Welding Equipment, Operating and

Safety Instructions.




















Table of Contents

Section 1 General Safety Information page 1

Section 2 Welding Equipment page 2

Section 3 Welding Machine locations and colour coding of cables page 3

Section 4 Technical data Charts page 4






















Section 1

General Safety Information
1) Always wear appropriate protective clothing i.e gloves, aprons, safety shoes and spats for
protection against U V rays created and reflected by the welding arc operation.
2) Wear the applicable eye and face protection helmets, fitted with the correct filter lens for
protection against the harmful I.R rays created and reflected by the welding arc operation.
3) Wear the applicable ear protection gear for protection against harmful loud noise within
close vicinity of your workplace.
4) Wear applicable breathing protection gear for protection against harmful fumes given off by
the welding process.
5) Make sure that the area around is safe. Remove any combustible materials away from your
work station. Never perform welding operation in an area containing combustible vapours,
flammable liquids or explosive dust.
6) Do not stand on the earthed work piece while changing the electrode.
7) Do not coil the welding cables around your body.
8) Do not touch any exposed copper strands of the welding cable, current carrying parts of the
connectors, earth clamp or electrode holder.
9) Should the welding cable, electrode holder or earth clamp radiate excessive heat, check all
connections and insulations and if damaged, replace immediately.
10) Be aware to protect other operators and persons close to your workplace from harmful U.V
and I.R rays emitted from the welding arc operation.












Section 2

Welding Equipment.
1) The input power cable of the welding machine shall only be connected by a qualified
electrician where there is no nova sockets provided for.
2) The input power cable should not be longer than 15 metres.
3) The welding machine should be connected away from; humid, acidic rain or wet areas.
4) The welding machine should be connected in a well ventilated area 30cm from another
welding machine or an obstacle.
5) Before commencing any welding operation checks to the input and out put welding cables
connections should be done to check if they are secure.
6) Do not change over the selector switch while the welding machine is in operation.
7) Use the welding cable which has the correct amperage for the work being done.
8) Welding machines and welding cables shall be used to the section to which they have been
allocated only.
9) Never tie the welding cables together use the appropriate cable connectors.
10) Never use damaged cables, helmets, electrode holders or PPE.














Section 3
Technical Data Chart for welding rods

Type Diameter (mm) Current (amps)
Mild steel 2.5 60-110
Mild steel 3.15 100-145
Mild steel 4 145-190
Mild steel 5 190-250
Stainless steel 2.5 45-80
Stainless steel 3.25 70-120
Stainless steel 4 100-150
Stainless steel 5 140-190
Ferron 3.15 80-120
Ferron 4 120-160
Cast iron 2 40-90
Cast Iron 2.5 40-90
Cast iron 3.15 65-105
Cast iron 4 100-135
Cast iron 5 150-190
Hard facing 3.15 110-145
Hard facing 4 140-180
Hard facing 5 180-270

Technical data taken from Afrox