ARCWELDINGSAFETY

…becausethere’s so muchmore to enjoy.

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Introduction

Arc welding is a safe occupation when sufficientmeasures are taken to protect the welder from poten-tial hazards. When these measures are overlooked orignored, however, welders can encounter such dangersas electric shock, overexposure to arc radiation, fumesand gases, and fire and explosion; any of which mayresult in fatal injuries.

So that you may recognize and safeguard yourselfagainst these hazards, every welder should be familiarwith the ANSI Z49.1 document, “Safety in Weldingand Cutting,” and should follow the safety practices inthe document whenever possible. However, you mayfind yourself working at a job-site where your super-visor is unavailable for advice, or where proper noiseor air measurements cannot be taken. In these andother cases, you can help protect yourself and othersby using six of the best safety measures you alreadyhave: your sight, smell, hearing, touch, taste … andcommon sense.

This bulletin is written with the arc welding oper-ator in mind, containing both mandatory safety prac-tices and those based on shop experience. Be sure toread ANSI Z49.1, and refer to the other publicationslisted at the end of the bulletin for more in-depth stud-ies of arc welding safety, as well as the manufacturers’instructions and material safety data sheets (MSDS’s).

Personal Protection

PROTECTIVE CLOTHINGWelders, like firemen, must wear clothing to pro-

tect them from being burned. Of all injuries towelders, burns are the most common due to sparkslanding on bare skin. Some welding arcs are veryintense with high amperages (over 500 amps) thatcould cause injury with just a few minutes of expo-sure. Others, could be more like a single birthday can-dle (around 30 amps). Different gear is required forthese two extremes.

The actual gear varies with the job being per-formed, but generally protective clothing must allowfreedom of movement while providing adequate cov-erage against burns from sparks, weld spatter, and arcradiation. Many types of clothing will protect youfrom ultra-violet radiation exposure, which appears asa skin burn (much like sunburn). Under the worst con-ditions, however, severe burns and skin cancer mayresult from excessive radiation.

Because of its durability and resistance to fire,wool clothing is suggested over synthetics (whichmelt when exposed to extreme heat) or cotton, unlessit is specially treated for fire protection. If possible,keep your clothes clean of grease and oil, as these sub-stances may ignite and burn uncontrollably in thepresence of oxygen.

Avoid rolling up your sleeves and pant-cuffs,because sparks or hot metal could get stuck in thefolds; also, wear your trousers overlapping your workboots, not tucked in, to keep particles from falling into

your boots. While we’re on the subject, we suggestleather high-tops with steel toes (especially whendoing heavy work).

Other protective wear for heavy work or especial-ly hazardous situations includes: flame-resistant suits,aprons, leggings, leather sleeves/shoulder capes, andcaps worn under your helmet.

Heavy, flame-resistant gloves, such as leather,should always be worn to protect your hands fromburns, cuts, and scratches. In addition, as long as theyare dry and in good condition, they will offer someinsulation against electric shock.

As to preventing electric shock, the key word isdry! We’ll have more on the subject later, but for nowkeep in mind that moisture can increase the potentialand degree of electric shock. When working in wetconditions, or when perspiring heavily, you must beeven more careful to insulate your body from electri-cally “live” parts.

ARC RAYS can burn.• Wear eye, ear and body protec-

tion.

Arc Rays

It is essential that your eyes are protected fromradiation exposure. Infrared radiation has been knownto cause retinal burning and cataracts. And even abrief exposure to ultraviolet (UV) radiation can causean eye burn known as “welder’s flash.” While thiscondition is not always apparent until several hoursafter exposure, it causes extreme discomfort, and canresult in swelling, fluid excretion, and temporaryblindness. Normally, welder’s flash is temporary, butrepeated or prolonged exposure can lead to permanentinjury of the eyes.

Other than simply not looking at an arc (obvious-ly, pretty hard to do if you’re welding every day), theonly preventive measure you can take is with the useof proper eye shading. Refer to the lens shade selector

SAFETY PRACTICES IN WELDING

WARNING

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chart in the supplements for the recommended shadenumbers for various arc welding processes. The gen-eral rule is to choose a filter too dark to see the weld,then move to lighter shades without dropping belowthe minimum rating. The filters are marked as to themanufacturer and shade number, the impact-resistantvariety are marked with an “H.”

Helmet-type shields and hand-held face shields(see Figure A) offer the most complete shadingagainst arc radiation. The shade slips into a window atthe front of the shield so that it can be removed andreplaced easily. The shields are made from a hardplastic or fiberglass, to also protect your head, face,ears, and neck from electric shock, heat, sparks, andflames. You should also use safety glasses with sideshields or goggles to protect your eyes from flyingparticles.

