I. How to use an electric welding machine
(I) Preparations before welding
1. The welding machine should be placed in a well-ventilated and dry place, and placed on a stable surface.
2. Check that the welding mask is free of light leakage and damage. Both welding personnel and assistants should wear appropriate personal protective equipment.
3. The welding clamp, power cord, and all connectors of the welding machine must be reliably connected and well insulated. Overheating at the connection points is not allowed, and the power cord terminals must not be exposed; they should be wrapped with electrical tape.
4. The length of the wire between the welding machine and the welding clamp shall not exceed 30 meters, and in special circumstances, it shall not exceed 50 meters. If the wire is damp or has broken strands, it shall be replaced immediately.
5. When welding cables cross roads, they must be elevated or buried underground in protective pipes. If they cross rails, they must pass under the rails.
6. The primary and secondary wiring of the AC welding machine must be accurate, and the input current must meet the equipment requirements. Contact with any live parts of the primary circuit is strictly prohibited.
7. The secondary tap connection copper plate must be tightened, and the terminal block should have a coil. Before closing the circuit breaker, carefully check that the contact bolts and other components are not loose or damaged.
(II) Precautions during welding
1. A reasonable welding process should be selected according to the technical conditions of the work. Overloading is not allowed, high current welding is not allowed, and metal cutting operations are not allowed with electric welding machines.
2. During load welding, the temperature rise of the welding machine should not exceed 60 degrees Celsius for Class A and 80 degrees Celsius for Class B. Otherwise, the machine should be stopped and cooled down before welding can be carried out.
3. The welding machine should be kept in a dry and well-ventilated area. When moving the welding machine, the power supply should be disconnected; do not drag the welding machine by its power cord. If a power outage occurs during welding, the power supply should be disconnected immediately.
4. Current adjustment is not permitted during welding. Adjustment must be made using the adjustment handle only after welding has stopped. Do not adjust too quickly or abruptly to avoid damaging the regulator.
5. Welding operations are prohibited under workpieces while the crane is in motion.
6. When welding in an area with crane wire ropes, care should be taken to prevent the welding machine ground wire from accidentally touching the hoisted wire rope to avoid sparks that could cause an accident.
7. When working in a damp area, welders must stand on insulated wooden boards and are not allowed to touch the welding machine wires or hold live welding clamps with their arms.
(III) Post-welding precautions
1. After completing the welding operation, the power should be cut off immediately, the welding machine switch should be turned off, and the power supply and ground wire of the welding clamp should be cleaned and tidied up to avoid short circuit when the switch is turned on.
2. If the automatic stop device fails during welding, the machine should be stopped immediately and the power disconnected for repair.
3. When removing weld slag, wear goggles. Keep your head away from the direction of slag splatter to avoid injury. Do not strike weld slag towards people present.
4. After outdoor work is completed, the welding machine should be covered to prevent it from getting wet in the rain.
5. When not welding (moving, repairing, adjusting, or taking a break during work), the power should be turned off to prevent accidents.
6. Check the welding machine monthly to ensure it is reliably grounded.
Welding machine auxiliary equipment includes gas welding goggles to prevent operators from being injured by ultraviolet rays, infrared rays or other rays generated by welding arcs or other welding energy sources; masks to protect the welder's eyes, face and neck during arc welding; white work clothes; welding gloves and foot protectors, etc.
II. Welding Station Maintenance
(I) Maintenance of the welding station
1) Before using the welding station, make sure the power cord and protective ground wire are in good condition.
2) Soldering irons should not be used for extended periods without heat to avoid burning out the tip and core.
3) When not in use, place the soldering iron on a soldering iron stand to prevent it from burning other items.
4) During the use of the electric soldering station, the soldering iron temperature and whether there is leakage should be checked regularly. If the temperature exceeds or falls below the specified range or there is leakage, the station should be stopped from use. Check twice a day and fill in the record.
5) When not in use, the welding station should be turned off and the plug should be unplugged.
(II) Maintenance of Metcal Soldering Station
1. Pre-use maintenance of the welding station
Before using a Metcal soldering station, always check that the cleaning sponge is not wet. Wet the sponge until it is no longer dripping wet. This ensures the soldering tip is properly cleaned and protected. Using a dry or overly wet sponge can damage the tip and make it difficult to apply solder.
2. Maintenance of the welding station during welding
Before using a Metcal soldering station, clean the soldering tip with a cleaning sponge to remove any impurities. This ensures a better solder joint quality, preventing cold solder joints and slowing down the oxidation of the soldering tip. Therefore, maintaining good cleanliness of the soldering tip can extend its lifespan.
3. Maintenance of the welding station after use
After using the Metcal soldering station, first adjust the temperature of the station to an appropriate level, then add a layer of new solder to the soldering tip for protection. This will protect the soldering tip from the air, thereby reducing the oxidation caused by contact with oxygen.
4. Maintenance of the welding station when not in use
When not in use, the power to the Metcal soldering station should be turned off to prevent the soldering tip from being exposed to high temperatures for extended periods. This can cause some of the flux on the soldering tip to turn into oxide deposits, reducing its thermal conductivity. (This applies to lead-free soldering stations without temperature control or automatic sleep function).
