Digital Pulsed Drop Control Arc Weld

Model: PDC350G

☞ Read the manual carefully before attempting operation of the equipment.

■ During repairs and maintenance of the welder, it is recommended that an expert who
has good working knowledge of welding equipment operate it.

■ To ensure safety, it is recommended that an experienced worker read the manual

carefully prior to operating the welding equipment.

■ Concerning safety training, you should consult conference, forum, and licensing test
materials provided by related academies or associations.

■ This manual should be located in a place with easy access, and should be referred to
in order to gain better understanding of working conditions for the welding
equipment.

■ Feel free to contact us or our distributors regarding any questions and concerns you
may have.

♣ For general inquiries and office telephone numbers, please refer to the back of the
manual.♣
Table of Contents

CONTENTS: - Page

1. Safety instructions ------------------------------------ 2

2. Caution in handling ------------------------------------ 27

3. Constitution of Product ------------------------------------ 28

4. Rating ------------------------------------ 29

5. Installation of Product - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30

6. Operation of Product ------------------------------------- 32

7. Check-up and Maintenance of Product - - - - - - - - - - -- - - - - - - - - - - - - - - - 39

8. Circuit diagram ------------------------------------- 45

9. Outline Dimensions - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

10. WIRE FEEDER ------------------------------------- 47

11. Torch ------------------------------------- 52

Thank you very much for your purchase.

. Connection HYOSUNG

1. Safety Instructions

1. Safety Instructions

The products described were developed, manufactured and

tested in compliance with the fundamental safety requirements
of the EU machine directive. These products normally pose no
danger to persons or property if used in accordance with the
handling stipulations and safety notes prescribed for their
configuration, mounting, and proper operation.

Nevertheless, there is some residual risk!

Therefore, you should read this manual before installing,

connecting or commissioning the products. Store this manual in
a place to which all users have access at any time!

Carefully read all descriptions in this manual before attempting

to use this welder.

The following symbols for dangers, warnings, and precautions

identify important safety messages in this manual

Carefully read all safety instructions including warnings and

precautions prior to installation, operation, or service of the
welder. Failure to comply with these instructions could result in
personal injury or even death .

-2-
. Connection HYOSUNG

1. Safety Instructions

SAFETY PRECAUTIONS
 Read this instruction manual carefully before using the equipment, and operate it correctly.
 The notes, cautions and warnings started in this and to protect you and others from injury and
damage.
 Although this welder has been designed and produced in great consideration of the safety, be sure
to observe the safety instructions in this manual.
Otherwise, serious accidents resulting in death or sever injury may occur.
 It is assumed that improper operation of this equipment will cause various levels
of Injury and damage. This instruction manual classifies the levels into the following three ranks.
And they are indicated with warning signs and signal terms. These warning symbols and signal
terms are used also on the warning labels on the requirement in the same meaning.

Warning
Signal term Contents
symbol

Indicates and imminently hazardous situation which, if

DANGER not avoided, will result in death or serious injury.

Indicates potentially hazardous situation, which, if not

WARNING avoided, could result in death or serious injury.

Indicates a potentially hazardous situation, which, if not

CAUTION avoided, may result in moderate or minor injury only
property damage.

The serious injury stated above means loss of eyesight, injury, burn (high temperature or low temperature),
electric, bone fracture and poisoning leaving aftereffect and requiring hospital treatment or long-term
treatment as an outpatient. The property damage means damage extended to the properties and equipment.

 “What to do’ and “what not to do“ when operating the equipment indicated as shown below.

Action to be done without fail For example,

MANDATORY
grounding work.

FORBIDDEN Action not is done.

These symbols apply the general cases.