Figure A. A helmet-type shield (a) required for pro-tecting the welder ’s eyes and face and (b) ahand-held face shield that is convenient forthe use of foremen, inspectors, and otherspectators.

Visible light can also be harmful, but it is easy totell if the light is dangerous: if it hurts to look at, thenit’s too bright. The same is true for infrared radiation:it can usually be felt as heat. However, there’s no realway for you to tell if you’re being exposed to UV radi-ation, so just don’t take chances: always wear eye pro-tection (see Supplement 1 for recommended lensshade numbers).

Noise

There are two good reasons to wear ear muffs orplugs:

a) to keep flying sparks or metal out of your ears;and

b) to prevent hearing loss as a result of workingaround noisy arc welding equipment, powersources, and processes (like air carbon arc cut-ting or plasma arc cutting).

As with radiation exposure to the eyes, the lengthand number of times that you are exposed to high lev-els of noise determine the extent of the damage toyour hearing, so be sure to avoid repeated exposure tonoise. If it is not possible to reduce the level of noiseat the source (by moving either yourself or the equip-ment, utilizing sound shields, etc.), then you shouldwear adequate ear protection.

If the noise in your work area becomes uncom-fortable, causing a headache or discomfort of the ears,

you could be damaging your hearing and shouldimmediately put on ear muffs or plugs.

In fact, the use of ear protection at all times is agood idea, as hearing loss is both gradual and adds upover time. Damage to your hearing may not be noticeduntil you have a complete hearing test at the doctor’s,and then it could be too late.

Inspection and Maintenanceof Equipment and Work

Before starting any arc welding operation, youshould make a complete inspection of your equip-ment. All it takes on your part is 5-10 minutes beforeyou turn on your welder; is that too much to spend inpreventing injury to yourself or your co-workers?

To begin with:• Have you read the instruction manual and do

you understand the instructions? (The instruc-tion manual for your welder is available uponrequest to your welding distributor or the man-ufacturer. See Supplement 4.)

• Have you read the warnings and instructions onthe equipment nameplates and decals as well asthe consumables labels and material safety datasheets? (For older equipment see Supplement 4to request a FREE Warning Label.)

For the welder:• Are all the connections tight, including the

earth ground?• Are the electrode holder and welding cable well

insulated and in good condition?• Are the settings correct for the job you’re about

to begin?

For an engine-driven welder:• Is it running OK?• Are all the hoses on tight?• Is the fuel cap on tight?• Is the engine leaking fuel or oil?• Is the original enclosure and fan guarding in

place? Check with your welding equipment dis-tributor if you are unsure. (See Supplement 5.)

For the work in general: (See also Supplements 3and 6)• Are the work area conditions such that normal

safety precautions can be observed or mustspecial equipment (i.e., ventilation, exhaust, orrespirator, welding equipment, protective

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equipment, safety equipment) or procedures beused?

• Are the cables the right size for your job?• Are they spread out and run neatly to prevent

overheating?• Is the gas cylinder connected properly?• Is the cylinder secure?• Is the work stable and easy to reach from where

you’re standing?• Is the Work Lead connected securely?• Is there enough dry insulation between your

body and the work piece?• Is there adequate ventilation in your work area?

Take some personal responsibility for your ownsafety. Notify your supervisor if equipment is in needof repair or not working properly or any unsafe condi-tion. You have the most to lose if you get hurt. Don’tallow yourself to work in a hazardous situation.

If the hazard is serious and cannot be correctedreadily, the machine will then be shut down until theneeded repairs are made. If the problem is limited tothe outside of the welder, such as a loose connectionor a damaged cable that needs to be replaced, discon-nect power to the welder and read the operating/serv-ice manual before doing anything. If the hazardrequires repairs to the inside of the welder or to theelectrical lines feeding the unit, call a service techni-cian or an electrician. Never attempt to make theserepairs if you are untrained.

Care and Cleaning of the Work Area

Keeping the area around your work neat is asimportant as maintaining your equipment. Perhapseven more-so, as the risk of injury is amplified by thelarger group of people involved. You may havealready inspected your equipment and found it to beOK, but all your caution won’t matter when, for exam-ple, a co-worker trips over your cable, causing you,and/or the people around you, to be injured by shock,hot metal, or from falling.

Keep all your equipment, cables, hoses, cylinders,etc. out of any traffic routes such as doors, hallways,and ladders. A good practice is to avoid clutter … andclean up your work area when you’re done! Not onlywill it help to protect yourself and others, you'll find itmuch easier for you to work efficiently.

Also, bear in mind that while you’re paying atten-tion to your work, other welders may be preoccupiedwith their own tasks and not watching where they’regoing. So be sure that there are protective screens inplace, just in case somebody happens to be passinginto your work area or walks into a shower of sparksor spatter.

