SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
This group of symbols means Warning! Watch Out! ELECTRIC
could result in death or serious injury. The possible haz-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
ards are shown in the adjoining symbols or explained in
symbols and related instructions below for necessary actions to
the text.
avoid these hazards.
NOTICE – Indicates statements not related to personal injury.
� Indicates special instructions.
1-2. Resistance Spot Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you ELECTRIC SHOCK can kill.
see the symbol, watch out, and follow the related instruc- Touching live electrical parts can cause fatal
tions to avoid the hazard. The safety information given be-
shocks or severe burns. The input power circuit
low is only a summary of the more complete safety
information found in the Principal Safety Standards. Read and machine internal circuits are also live when
and follow all Safety Standards. power is on. Incorrectly installed or improperly
grounded equipment is a hazard.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as � Do not touch live electrical parts.
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge, � Wear dry, hole-free insulating gloves and body protection.
training and experience, has successfully demonstrated the � Additional safety precautions are required when any of the follow-
ability to solve or resolve problems relating to the subject ing electrically hazardous conditions are present: in damp loca-
matter, the work, or the project and has received safety tions or while wearing wet clothing; on metal structures such as
training to recognize and avoid the hazards involved.
floors, gratings, or scaffolds; when in cramped positions such as
During operation, keep everybody, especially children, sitting, kneeling, or lying; or when there is a high risk of unavoid-
away. able or accidental contact with the workpiece or ground. For these
conditions, see ANSI Z49.1 listed in Safety Standards. And, do not
SPOT WELDING can cause fire or work alone!
explosion. � Do not store or use equipment in standing water.
Sparks can fly off from the welding arc. The flying � Disconnect input power before installing or servicing this equip-
sparks, hot workpiece, and hot equipment can ment. Lockout/tagout input power according to OSHA 29 CFR
cause fires and burns. Accidental contact of elec- 1910.147 (see Safety Standards).
trode to metal objects can cause sparks, explosion, overheating, or � Properly install, ground, and operate this equipment according to
fire. Check and be sure the area is safe before doing any welding. this manual and national, state, and local codes.
� Remove all flammables within 35 ft (10.7 m) of the weld. If this is � Always verify the supply ground — check and be sure that input
not possible, tightly cover them with approved covers. power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
� Do not spot weld where flying sparks can strike flammable
grounded receptacle outlet.
material.
� When making input connections, attach the grounding conductor
� Protect yourself and others from flying sparks and hot metal.
first—double-check connections.
� Be alert that welding sparks can easily go through small cracks
� Keep cords dry, free of oil and grease, and protected from hot met-
and openings to adjacent areas.
al and sparks.
� Watch for fire, and keep a fire extinguisher nearby.
� Frequently inspect input power cord and ground conductor for
� Do not weld on containers that have held combustibles, or on damage or bare wiring — replace immediately if damaged — bare
closed containers such as tanks, drums, or pipes unless they are wiring can kill.
properly prepared according to AWS F4.1 (see Safety Standards).
� Turn off all equipment when not in use.
� Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline). � For water-cooled equipment, check and repair or replace any leak-
ing hoses or fittings. Do not use any electrical equipment if you are
� Remove any combustibles, such as a butane lighter or matches,
wet or in a wet area.
from your person before doing any welding.
� Use only well-maintained equipment. Repair or replace damaged
� After completion of work, inspect area to ensure it is free of sparks,
parts at once. Maintain unit according to manual.
glowing embers, and flames.
� Do not exceed the equipment rated capacity. � Wear a safety harness if working above floor level.
� Use only correct fuses or circuit breakers. Do not oversize or by- � Keep all panels, covers, and guards securely in place.
pass them.
� Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B FLYING SPARKS can injure.
for hot work and have a fire watcher and extinguisher nearby.
Very often sparks fly off from the joint area.
� Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leath- � Wear approved face shield or safety goggles with
er gloves, heavy shirt, cuffless trousers, high shoes, and a cap. side shields.
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� Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leath-
FUMES AND GASES can be
er gloves, heavy shirt, cuffless trousers, high shoes, and a cap. hazardous.
� Protect others in nearby areas by using approved flame-resistant Welding produces fumes and gases. Breathing
or noncombustible fire curtains or shields. Have all nearby per- these fumes and gases can be hazardous to your
sons wear safety glasses with side shields. health.
� Keep your head out of the fumes. Do not breathe the fumes.
HOT PARTS can burn. � Ventilate the work area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
� Do not touch hot parts bare handed.
to determine adequate ventilation is to sample for the composition
� Allow cooling period before working on equipment. and quantity of fumes and gases to which personnel are exposed.