-3-
. Connection HYOSUNG

1. Safety Instructions

Fumes and Gases

INTRODUCTION manganese overexposure can affect

Many welding, cutting, and allied the central nervous system resulting in
processes produce fumes and gases, impaired speech and movement.
which may be harmful to your health. • In confined spaces the gases might
displace breathing air and cause
DEFINITION asphyxiation.
• Fumes are solid particles which
originate from welding consumables, HOW TO AVOID OVEREXPOSURE
the base metal, and any coatings • Keep your head out of the fumes.
present on the base metal. • Do not breathe the fumes.
• In addition to shielding gases that may • Use enough ventilation or exhaust at
be used, gases are produced during the the arc, or both, to keep fumes and
welding process or may be produced by gases from your breathing zone and
the effects of process radiation on the general area.
surrounding environment. • In some cases, natural air movement
• Acquaint yourself with the effects of provides enough ventilation and fresh
these fumes and gases by reading the air.
Material Safety Data Sheets (MSDSs) • Where ventilation is questionable, use
for all materials used (consumables, air sampling to determine the need for
base metals, coatings, and cleaners). corrective measures.
• For help, consult a recognized • Use mechanical ventilation to improve
specialist in Industrial Hygiene or air quality.
Environmental Services. • If engineering controls are not feasible,
• The amount and composition of these use an approved respirator.
fumes and gases depend upon the • Work in a confined space only if it is
composition of the filler metal and base well ventilated, or while wearing an
material, welding process, current level, airsupplied respirator. Fumes from
arc length, and other factors. welding or cutting and oxygen depletion
can alter air quality causing injury or
POSSIBLE EFFECTS OF OVEREXPOSURE death. Be sure the breathing air is safe.
• Depending on material involved ranges • Follow OSHA guidelines for permissible
from irritation of eyes, skin, and exposure limits (PELs) for various
respiratory system to more severe fumes.
complications. • Follow the American Conference of
• Effects may occur immediately or at Governmental Industrial Hygienists
some later time. recommendations for threshold limit
• Fumes can cause symptoms such as values (TLVs) for fumes and gases.
nausea, headaches, dizziness, and • Have a recognized specialist in
metal fume fever. Industrial Hygiene or Environmental
• The possibility of more serious health Services check the operation and air
effects exists when highly toxic quality and make recommendations for
materials are involved. For example the specific welding or cutting situation.

-4-
. Connection HYOSUNG

1. Safety Instructions

Radiation

INTRODUCTION using suitable shielding around the electron

Most arc welding and cutting processes, beam welding area.
laser welding, and torch welding, cutting, • Produced during grinding (pointing) of
and brazing, or soldering produce thoriated tungsten electrodes for Gas
quantities of radiation requiring Tungsten Arc Welding (GTAW) process
precautionary measures. Some -- the grinding dust is radioactive.
processes, such as resistance welding and • Controlled by using local exhaust and, if
cold pressure welding, ordinarily produce necessary, an approved respirator.
negligible quantities of radiant energy.
NONIONIZING RADIATION
DEFINITION • Intensity and wavelength of energy
Radiation is electromagnetic energy given produced depend on the process,
off by the arc or flame that can injure eyes welding parameters, electrode and
and burn skin. An operator sees visible base metal composition, fluxes, and
light radiation. However, he does not see any coatings or plating on the base
ultraviolet or infrared radiation. Radiation material.
is often silent and undetected, yet injury • Ultraviolet radiation increases
occurs. Have all users learn about the approximately as the square of the
effects of radiation. welding current.
• Visible brightness (luminance) of the
EFFECTS OF RADIATION arc increases at a much lower rate.
The effects of radiation depend on the • Processes using argon produce larger
wavelength, intensity, and length of time amounts of ultraviolet radiation than
one is exposed to the radiant energy. those using most other shielding gases.
Although a variety of effects is possible,
the following two injuries are most HOW TO PROTECT AGAINST IONIZING
common: RADIATION
• Skin burns. • Required protection varies with time of
• Eye damage. exposure, distance from source, and
shielding used.
TYPES OF RADIATION • Follow recommended procedures in
There are two types of radiation associated AWS F2.1.
with welding operations: • When grinding (pointing) thoriated
• Ionizing (such as X-rays). tungsten electrodes, always use local
• Non-ionizing (such as ultraviolet, visible exhaust and, if necessary, respiratory
light, or infrared). protection to prevent inhalation of dust.
• External radiation from thoriated
IONIZING RADIATION tungsten electrodes during storage,
• Produced by the electron beam welding welding, or disposal of residues is
process. negligible under normal conditions.
• Controlled within acceptable limits by

-5-
 . Connection HYOSUNG

1. Safety Instructions

Radiation

HOW TO PROTECT AGAINST • Locate welding operations so that other

NONIONIZING RADIATION workers are not exposed to either direct
• Use welding helmet with correct shade or reflected radiation. Use screens,
of filter plate according to ANSI Z87.1. curtains, or adequate distances from
other work stations, aisles, or walkways
Note: Transparent welding curtains are to avoid exposure.
not intended as welding filter plates, but • Wear safety glasses with UV protective
rather are intended to protect side shields in addition to a proper
passersby from incidental exposure. welding helmet with filter plate. The
• Protect exposed skin with adequate side shields provide needed protection
gloves and clothing according to ANSI Z49.1. from reflected radiation.
• Be aware of reflections from welding arcs, • Have all persons wear safety glasses
and protect all persons from with UV protective side shields anytime
intense reflections. near welding or cutting areas.
• Choose safety glasses according to
Note: Paints using titanium dioxide or ANSI Z87.1.
zinc oxide as major pigmentation media
have a low reflectance for ultraviolet
radiation.