Consider whether the area in which you will beworking creates or increases the level of hazard to youthus requiring special procedures or equipment.Factors such as electrical safety, fume ventilation andrisk of fire or explosion may be affected. See later sec-tions on those topics and other documents in“Bibliography and Suggested Reading” for furtherinformation.

Gas Cylinders

Because of the explosive nature of cylinders, youmust pay particularly close attention to their storageand use. Examine the cylinders as you did the rest ofyour equipment; check the cylinder label to make sureit is the correct shielding gas for the process, and thatthe regulators, hoses, and fittings are the right ones forthat gas and pressure, and are in good condition.

Cylinders must be secured in an upright posi-tion, with the valve caps in place, in an area awayfrom combustibles and fuels, and safeguarded fromdamage, heat, and flames. When in use, keep them outof traffic routes and flying sparks, with all hoses runneatly to the welding area. Never allow the electrodeor other “electrically hot” parts of your welder totouch a cylinder. “Crack” the valve open to preventdirt from entering the regulator; open the cylindervalve only when standing to one side of the cylinder,away from welding or other sources of ignition.Return damaged cylinders to the supplier. Refer to theCompressed Gas Association pamphlet P-1, “SafeHandling of Gas Cylinders,” for further information.

CYLINDER may explode if dam-aged.• Keep cylinder upright and chained

to support.• Never allow welding electrode to

touch cylinder.

Specific Concerns

POSSIBLE SHOCK HAZARDSThe hazard of electric shock is one of the most

serious and immediate risks facing you as a welder.Contact with metal parts which are “electrically hot”can cause injury or death because of the effect of theshock upon your body or a fall which may result fromyour reaction to the shock. The electric shock hazardassociated with arc welding may be divided into twocategories which are quite different:

– Primary Voltage Shock (i.e., 230, 460 volts);and

– Secondary Voltage Shock (i.e., 6-100 volts).

HIGH VOLTAGE can kill.• Do not operate with covers

removed.• Disconnect input power before

servicing.• Do not touch electrically live

parts.

The primary voltage shock is very hazardousbecause it is much greater than the welder secondaryvoltage. You can receive a shock from the primary(input) voltage if you touch a lead inside the welderwith the power to the welder “on” while you have

WARNING

WARNING

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your body or hand on the welder case or other ground-ed metal. Remember that turning the welder powerswitch “off” does not turn the power off inside thewelder. The input power cord must be unplugged orthe power disconnect switch turned off. You shouldnever remove fixed panels from your welder; in fact,always have a qualified technician repair your welderif it isn’t working properly. Also, your welder shouldbe installed by a qualified electrician so it will be cor-rectly wired for the primary voltage which supplies itpower and so the case will be connected to an earthground. The case must be grounded so that if a prob-lem develops inside the welder a fuse will blow, let-ting you know that repair is required. Never ignore ablown fuse because it is a warning that something iswrong.

ELECTRIC SHOCK can kill.• Do not touch electrically live parts

or electrode with skin or wet cloth-ing.

• Insulate yourself from work andground.

A secondary voltage shock occurs when youtouch a part of the electrode circuit — perhaps a barespot on the electrode cable — at the same time anoth-er part of your body is touching the metal upon whichyou’re welding (work). To receive a shock your bodymust touch both sides of the welding circuit — elec-trode and work (or welding ground) — at the sametime. To prevent secondary voltage shock, you mustdevelop and use safe work habits:

• Wear dry gloves in good condition when weld-ing.

• Do not touch the electrode or metal parts of theelectrode holder with skin or wet clothing.

• Keep dry insulation between your body (in-cluding arms and legs) and the metal beingwelded or ground (i.e., metal floor, wet ground).

• Keep your welding cable and electrode holderin good condition.

These rules are basic to welding and you shouldalready know them. Check out the warning on yourwelder or electrode box next time you weld. You will

probably not have a shock while welding if you followthese rules.

Though it may be more difficult to follow therules under some conditions, the rules still apply. Useplywood, rubber mats, or some other dry insulation tostand or lie upon. Keep your gloves dry even if youhave to keep an extra pair. Don’t rest your body, arms,or legs on the workpiece, especially if your clothing iswet or bare skin is exposed (and it should not be if youare dressed properly). In addition to the normal safetyprecautions, if welding must be performed under elec-trically hazardous conditions (in damp locations orwhile wearing wet clothing; on metal structures suchas floors, gratings or scaffolds; when in cramped posi-tions such as sitting, kneeling or lying, if there is ahigh risk of unavoidable or accidental contact with thework piece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage Welder• DC Manual (Stick) Welder• AC Welder with Reduced Voltage ControlThe condition of your electrode holder and elec-

trode cable is also very important. The plastic or fiberinsulation on the electrode holder protects you fromtouching the metal “electrically hot” parts inside.Always inspect your electrode holder before turningthe welder on. Replace the holder if it is damaged —don’t try to repair it unless you have replacementparts.