� To handle hot parts, use proper tools and/or wear � If ventilation is poor, wear an approved air-supplied respirator.
heavy, insulated welding gloves and clothing to � Read and understand the Safety Data Sheets (SDSs) and the
prevent burns. manufacturer’s instructions for adhesives, coatings, cleaners, con-
sumables, coolants, degreasers, fluxes, and metals.
MOVING PARTS can injure. � Work in a confined space only if it is well ventilated, or while wear-
ing an air-supplied respirator. Always have a trained watchperson
The tong tips, tongs, and linkages move during nearby. Welding fumes and gases can displace air and lower the
operation. oxygen level causing injury or death. Be sure the breathing air is
safe.
� Keep away from moving parts.
� Do not weld in locations near degreasing, cleaning, or spraying
� Keep away from pinch points. operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
� Do not put hands between tips.
� Do not weld on coated metals, such as galvanized, lead, or cadmi-
� Keep all guards and panels securely in place. um plated steel, unless the coating is removed from the weld area,
the area is well ventilated, and while wearing an air-supplied respi-
� OSHA and/or local codes can require additional guarding to suit
rator. The coatings and any metals containing these elements can
the application.
give off toxic fumes if welded.
1-3. Additional Hazards For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. ELECTRIC AND MAGNETIC FIELDS
(EMF) can affect Implanted Medical
� Do not install or place unit on, over, or near com-
bustible surfaces.
Devices.
� Do not install unit near flammables. � Wearers of Pacemakers and other Implanted Med-
� Do not overload building wiring — be sure power ical Devices should keep away.
supply system is properly sized, rated, and protected to handle � Implanted Medical Device wearers should consult their doctor and
this unit. the device manufacturer before going near arc welding, spot weld-
ing, gouging, plasma arc cutting, or induction heating operations.
FALLING EQUIPMENT can injure.
� Use correct procedures and equipment of ad- OVERUSE can cause
equate capacity to lift and support unit. OVERHEATING.
� Follow the guidelines in the Applications Manual � Allow cooling period; follow rated duty cycle.
for the Revised NIOSH Lifting Equation (Publica-
tion No. 94-110) when manually lifting heavy parts or equipment. � Reduce duty cycle before starting to weld again.
� Secure unit during transport so it cannot tip or fall.
BATTERY EXPLOSION can injure.
READ INSTRUCTIONS.
� Do not use welder to charge batteries or jump start
� Read and follow all labels and the Owner’s Manual vehicles unless it has a battery charging feature
carefully before installing, operating, or servicing designed for this purpose.
unit. Read the safety information at the beginning
of the manual and in each section.
� Use only genuine replacement parts from the manufacturer.
� Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and lo-
cal codes.
FLYING METAL OR DIRT can injure
eyes.
� Wear approved safety glasses with side shields or
wear face shield.
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1-4. California Proposition 65 Warnings
WARNING – This product can expose you to chemicals in- For more information, go to www.P65Warnings.ca.gov.
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding Safe Practices for the Preparation of Containers and Piping for Weld-
Society standard ANSI Standard Z49.1. Website: www.aws.org. ing and Cutting, American Welding Society Standard AWS F4.1.
Website: www.aws.org.
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub- Safe Practice For Occupational And Educational Eye And Face Pro-
part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: tection, ANSI Standard Z87.1, from American National Standards In-
www.osha.gov. stitute. Website: safetyequipment.org.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement Standard for Fire Prevention During Welding, Cutting, and Other Hot
on the Uses of TLVs and BEIs. Website: www.osha.gov. Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
National Electrical Code, NFPA Standard 70 from National Fire Pro-
tection Association. Website: www.nfpa.org. Spot 2024–01
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
1-6. EMF Information
Electric current flowing through any conductor causes localized elec- 4. Keep head and trunk as far away from the equipment in the weld-
tric and magnetic fields (EMF). The current from arc welding (and al- ing circuit as possible.
lied processes including spot welding, gouging, plasma arc cutting,
5. Connect work clamp to workpiece as close to the weld as
and induction heating operations) creates an EMF field around the
possible.
welding circuit. EMF fields can interfere with some medical implants,
e. g. pacemakers. Protective measures for persons wearing medical 6. Do not work next to, sit or lean on the welding power source.
implants have to be taken. For example, restrict access for passers 7. Do not weld whilst carrying the welding power source or wire
−by or conduct individual risk assessment for welders. All welders feeder.
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit: About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a
Implanted Medical Device wearers should consult their doctor and the
cable cover. device manufacturer before performing or going near arc welding,
2. Do not place your body between welding cables. Arrange cables spot welding, gouging, plasma arc cutting, or induction heating opera-
to one side and away from the operator. tions. If cleared by your doctor, then following the above procedures
3. Do not coil or drape cables around your body. is recommended.
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