-6-
. Connection HYOSUNG

1. Safety Instructions

Noise

INTRODUCTION • The time required to develop

In welding, cutting, and allied operations, permanent hearing loss depends on
noise may result from the process, the individual susceptibility, noise level, and
power source, or other equipment. Air exposure duration.
carbon arc cutting and plasma arc cutting • There is evidence that excessive noise
are examples of processes which are affects other bodily functions and
frequently noisy. Engine-driven generators behavior as well.
may also be quite noisy. Excessive noise
is a known health hazard. HOW TO PROTECT AGAINST NOISE
• Reduce the intensity of the source.
DEFINITION • Shield the source where practical.
Scientifically, noise is composed of several • Use engineering control methods, such
frequencies and involves random changes as room acoustics, to control noise.
in frequency or amplitude. Sound waves • If engineering methods fail to reduce
are produced when the air is mechanically noise to acceptable levels, wear
disturbed. Sound is measured by its approved personal protective devices
frequency (pitch-high or low) and intensity such as ear muffs or ear plugs
(loudness). Practically, noise is unwanted appropriate for the situation.
or unpleasant sound. It can get in the way • Follow OSHA regulations which require
of the sounds we would rather hear and a Hearing Conservation Program if
often need to hear for safety reasons. noise levels reach 85 dB on an 8-hour,
Time Weighted Average (TWA) basis.
EFFECTS OF OVEREXPOSURE TO • If noise level is questionable, have a
NOISE certified safety specialist or Industrial
• Loss of hearing that may be either full Hygienist take measurements and
or partial and either temporary or make recommendations.
permanent.
• Hearing loss may be a temporary
threshold shift from which the ears may
recover if removed from the noise
source.

-7-
 . Connection HYOSUNG

1. Safety Instructions

Chromium and Nickel in Welding Fume

INTRODUCTION • NIOSH Criteria Documents 76–129 and

The fume from welding processes may 77–164 (listed below) contain these
contain compounds of chromium, including conclusions based on data from the
hexavalent chromium, and of nickel. The chromate producing industry and from
composition of the base metals, the nickel ore-refining processes.
welding materials used, and the welding • Conclusions from the International
processes affect the specific compounds Agency for Research on Cancer
and concentrations found in the welding (IARC): (1) there is limited evidence in
fume. humans for the carcinogenicity of
welding fumes and gases, and (2) there
IMMEDIATE EFFECTS OF OVEREXPOSURE is inadequate evidence in experimental
TO FUMES CONTAINING CHROMIUM AND animals for the carcinogenicity of
NICKEL welding fumes.
• Similar to the effects produced by
fumes from other metals. OVERALL EVALUATION
• Cause symptoms such as nausea, • Welding fumes are possibly
headaches, dizziness, and respiratory carcinogenic to humans (Group 2B).
irritation. • No determination has yet been made
• Some persons may develop a concerning the health effects on
sensitivity to chromium or nickel which welders or users of chromium- or
can result in dermatitis or skin rash. nickel-containing alloys.
• Nevertheless, give consideration to the
CHRONIC (LONG TERM) EFFECTS OF NIOSH and IARC conclusions.
EXPOSURE TO FUMES CONTAINING
CHROMIUM AND NICKEL HOW TO PROTECT AGAINST
• Definite effects are not yet determined OVEREXPOSURE
• Conclusions from the National Institute • Do not breathe fumes and gases. Keep
for Occupational Safety and Health your head out of the fumes.
(NIOSH): some forms of hexavalent • Use enough ventilation or exhaust at
chromium and nickel and their inorganic the arc or both to keep fumes and
compounds should be considered gases from your breathing zone and
occupational carcinogens (cancercausing general area.
agents). • If ventilation is questionable, use air
sampling to determine the need for
corrective measures.
• Keep exposure as low as possible.