The same is true of the electrode cable except thatwhen not replaced it may be repaired using good elec-trical tape. If your cable has been repaired, be sure tocheck and see that the tape is secure before you turnthe welder on.

Remember, a stick electrode is always “electrical-ly hot” when the welder is on — treat it with respect.If you do experience a shock, think of it as a warning— check your equipment, work habits and work areato see what is wrong before continuing to weld.

WELDING SPARKS can cause fireor explosion.• Keep flammable material away.

FIRE HAZARDSBecause of the extreme temperatures associated

with any arc welding process, you should always beaware of fire hazards. The heat of the welding arc canreach temperatures of 10,000°F, but this heat in itselfis not generally a fire hazard. The danger of fire actu-ally results from the effects of this intense heat uponyour work and in the form of sparks and molten met-als. Because these can spray up to 35 feet from yourwork, you must recognize and distance yourself fromcombustible materials. It is also important to be surethe work is not in contact with any combustible whichit may ignite when heated. These materials fall intothree categories: liquid (gasoline, oil, paints, and thin-ners); solid (wood, cardboard, and paper); andgaseous (acetylene and hydrogen).

WARNING

WARNING

Figure B. Always inspect your electrode holder beforeturning the welder on.

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Watch where the sparks and metals are fallingfrom your work: if there are flammable materialsincluding fuel or hydraulic lines in your work area andyou can’t move either your work or the combustiblesubstances, put a fire-resistant shield in place. Ifyou’re welding above the ground or off a ladder, makesure that there are no combustibles underneath. Also,don’t forget about your co-workers, and everybodyelse who may be in the work area, as they probablywouldn’t appreciate being hit with slag or sparks fromyour work.

Particular care must be taken when welding orcutting in dusty locations. The nature of the dust maybe extremely volatile in the heat of the arc or in thepresence of a hot spark. Fine dust particles may read-ily oxidize and without warning result in a flash fire oreven an explosion.

If you are not sure of the combustible or volatilenature of residue or dust in the work area, no weldingor cutting should take place until a responsible personhas inspected the area and given approval for thework.

Before you start welding, inspect the surface ofyour work, looking for flammable coatings or anyunknown substances that would ignite when heated.Because of the extreme fire and explosion hazardsinherent to welding on or around containers and pip-ing that may have combustible materials, such workshould be handled only by experienced welders whoreview and follow the safety practices recommendedin the American Welding Society document F4.1,“Recommended Safe Practices for the Preparation forWelding and Cutting of Containers and Piping WhichHad Held Hazardous Substances.”

Know where the fire alarms and fire extinguishersare located, and check the pressure gauges so youdon’t rely upon one that’s empty. If there are none inthe area, make sure that you have access to fire hoses,sand buckets, fire-resistant blankets, or other firefighting equipment. If you’re welding within 35 feetor so of flammable materials, you should have a firewatcher to see where your sparks are flying, and tograb an extinguisher or alarm if needed. Both you andthe fire watcher should wait for a half hour after allwelding is finished to find and put out any smolderingfires that may have resulted from your welding.

As with other emergencies that may result fromwelding accidents, the first rule is: don’t panic.Depending on the size of the fire, shut off yourwelder; sound the fire alarm to warn others and thefire department; and get to the fire exits as quickly aspossible.

FUMES AND GASES can be danger-ous.• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathingzone.

FUMES AND GASESBecause of the variables involved in fume and gas

generation from arc welding and allied processes(such as the welding process and electrode, the basemetal, coatings on the base metal, and other possiblecontaminants in the air), we’ll have to treat the subjectin a rather general way, lumping all but the more haz-ardous situations together. Although the health con-siderations will vary according to fume and gas com-position and individual reactions, the precautions wespecify will hold true for all fumes and gases. Again,it really boils down to you and your senses.

The fume plume contains solid particles from theconsumables, base metal, and base metal coating.Depending on the length of exposure to these fumes,most acute effects are temporary, and include symp-toms of burning eyes and skin, dizziness, nausea, andfever. For example, zinc fumes can cause metal fumefever, a temporary illness that is similar to the flu.Chronic long-term exposure to welding fumes canlead to siderosis (iron deposits in the lungs) and mayaffect pulmonary function.

