Miller A-500 Owner's Manual - Page 5
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SECTION
1-SAFETY RULES FOR
OPERATION
OF ARC
WELDING
POWER SOURCE
1-1.
INTRODUCTION
1-2.
A.
We
learn
by experience.
Learning safety through
personal
experience,
like
a
child
touching
a
hot
Stove
is
harmful,
wasteful,
and unwise. Let the
experience
of others teach
you.
Safe
practices developed
from
experience
in the
use
of weld
ing
and
cutting
are
described in this manual.
Research,
devel
opment, and field
experience
have evolved reliable
equipment
and safe
installation, operation,
and
servicing practices.
Acci
dents
occur
when
equipment
is
improperly
used
or
main
tained. The
reason
for the safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical volumes
to
explain.
It is wiser
to
follow the rules.
Read
and understand these safe
practices
before
attempting
to
install,
operate,
or
service the
equipment. Comply
with
these
procedures
as
applicable
to
the
particular equipment
used and their instruction
manuals,
for
personal safety
and
for the
safety
of others.
Failure
to
observe these safe
practices
may
cause
serious in,
jury
or
death. When
safety
becomes
a
habit,
the
equipment
can
be used with confidence.
These
safe
practices
are
divided
into
two
Sections:
1
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)(only).
Reference standards: Published Standards
on
safety
are
also
available for additional and
more
complete
procedures
than
those
given
in this manual.
They
are
listed in the Standards
Index in this manual. ANSI Z49.1 is the
most
complete.
The
National
Electrical
Code.
Occupational
Safety
and
Health
Administration,
local industrial
codes,
and local in
spection requirements
also
provide
a
basis for
equipment
in
stallation,
use,
and service.
GENERAL PRECAUTIONS
Burn Prevention
Wear
protective clothing
-
leather
(or asbestos) gauntlet
gloves,
hat,
and
high safety.toe
shoes. Button
shirt
collar and
pocket flaps,
and
wear
cuffless
trousers
to
avoid entry of
sparks
and
slag.
Wear helmet with
safety goggles
or
glasses
with side shields
underneath, appropriate
filter lenses
or
plates (protected
by
clear
cover
glass).
This is
a
MUST for
welding
or
cutting.
(and
chipping)
to
protect the eyes from radiant energy and
flying
metal.
Replace
cover
glass
when
broken, pitted,
or
spattered.
See 1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot metal
such
as
electrode stubs and
workpieces
should
never
be handled without
gloves.
Medical first aid and
eye
treatment.
First aid
facilities and
a
qualified
first aid person should be availthle for each shift
unless medical facilities
are
close
by
for immediate
treatment
of flash burns of the
eyes
and skin burns.
Ear
plugs
should be
worn
when
working
on
overhead
or
in
a
confined space.
A hard hat should be
worn
when
others work
overhead.
Flammable hair
preparations
should
not
be used
bypersons
intending
to
weld
or
Cut.
B.
Toxic Fume Prevention
Adequate
ventilation. Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them with
adequate
ventilation
as
described
in
ANSI Stan
dard
Z49.1
listed
1
in
Standards index. NEVER
ventilate
with oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or cut)
may
produce
harmful
concentrations
of
toxic
fumes.
Adequate
local
exhaust ventilation
must
be
used,
or
each
person
in the
area
as
well
as
the operator
must
wear
an
airsupplied
respirator.
For
beryllium,
both
must
be used.
Metals coated with
or
containing
materials that emit toxic
fumes should
not
be heated unless
coating
is removed from
the work
surface,
the
area
is well
ventilated,
or
the operator
wears
an
air-supplied respirator.
Work
in
a
confined space
only
while it is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied respirator.
Gas leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large quantities
can
change
oxygen concentration
danger.
ously.
Do-not
bring
gas
cylinders
into
a
confined space.
Leaving
confined space, shut OFF gas
supply
at
source
to
prevent
possible
accumulation of gases
in the space
if
down
stream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that the space is
safe before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed by
the
heat of the
arc
(or flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and other
lung
and eye
irritating products.
The
ultra
violet
(radiant)
energy
of
the
arc
can
also
decompose
tn
chloroethylene
and
perchloroethylene
vapors
to
form
phos
gene.
DO NOT WELD
or
cut
where solvent vapors
can
be
drawn into the
welding
or
cutting atmosphere
or
where the
radiant energy
can
penetrate
to
atmospheres
con
taiiiing
even
minute
amounts
of trich
loroethylene
or
perchloroethylene.
C.
Fire and
Explosion
Prevention
Causes of fire and
explosion
are:
combustibles reached
by
the
arc,
flame, flying sparks,
hot
slag
or
heated
material;
misuse
of
compressed
gases and
cylinders;
and short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through cracks, along pipes, through
windows
or
doors,
and
through
wall
or
floor
openings,
Out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
fly
35 feet.
To prevent fires and
explosion:
Keep equipment
clean and
operable,
free of
oil,
grease, and
(in
electrical
parts)
of metallic
particles
that
can
cause
short
circuits.
If combustibles
are
in
area,
do NOT weld
or
Cut.
Move the
work if
practicable,
to
an
area
free of
combustibles. Avoid
paint
spray rooms,
dip tanks,
storage
areas,
ventilators. If the
work
cannot
be
moved,
move
combustibles
at
least
35
feet
away
out
of
reach
of
sparks
and
heat;
or
protect
against
ignition
with suitable and
snug-fitting,
fire-resistant
covers or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be
welded
on
(or cut).
Walls, ceilings,
and
floor
near
work
should be
protected by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing by
with
suitable
fire
ex
tinguishing
equipment
during
and for
some
time after weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including building
Construc
tion)
are
within 35 feet
b.
appreciable
combustibles
are
further than 35
feet but
can
be
ignited by
sparks
c.
openings
Iconcealed
or
visible)
in
floors
or
walls within
35
feet may expose combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings, roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted heat.
Hot work
permit
should
be
obtained before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After work
is
done,
check that
area
is free of
sparks,
glowing
embers,
and flames.
An
empty
container that held
combustibles,
or
that
can
pro
duce flammable
or
toxic vapors when
heated,
must
never
be
welded
on
or
cut, unless container has first been cleaned
as
described
in
AWS Standard
A6.O.
listed 3 in
Standards
index.
OM-233
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