-8-
 . Connection HYOSUNG

1. Safety Instructions

Electrical Hazards

INTRODUCTION shoes or standing on a dry insulated

Electric shock from welding and cutting mat or platform.
equipment can result in death or severe • Use fully insulated electrode holders.
burns. Additionally, serious injury can Never dip the holder into water to cool it
occur if the welder falls as a result of the or lay it on conductive surfaces or the
shock. work surface.
All of the following are electrically • Do not touch holders connected to two
energized when the power is “on”: welding machines a the same time.
electrode and welding circuit, input power • Do not allow the holder or electrode to
circuit and machine internal circuits, the come in contact with any other person.
wire, reel of wire, drive rolls, and all other • Do not use worn, damaged,
metal parts touching the energized undersized, or poorly spliced cables,
electrode. welding gun cables, or torch cables.
Make sure all connections are tight,
HOW TO AVOID ELECTRIC SHOCKS clean, and dry.
Use proper precautionary measures and • Do not wrap cables carrying electric
recommended safe practices at all times. current around any part of your body.
Train all personnel using welding and • Ground workpiece as required by
cutting equipment to reduce the risk of codes.
injuries, fatalities, and electrical accidents, • When required, ground the workpiece
by following these instructions: to a good electrical earth ground. The
• Read all instructions, labels, and work lead is not a ground lead. Do not
installation manuals before installing, use the work lead as a ground lead.
operating, or servicing the equipment. Use a separate connection to ground
• Train all personnel involved in welding the workpiece to earth.
operations to observe safe electrical • Do not touch an energized electrode
work practices according to OSHA while you are in contact with the work
1910.332. circuit.
• Do not touch live electrical parts. • When using auxiliary power from
• Have all installation, operation, welding generators, it is recommended
maintenance, and repair work that you use a circuit protected by a
performed only by qualified people. ground fault circuit interrupter (GFCI)
• Properly install and ground the such as receptacles in boxes, extension
equipment in accordance with the cords, and the like. Use of an assured
instruction manual and national, state, grounding system is also acceptable
and local codes. and is equivalent to use of a GFCI
• Do not work alone where there are protected circuit.
electrically hazardous conditions • In confined spaces or in locations that
• Wear dry, insulating gloves in good are electrically hazardous due to water
condition and protective clothing. or perspiration, do not use welding
• Insulate yourself from the workpiece equipment with AC output unless it is
and ground by wearing rubber soled also equipped with a voltage reducer

-9-
 . Connection HYOSUNG

1. Safety Instructions

Electrical Hazards

and remote output control. Use before further use.

equipment with DC output and do not • Keep all covers and panels securely in
work alone. place.
• Additional safety precautions are Follow lockout/tagout procedures (see
required when welding is performed AWS Safety and Health Fact Sheet No. 18,
under any of the following electrically Lockout/Tagout).
hazardous conditions: in damp
locations or while wearing wet clothing; WEARERS OF PACEMAKERS
on metal floors, gratings, scaffolds, or • The technology of heart pacemakers
other metal structures; in cramped changes frequently and this may
positions such as sitting, kneeling, or change the way these devices are
lying; or when there is a high risk of affected by other electrical devices
unavoidable or accidental contact with including welding equipment. Wearers
the workpiece or ground. Where these of pacemakers or other electronic
conditions are present, use one of the equipment vital to life should be
following types of equipment presented instructed to check with their doctor and
in order of preference: with the device manufacturer to
1) a semiautomatic DC constant voltage determine if any hazard exits when
metal electrode (wire) welder, near welding or cutting operations. See
2) a DC manual covered electrode (stick) AWS Fact Sheet No. 16 for additional
welder, or information about pacemakers and
3) an AC welder with reduced open-circuit welding.
voltage. In most situations, use of a DC,
constant voltage wire welder is PROCEDURES FOR ELECTRIC SHOCK
recommended. • Turn off the electric power.
And, do not work alone! • Use nonconducting material, such as
Wear a safety harness to prevent falling wood, to free the victim from contact
if working above floor level where there with live parts or wires.
are no other protective structures such • If the victim is not breathing, call for
as railings, walls, guard fences, or the emergency services. Administer
like. cardiopulmonary resuscitation (CPR)
Turn off all equipment when not in use. immediately after breaking contact with
Disconnect the power to equipment that the electrical source. Continue CPR
will be left unattended or out of service. until breathing starts or until help
• Disconnect the input power or stop the arrives.
engine before installing or servicing the • Where an automatic electronic
equipment. Lock the input disconnect defibrillator (AED) is available use
switch in the “open” position, or remove according to instructions.
the fuses, so that power cannot be • Treat an electrical burn as a thermal
turned on accidentally. burn by applying clean, cold (iced)
• Use only well maintained equipment. compresses. Prevent contamination,
Routinely inspect welding equipment and cover with a clean, dry dressing.
and repair or replace all damaged parts
- 10 -
 . Connection HYOSUNG

