocked filter can cause Voiding of cooler service warranty Cavitation damage to the pump heads inlet areas Welding accessory damage from overheating due to insufficient coolant flow rate A new or properly cleaned pump inlet filter should restore the cooler s performance For additional service and periodic maintenance details and for recommended coolants follow the rec ommendations listed in the following paragraph
42. the coolant UNDER COOLER CART LINCOLN 5 E 1 TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or ar
43. ts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the g
44. your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and unde
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