Manganese overexposure can affect the centralnervous system, resulting in impaired speech andmovement. This condition is considered irreversible.Bronchitis and some lung fibrosis have been reported.

Fumes from the use of stainless steel and otherspecialized consumables have the potential to containcertain compounds of chromium and/or nickel. Someof these compounds are known or suspected to havecaused lung cancer in processes other than welding.Therefore, it is recommended to keep exposures aslow as possible.

Cadmium also requires extra precautions. Thistoxic metal can be found on steel and steel fasteners asa coating, or in silver solder. Cadmium fumes can befatal even under brief exposure, with symptoms muchlike those of metal fume fever. These two should notbe confused. 20 minutes of welding in the presence ofcadmium can be enough to cause fatalities, withsymptoms appearing within an hour, and death fivedays later.

The gases that result from an arc welding processalso present potential hazard. Most of the shieldinggases (argon, helium, and carbon dioxide) are non-toxic, but as they are released they displace oxygen inyour breathing air, causing dizziness, unconscious-ness, and death the longer your brain is denied theoxygen it needs. In contrast, the heat and the UV radi-ation, can cause the eyes to tear and irritate the lungs.Some degreasing compounds such as trichlorethyleneand perchlorethylene can decompose from the heatand ultraviolet radiation of an arc. Because of thechemical breakdown of vapor-degreasing materialsunder ultraviolet radiation, arc welding should not bedone in the vicinity of a vapor-degreasing operation.Carbon-arc welding, gas tungsten-arc welding and gasmetal arc welding should be especially avoided insuch areas, because they emit more ultraviolet radia-tion than other processes. Also, keep in mind thatozone and nitrogen oxides are formed when UV radi-ation passes through the air. These gases causeheadaches, chest pains, irritation of the eyes, and anitchiness in the nose and throat.

WARNING

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There is one easy way to reduce the risk of haz-ardous fumes and gases: keep your head out of thefume plume! As obvious as this sounds, it is a com-mon cause of fume and gas overexposure because theconcentration of fume and gases is greatest in theplume. In addition, use mechanical ventilation or localexhaust at the arc to direct the fume plume away fromyour face. If this is not sufficient, you may need fixedor moveable exhaust hoods to draw the fume from thegeneral area. Finally, it may be necessary to wear anapproved respiratory device if sufficient ventilationcan not be provided (see Ventilation section for weld-ing area requirements and types of exhaust). As a ruleof thumb, if the air is visibly clear and you are com-fortable, then the ventilation is probably adequate foryour work.

The most effective way to identify these fumesand gases is to have a specialist take a sample of theair around you. If this is impractical, however, thereare steps that you can take to identify hazardous sub-stances. First, read the product label and material safe-ty data sheet for the electrode posted in the work placeor in the electrode or flux container to see what fumescan be reasonably expected from use of the product.Secondly, know what the base metal is, and determineif there is any paint or coating that would cause toxicfumes and/or gases. If you start to feel dizzy or nau-seous, there is a possibility that you are being overex-posed to fumes and gases, or suffering from oxygendeficiency. In either case, try to improve the ventila-tion in your area. If that doesn’t work: turn off youwelder; get some fresh air immediately; and notifyyour supervisor and co-workers so the situation can becorrected and other workers can avoid the hazard.

NOTE: The MSDS for all Lincoln consum-ables is available on Lincoln’s website: www.lincolnelectric.com

Ventilation

The respiratory health hazards associated withwelding operations are caused principally by inhala-tion of gases, dusts, and metal fumes. The type andquantity of toxic fumes in a welding area depend onthe type of welding being done, the filler and basemetals used, contaminants on the base metal, solventsin the air, and the amount of air movement or ventila-tion in the area. Good ventilation is the key to avoid-ing or minimizing respiratory hazards.

When welding and cutting mild steels, naturalventilation is usually considered sufficient to meetrequirements, provided that:

1. The room or welding area contains at least10,000 cubic feet (about 22' x 22' x 22') foreach welder.

2. The ceiling height is not less than 16 feet.3. Cross ventilation is not blocked by partitions,

equipment, or other structural barriers.4. Welding is not done in a confined space.Spaces that do not meet these requirements should

be equipped with mechanical ventilating equipmentthat exhausts at least 2000 cfm of air for each welder,except where local exhaust hoods or booths, or air-line respirators are used.

When welding with electrodes which require spe-cial ventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead or cad-mium plated steel and other metals or coatings whichproduce highly toxic fumes, keep exposure as low aspossible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. In con-fined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

EXHAUST HOODS AND BOOTHSLocal exhaust of welding fumes can be provided

by adjustable hoods or by fixed enclosures or booths(see Figure C). Individual movable hoods are particu-larly suitable for bench welding, but can be used forany welding or cutting job provided that the hood canbe moved so that it is always close to the joint beingwelded. These hoods are more economical to operatethan a general ventilation system, particularly in thewinter, because they require less replacement air to bebrought into the room and heated.