1. Safety Instructions

FIRE AND EXPLOSION PREVENTION

INTRODUCTION combustibles with a cover made of fire-

Welding, cutting, and allied processes resistant material.
produce molten metal, sparks, slag, and hot • Remove or make safe all combustible
work surfaces. These can cause fire or materials for a radius of 35 feet (10 meters)
explosion if precautionary measures are not around the work area.
followed. • Using fire-resistant material, cover or block
all open doorways, windows, cracks, and
MAIN CAUSES OF FIRES IN WELDING AND other openings.
CUTTING—FLYING SPARKS • If possible, enclose the work area with
• Sparks can travel up to 35 feet (10 meters) portable fire-resistant screens.
on a horizontal direction from the work area. • Protect combustible walls, ceilings, floors,
Note: Sparks and molten metal can travel etc., from sparks and heat with fire-resistant
greater distances when falling. covers.
• Sparks can pass through or become lodged • If working on a metal wall, ceiling, etc.,
in cracks, clothing, pipe holes, and other prevent ignition of combustibles on the other
small openings in floors or partitions. side by moving the combustibles to a safe
location.
TYPICAL COMBUSTIBLE MATERIALS AND • If relocation of combustibles cannot be
CONDITIONS done, designate someone to serve as a fire
• Parts of buildings such as floors, partitions, watch, equipped with a fire extinguisher,
and roofs. during the welding operation and for at least
• Contents of buildings such as wood, paper, one half-hour after welding is completed.
clothing, plastics, chemicals, and flammable • Do not weld or cut on material having a
liquids and gases. combustible coating or combustible internal
• Outdoor combustible materials include dry structure, as in walls or ceilings, without an
leaves, grass, and brush. approved method for eliminating the hazard.
• Welding and cutting have caused • Do not dispose of hot slag in containers
explosions when performed in spaces holding combustible material.
containing • Keep a charged fire extinguisher nearby,
flammable gases, vapors, liquids, or dusts. and know how to use it.
• After welding or cutting, make a thorough
HOW TO PREVENT FIRES examination for evidence of fire. Remember
• Remove any combustible material from the that easily visible smoke or flame may not
work area. be present for some time after the fire has
• Where possible, move the work to a started.
location well away from combustible • Be aware that overloading and improper
materials. sizing can cause overheating of electrical
• If relocation is not possible, protect equipment and possible fire hazard.
• Be sure all electrical equipment and wiring
are installed properly and have
recommended circuit protection.

- 11 -
 . Connection HYOSUNG

1. Safety Instructions

FIRE AND EXPLOSION PREVENTION

• Be sure the work cable is connected to the • Do not apply heat to a workpiece covered by
work as close to the welding area as an unknown substance or whose coating can
practical. produce flammable, toxic, or reactive vapors
Work cables connected to the building when heated.
framework or other locations some distance • Develop adequate procedures, and use
from the welding area increase the proper equipment to do the job safely.
possibility of the welding current passing • Provide adequate ventilation in work areas
through lifting chains, crane cables, or other to prevent accumulation of flammable gases,
alternate circuits. This can create fire and vapors, or dusts.
shock hazards or overheat lifting chains or • Clean and purge containers before applying
cables until they fail. heat.
• Do not weld or cut in atmospheres • Vent closed containers, including castings,
containing dangerously reactive or before preheating, welding, or cutting. Venting
flammable gases, vapors, liquids, or dust. prevents the buildup of pressure and possible
• Do not apply heat to a container that has explosion due to the heating and expansion of
held an unknown substance or a gases.
combustible material whose contents, when
heated, can produce flammable or explosive
vapors.

- 12 -
 . Connection HYOSUNG

1. Safety Instructions

BURN PROTECTION

INTRODUCTION • Remove any combustibles, such as a butane

Sparks and spatter fly off from the welding lighter or matches, from your person before
process. Hot metal and sparks blow out from doing any welding or cutting
the cutting process. The workpiece and • If combustible substances spill on clothing,
equipment get hot. The flying sparks and hot change to clean fire-resistant clothing before
metal, spatter, hot workpiece, and hot doing any welding or cutting.
equipment can cause burns. Additionally, • Use aprons, cape-sleeves, leggings,
arc rays can cause radiation burns (see Fact shoulder covers, and bibs designed and
Sheet No. 2). approved for welding and cutting service.
• Where unusually heavy welding or cutting is
HOW TO PREVENT BURNS involved, use sheet metal shields for
• Wear dry, hole-free insulating gloves. extra protection.
• Touching hot equipment such as electrode • For highly hazardous processes or jobs, give
holders, gun tips, and nozzles can cause serious consideration to automation.
burns—always wear insulated gloves or • Do not attempt to repair or disconnect
allow a cooling period when touching electrical equipment under load.
these and any associated parts of Disconnecting under load produces arcing of
equipment that are near the actual the contacts and may cause burns or shocks.
welding or cutting operation.
• Wear oil-free protective garments such as HOW TO PROTECT OTHERS FROM BURNS
leather gloves, heavy shirt, cuffless pants, • Use noncombustible screens or barriers to
high shoes, and a cap. protect nearby persons or watchers.
• Do not wear pants with cuffs or shirts with • Mark hot work pieces to alert others of the
open pockets or any clothing that can catch burn and fire hazards.
and hold molten metal or sparks. • If job requires several persons, have all wear
• Wear high top shoes or leather leggings proper protective gear and follow all
and fire-resistant boots. required procedures.
• Use approved helmets or hand shields that
provide protection for the face, neck, and
ears, and wear a head covering to protect
the head.
• Wear approved safety goggles with side
shields.
• When welding or cutting overhead or in
confined spaces, wear flame-resistant ear
plugs or ear muffs to keep sparks out of
ears.
• Keep clothing free of grease, oil, solvents,
or any flammable substances.

- 13 -
 . Connection HYOSUNG

1. Safety Instructions

MECHANICAL HAZARDS

INTRODUCTION HAND TOOL SAFETY

Like other industries that work with metals, • Use tools safely.
welding and cutting are seldom done in • Use the right tool for the job. Be sure it is the
isolation. right size.
Other equipment and tools are normally used • Use good quality tools, and use them for the
and kept nearby. The use of, or the job they were intended to perform. For
closeness to, mechanical equipment can example, it is often tempting to use a
present hazards to the welder. A knowledge screwdriver for a chisel or a pair of pliers for
of the proper use of power tools, such as a wrench—avoid such practices. The right
grinders, chippers, drills, and various hand tool will do the job faster and safer.
tools, is important to welder safety. Know and • Keep a firm grip on tools to prevent them
understand the safe limits and proper use of from slipping away.
cranes, positioners, and other material • Do not overload or force a tool beyond its
handling equipment, and use the appropriate capabilities.
guards and personal protective equipment. • Never force a tool.
Recommendations concerning frequently • Foresee results of unexpected occurrences
encountered mechanical hazards in welding such as tools getting away, binding, or
follow. coming loose from their handles.
• Check any tool that has become jammed or
GRINDING WHEEL SAFETY otherwise overstressed for damage
• Follow grinding wheel speed limitations before reuse.
according to manufacturer’s instructions. • Anticipate the reactive force from tools.
• Do not grind on the side of a wheel not • Anticipate what might happen to a
designed for such service. component that is to be loosened or unbolted
• When starting a new wheel, stand to the from its working position.
side until it reaches speed, and correct any • When using tools that involve weights and
abnormalities noted. spring tension, be certain that all pressures
• Be sure guards are in place and properly are applied and released in a safe manner.
used. • Follow lockout procedures for equipment
and tools specifying such a procedure.
PERSONAL PROTECTIVE EQUIPMENT • Do not bypass interlocks on equipment.
• Wear proper eye and hand protection. Bypassing defeats the safety device and
• Use face shields, safety glasses, and creates a possibly serious hazard.
goggles as appropriate. • Inspect tools before use.
• Wear dry, hole-free insulating gloves when • Never use a tool that is in poor or faulty
welding or cutting. condition.
• Avoid wearing loose items such as rings, • Keep all hand tools in good working
necklaces, bracelets, long hair, loose condition.
clothing, neckties, scarves, earrings, and
beards.
• Watch out for sharp objects, pinch points,
and moving objects.
- 14 -
 . Connection HYOSUNG

1. Safety Instructions

MECHANICAL HAZARDS

• Store hand tools in a safe place. Many • For additional information of the safe
accidents are caused by tools falling off operation and guarding of mechanical
ladders, shelves, or scaffolds that are being equipment, refer to the manufacturers’ safe
moved. Each tool should have a designated operating procedures for the equipment
place in the tool box or electrician’s pouch. being used.

TRIPPING AND FALLING

.
INTRODUCTION • Restricted vision caused by needed safety
Welding, cutting and associated processes gear such as welding helmets and safety
take place in a wide variety of locations under goggles.
many different conditions. Welding and cutting • Failure to fully understand the hazards, such
occur in shops and factories on the floor level, as toxic fumes, when entering a pit,
on high steel in skyscraper construction, in tank, or compartment.
pits, vats, mines, tanks, ship compartments,
and literally everywhere that metals are joined HOW TO PREVENT TRIPPING AND
or cut. FALLING
• Be alert, awake, and concentrated about the
CAUSES OF TRIPPING AND FALLING job and the work area; notice any changing
• Poor housekeeping of materials, equipment, conditions; stay focused—do not let yourself
hoses, and tools. or others be preoccupied or woozy on the
• Scattered parts and pieces either left over or job.
waiting for use. • Wear and use only the correct, approved
• Failure to use approved safety belts and equipment for the specific job; be sure it is
harnesses or incorrect use of them when properly installed and used.
working above floor level. • Do not carry things that obstruct your view or
• Electric shock from faulty equipment. that upset your balance.
• Sudden loud noises or shouts. • Prohibit horseplay on the job.
• Incorrect or improperly used or installed • Follow all standard safe practices required
safety equipment such as ladders, by your employer.
guardrails, scaffolds, and nets. • Keep the work area clean and neat—ask
• Failure to wear proper personal protective your supervisor for help if this is a problem.
wear such as skid-resistant soles on shoes • Do not take chances or unnecessary risks—
to meet the needs of the job. such actions can cause accidents.
• Horseplay or unsafe actions, such as
tossing tools to each other or bumping
someone in a precarious position