Minimum required air velocity at the zone ofwelding is 100 fpm when the hood is at its farthestposition from the joint being welded. For a 3 inchwide-flange suction opening, this velocity required anair velocity of 150 cfm at 4 to 6 inches from the arc,and 600 cfm at 12 inches from the arc.

A ventilated booth is a second type of localexhaust arrangement. A booth is a fixed enclosure thatconsists of a top and at least two sides that surroundthe welding operation. Airflow requirements are simi-lar to those for movable hoods — sufficient to main-tain a velocity away from the welder of at least 100fpm.

WORKING IN CONFINED SPACESWhen arc welding in a confined area, such as a

boiler, a tank, or the hold of a ship, bear in mind thatall the hazards associated with normal arc welding areamplified, so the precautions mentioned here are evenmore important. There is a greater danger that enoughflammable gases may be present in the confinedspace to cause an explosion. The metal of the enclo-sure can become part of the welding circuit, so anymetal you touch (the walls, floor, ceiling) is electri-

Figure C. A typical ventilated booth for exhausting airfrom the welding operation.

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cally “hot.” Welding fumes can accumulate more rap-idly, with a higher concentration; gases can force outthe breathable air, suffocating you in the process.

You can see the danger involved in this area ofwelding: you really have to be on your guard. Spareno effort in making sure that your body is insulatedfrom the workpiece and ground by dry insulation.Wear dry gloves and only use a well-insulated elec-trode holder. Semiautomatic constant voltage welderswith cold electrode or stick welders equipped with adevice to lower the no-load voltage are recommended,especially when the work area is wet. Make sure thatthere is adequate ventilation (be it forced or throughan air supplied respirator), and that there are no flam-mable coatings, liquids or gases nearby. Lastly, youmust have someone outside the enclosure trained tohandle emergencies, with rescue procedures and ameans to disconnect power to your equipment and pullyou out if danger arises. We cannot stress this strong-ly enough: however experienced you are, do notattempt work of this nature without constant commu-nication with the person outside the confined area.You cannot be too careful when welding within a con-fined area; any, repeat any, problem that arises canimmediately become life-threatening.

ELECTRIC AND MAGNETIC FIELDSElectric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF).Welding current creates EMF fields around weldingcables and welding machines. EMF fields may inter-fere with some pacemakers, and welders having apacemaker should consult their physician beforewelding. Exposure to EMF fields in welding may haveother health effects which are now not known. Allwelders should use the following procedures in orderto minimize exposure to EMF fields from the weldingcircuit:

• Route the electrode and work cables together –Secure them with tape when possible.

• Never coil the electrode lead around your body.• Do not place your body between the electrode

and work cables. If the electrode cable is onyour right side, the work cable should also beon your right side.

• Connect the work cable to the workpiece asclose as possible to the area being welded.

• Do not work next to welding power source.

SUPPLEMENT 1Guide for Shade Numbers

Minimum Suggested(1)

Electrode Size Arc Protective Shade No.Operation 1/32 in. (mm) Current (A) Shade (Comfort)

Shielded metal arc Less than 3 (2.5) Less than 60 7 –welding 3-5 (2.5–4) 60-160 8 10

5-8 (4–6.4) 160-250 10 12More than 8 (6.4) 250-550 11 14

Gas metal arc Less than 60 7 –welding and flux 60-160 10 11cored arc welding 160-250 10 12

250-500 10 14Gas tungsten arc Less than 50 8 10welding 50-150 8 12

150-500 10 14Air carbon (Light) Less than 500 10 12Arc cutting (Heavy) 500-1000 11 14Plasma arc welding Less than 20 6 6 to 8

20-100 8 10100-400 10 12400-800 11 14

Plasma arc cutting (Light)(2) Less than 300 8 9(Medium)(2) 300-400 9 12(Heavy)(2) 400-800 10 14

Torch brazing – – 3 or 4Torch soldering – – 2Carbon arc welding – – 14

Plate thicknessin. mm

Gas weldingLight Under 1/8 Under 3.2 4 or 5Medium 1/8 to 1/2 3.2 to 12.7 5 or 6Heavy Over 1/2 Over 12.7 6 or 8

Oxygen cuttingLight Under 1 Under 25 3 or 4Medium 1 to 6 25 to 150 4 or 5Heavy Over 6 Over 150 5 or 6

(1) As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficientview of the weld zone without going below the minimum. In oxyfuel gas welding or cutting where the torch produces a highyellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line the visible light of the (spectrum) operation

(2) These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc ishidden by the workpiece.