- 15 -
 . Connection HYOSUNG

1. Safety Instructions

FALLING OBJECTS

INTRODUCTION • Notify others of overhead work and any

Welding, cutting, and associated processes changing job conditions.
often take place in areas where failing • Remember, a welding helmet or goggles
objects may be present. Failing objects may restricts vision and may prevent taking the
seriously injure or kill. Failing objects are action necessary to avoid falling objects.
common problems on construction and • Post areas where failing objects are a
demolition sites of all kinds, from buildings to hazard.
bridges, and are also often a problem during
maintenance work. HOW TO PREVENT FALLING OBJECTS
• Be certain that material being welded or cut
HOW TO PROTECT AGAINST FALLING is secured from failing.
OBJECTS • Do not permit loose objects near the edge
• Wear approved head and foot protection. 19 of overhead structures.
• Be alert and aware of your total work • Cover floor and wall openings.
environment and any possible overhead • Use toe boards with guardrails.
objects before you start working. • Do not kick, throw, or push anything off
• Place a safety net or equivalent below overhead structures this includes electrode
overhead work. stubs and scrap metal.
• Follow safe work practices when working • Do not create failing objects for others—be
below overhead activities. alert to all your actions.

- 16 -
 . Connection HYOSUNG

1. Safety Instructions

CONFINED SPACES

INTRODUCTION/DEFINITION and venting, if feasible—keep vents open

Many different places require welding, cutting, and valves leak-free.
and heating work. Some of these places lack • Lock out all systems not required during
room and become “confined spaces.” welding, cutting, or heating.
Confined spaces have the following • Provide means for readily turning off power,
characteristics: gas, and other supplies from outside the
• Limited space, entry, or exit. confined space.
• Poor ventilation—lack of safe breathing air • Protect or remove any hazardous materials
and possible buildup of hazardous gases, or materials which may become a physical or
fumes, and particles. health risk when heated or exposed to an
arc.
EXAMPLES OF CONFINED SPACES
• Small rooms. • Storage tanks. REQUIRED ACTIONS DURING WORK IN A
• Process vessels. • Pipelines. CONFINED SPACE
• Pits • Sewers. • Continuously ventilate and monitor confined
• Tunnels. • Silos. space to ensure that fumes and gases do not
• Vats. • Degreasers exceed safe exposure limits as found in
• Reactor vessels. • Boilers OSHA (Occupational Safety and Health
• Underground utility vaults. Administration) regulations Title 29, CFR
• Compartments of ships. Part 1910, 1000.
• Unventilated corners of a room. • Use NIOSH/MSHA (National Institute for
• Ventilation and exhaust ducts. Occupational Safety and Health/Mine Safety
• Furnaces. and Health Administration) approved
breathing device when required by code,
REASONS FOR DEATHS AND SERIOUS instruction, or good practice.
INJURIES FROM WELDING IN CONFINED • Keep unnecessary persons and equipment
SPACES out of and away from the confined space.
• Fire. • Explosion. • Do not allow equipment to block exit or
• Electric shock. • Asphyxiation. possible rescue efforts.
• Exposure to hazardous air contaminants. • Place as much equipment as possible
outside the confined space.
ACTIONS REQUIRED BEFORE APPROVING • Do not go into a confined space unless a
START OF WORK IN A CONFINED SPACE watchperson, properly equipped and trained
• Open all covers and secure them from for rescue, is outside and maintaining
closing. continuous communications with worker
• Test confined space atmosphere for (1) inside.
suitable oxygen content, (2) no combustibles • Provide means for turning off power,
or reactives, (3) no toxics. gases, and fuel from inside the confined
Note: The testing requires special equipment space, if feasible, especially if outside
and training. turn-off means are not provided, feasible,
• Isolate lines by capping or double valving or certain.