Data from ANSI Z49.1-1999

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ANSI Z87.1, Practice for Occupational and EducationalEye and Face Protection, American National StandardsInstitute, 11 West 42nd Street, New York, NY 10036.

Arc Welding and Your Health: A Handbook of HealthInformation for Welding. Published by The AmericanIndustrial Hygiene Association, 2700 Prosperity Avenue,Suite 250, Fairfax, VA 22031-4319.

NFPA Standard 51B, Cutting and Welding Processes,National Fire Protection Association, 1 BatterymarchPark, P.O. Box 9146, Quincy, MA 02269-9959.

OSHA General Industry Standard 29 CFR 1910 SubpartQ. OSHA Hazard Communication Standard 29 CFR1910.1200. Available from the Occupational Safety andHealth Administration at http://www.osha.org or contactyour local OSHA office.

The following publications are published byThe American Welding Society, P.O. Box 351040,Miami, Florida 33135. AWS publications may bepurchased from the American Welding society athttp://www.aws.org or by contacting the AWS at800-854-7149.

ANSI, Standard Z49.1, Safety in Welding, Cutting andAllied Processes.

AWS F1.1, Method for Sampling Airborne ParticulatesGenerated by Welding and Allied Processes.

AWS F1.2, Laboratory Method for Measuring FumeGeneration Rates and Total Fume Emission of Weldingand Allied Processes.

AWS F1.3, Evaluating Contaminants in the WeldingEnvironment: A Strategic Sampling Guide.

AWS F1.4, Methods for Analysis of AirborneParticulates Generated by Welding and Allied Processes.

AWS F1.5, Methods for Sampling and Analyzing Gasesfrom Welding and Allied Processes.

AWS F3.2, Ventilation Guide for Welding Fume Control

AWS F4.1, Recommended Safe Practices for thePreparation for Welding and Cutting of Containers andPiping That Have Held Hazardous Substances.

AWS SHF, Safety and Health Facts Sheets.

SUPPLEMENT 2Bibliography and Suggested Reading

Listed below are some typical ingredients in welding electrode and their TLV (ACGIH) and PEL (OSHA) exposure limits.

Ingredients CAS No. TLV mg/m3 PEL mg/m3

Aluminum and/or aluminum alloys (as Al)***** 7429-90-5 10 15

Aluminum oxide and/or Bauxite***** 1344-28-1 10 10

Barium compounds (as Ba)***** 513-77-9 **** ****

Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 1.0(b)

Fluorides (as F) 7789-75-5 2.5 2.5

Iron 7439-89-6 10* 10*

Limestone and/or calcium carbonate 1317-65-3 10 15

Lithium compounds (as Li) 554-13-2 10* 10*

Magnesite 1309-48-4 10 15

Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*

Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.2 1.0(c)

Mineral silicates 1332-58-7 5** 5**

Molybdenum alloys (as Mo) 7439-98-7 10 10

Nickel***** 7440-02-0 1.5 1

Silicates and other binders 1344-09-8 10* 10*

Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*

Strontium compounds (as Sr) 1633-05-2 10* 10*

Zirconium alloys and compounds (as Zr) 12004-83-0 5 5

Supplemental Information:(*) Not listed. Nuisance value maximum is 10 milligrams per cubic meter. PEL

value for iron oxide is 10 milligrams per cubic meter. TLV value for iron oxideis 5 milligrams per cubic meter.

(**) As respirable dust.

(*****) Subject to the reporting requirements of Sections 311, 312, and 313 of theEmergency Planning and Community Right-to-Know Act of 1986 and of40CFR 370 and 372.

(c) Values are for manganese fume. STEL (Short Term ExposureLimit) is 3.0 milligrams per cubic meter.

(****) There is no listed value for insoluble barium compounds. The TLVfor soluble barium compounds is 0.5 mg/m3.

TLV and PEL values are as of 2004. Always check Material SafetyData Sheet (MSDS) with product or on the Lincoln Electric websiteat http://www.lincolnelectric.com

– 10 –

SUPPLEMENT 3Arc Welding Safety Precautions

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

– 11 –

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

– 12 –

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.

6.h. Also see item 1.c.

– 13 –Mar. ‘93

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

– 14 –

SUPPLEMENT 4Warning Label/Operating Manual Request Form

NOTE:S18494 WARNING LABELS, SUCH AS THE ONEBELOW FOR LINCOLN ELECTRIC WELDERS,ARE AVAILABLE FREE OF CHARGE to updateyour welding equipment. Operating manuals are also

available upon request. PLEASE write to The LincolnElectric Company, 22801 St. Clair Ave., Cleveland,Ohio 44117-1199 or visit www.lincolnelectric.com

SUPPLEMENT 5Engine Welder Fan Guards

In order to determine whether your engine welder has theproper fan guards, compare your welder with the photobelow. If your welder lacks the guards shown, contactyour nearest Lincoln Field Service Shop or Distributorfor assistance.

NOTE: On some engine welders, including the SA-200, the original fan guard designshown above has been modified to provide added protection and/or to make itmore likely to be replaced after maintenance. Check with a Lincoln FieldService Shop or Distributor to determine if updated guarding is available foryour welder.

– 15 –

SUPPLEMENT 6Welding Safety Checklist

Hazard Factors to Consider Precaution Summary

Electric shock can • Wetness • Insulate welder from workpiece and ground using dry insulation. Rubber kill • Welder in or on workpiece mat or dry wood.

• Confined space • Wear dry, hole-free gloves. (Change as necessary to keep dry.)• Electrode holder and • Do not touch electrically “hot” parts or electrode with bare skin or wet

cable insulation clothing.• If wet area and welder cannot be insulated from workpiece with dry

insulation, use a semiautomatic, constant-voltage welder or stick welderwith voltage reducing device.

• Keep electrode holder and cable insulation in good condition. Do notuse if insulation damaged or missing.

Fumes and gases • Confined area • Use ventilation or exhaust to keep air breathing zone clear, comfortable.can be dangerous • Positioning of welder’s head • Use helmet and positioning of head to minimize fume in breathing zone.

• Lack of general ventilation • Read warnings on electrode container and material safety data sheet (MSDS)• Electrode types, i.e., for electrode,

manganese, chromium, • Provide additional ventilation/exhaust where special ventilation etc. See MSDS requirements exist.

• Base metal coatings, • Use special care when welding in a confined area.galvanize, paint • Do not weld unless ventilation is adequate.

Welding sparks • Containers which have held • Do not weld on containers which have held combustible materials (unlesscan cause fire or combustibles strict AWS F4.1 procedures are followed). Check before welding.explosion • Flammable materials • Remove flammable materials from welding area or shield from sparks, heat.

• Keep a fire watch in area during and after welding.• Keep a fire extinguisher in the welding area.• Wear fire retardant clothing and hat. Use earplugs when welding overhead.

Arc rays can burn • Process: gas-shielded arc • Select a filter lens which is comfortable for you while welding.eyes and skin most severe • Always use helmet when welding.

• Provide non-flammable shielding to protect others.• Wear clothing which protects skin while welding.

Confined space • Metal enclosure • Carefully evaluate adequacy of ventilation especially where electrode requires• Wetness special ventilation or where gas may displace breathing air.• Restricted entry • If basic electric shock precautions cannot be followed to insulate welder from• Heavier than air gas work and electrode, use semiautomatic, constant-voltage equipment with• Welder inside or on cold electrode or stick welder with voltage reducing device.

workpiece • Provide welder helper and method of welder retrieval from outside enclosure.

General work area • Cluttered area • Keep cables, materials, tools neatly organized.hazards

• Indirect work (welding • Connect work cable as close as possible to area where welding is beingground) connection performed. Do not allow alternate circuits through scaffold cables, hoist

chains, ground leads.

• Electrical equipment • Use only double insulated or properly grounded equipment.• Always disconnect power to equipment before servicing.

• Engine-driven equipment • Use in only open, well ventilated areas.• Keep enclosure complete and guards in place.• See Lincoln service shop if guards are missing.• Refuel with engine off.• If using auxiliary power, OSHA may require GFI protection or assured

grounding program (or isolated windings if less than 5KW).

• Gas cylinders • Never touch cylinder with the electrode.• Never lift a machine with cylinder attached.• Keep cylinder upright and chained to support.

LINCOLN NORTH AMERICADISTRICT SALES OFFICES

U.S.A.ALABAMABIRMINGHAM 35124-1156 (205) 988-8232MOBILE 36582-5209(251) 443-6524

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ARIZONAPHOENIX 85260-1745(480) 348-2004

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LINCOLN INTERNATIONAL HEADQUARTERS

HARRIS CALORIFIC DIVISION2345 Murphy Blvd., Gainesville, Georgia 30504 U.S.A.

Phone: 1-800-241-0804 • Fax: (770) 535-0544 • Web Site: www.harriscal.com

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EUROPEBarcelona, Spain Phone: 34 91 816 4266

RUSSIA, AFRICA & MIDDLE EASTCleveland, Ohio U.S.A.Phone: (216) 481-8100

ASIA PACIFICSingaporePhone: 65 6773 6689AustraliaPhone: 61 2 9772 7222

Products and ServicesE205 9/04