- 17 -
 . Connection HYOSUNG

1. Safety Instructions

CONTACT LENS WEAR

.
INTRODUCTION • Have all employees wearing contact lenses
Since 1967, the American Welding Society notify their immediate supervisors and the plant
has received reports concerning welders safety medical personnel about their use of
who have claimed to have had contact contacts—let people know you wear them.
lenses fused to their eyes, either by the heat • Train all first aid personnel in the proper
of the arc or by microwave radiation. Not removal of contact lenses.
one of these reports has been • Encourage the wearing of contact lenses in
substantiated, and safety bulletins issued by industry for those employees whose
the Occupational Safety and Health central and peripheral vision can be increased
Administration (OSHA), the Food and Drug by contact lenses, as contrasted tospectacle
Administration (FDA), and the National lenses. Examples of such employees are
Safety Council (NSC) have all refuted that those who have had a cataract removed from
such incidents could possibly have one or both eyes, those with irregular
occurred. The American Optometric astigmatism from corneal scars, or
Association (AOA) has stated that keratoconus, and those who are extremely
improvements in lens materials, and in nearsighted.
design, fitting, and care procedures, have • Have employees keep a spare pair of
eliminated many of the problems formerly contacts or prescription spectacles, or both, in
associated with contact lenses. The their possession on the job to avoid an
Association noted that contact lenses do not inability to function if they should damage or
make the eye more susceptible to injury nor lose a contact lens while working.
will they make matters worse if an eye injury • Do not permit safety and medical personnel to
accidentally happens. discriminate against an employee who can
• The sum of all the research is this— achieve visual rehabilitation by contact lenses,
wearing contact lenses poses no problem either in job placement or on return to a job
for welders in most normal situations. category.
• Have safety and medical personnel determine
GUIDELINES FOR USE OF CONTACT on an individual basis the need for wearing
LENSES spectacles or contact lenses in jobs which
Use the following guidelines, adapted from require unique visual performance. Carefully
the Contact Lens Ophthalmologists consider also the recommendations of the
Association (CLAO), and endorsed by the Occupational Safety and Health
AWS, where contact lenses are worn in Administration and the National Institute for
welding situations: Occupational Safety and Health.
• Wear contact lenses in industrial
environments, in combination with
appropriate industrial safety eyewear,
except where there is likelihood of injury
from intense heat, massive chemical
splash, highly particulate atmosphere, or
where specific regulations prohibit such
use

- 18 -
 . Connection HYOSUNG

1. Safety Instructions

ERGONOMICS IN THE
WELDING ENVIRONMENT

INTRODUCTION • Address all initial complaints in a timely

The welding environment introduces many manner.
challenges to the field of ergonomics, many of • Interact with the worker and discuss possible
which are now just being understood, not only solutions to give the employee ownership of
by the manufacturing/processing sector, but any new plans and to gain acceptance for
by the medical profession as well. any redesign solutions.
• Redesign the workstation in conjunction with
DEFINITION the employee so he feels part of the process,
Ergonomics, also called human factors uses the new design, and helps develop
engineering, involves designing the other ideas for future improvements.
workplace to fit the needs of the workers,
rather than trying to make workers adjust to WORKSTATION DESIGN FACTORS
the workplace. When a workplace is designed Some of the many factors that require
properly, the worker performing the task feels consideration when analyzing and designing
comfortable with the job both physically and the welding environment include the following:
psychologically. Quality and production • The physical ability of the worker (history).
increase, and all parties benefit from the • The weight of the gun.
improved conditions. • The design of tools.
• The position of the work.
PROBLEMS RESULTING FROM POOR • The body mechanics of the individual
ERGONOMICS welding operation.
• Repetitive Motion Disorder (RMD). • The type of protective equipment the welder
• Cumulative Trauma Injury (CTI). is using.
• Lower productivity. • The work space (size, lighting, temperature,
• Lower quality. noise, vibration, etc.)
• Worker dissatisfaction. • Physical requirements of the job (lifting,
turning, reaching).
POSSIBLE SOLUTIONS TO ERGONOMIC • Mental requirements of the job (motivation,
PROBLEMS alertness, concentration).
• Recognize that both RMD and CTI are often
felt to be a type of short term weakness or
fatigue, when actually they are the start of
potentially larger injuries.

- 19 -
 . Connection HYOSUNG

1. Safety Instructions

GRAPHIC SYMBOLS FOR

PRECAUTIONARY LABELS

INTRODUCTION RATIONALE FOR STANDARDIZED

Existing standards, such as American SYMBOLS
National Standards Institute (ANSI) Z49.1, The welding and cutting industry needs
ANSI Z535.4, and National Electrical standardized symbols and uniform methods of
Manufacturer’s Association (NEMA) EW6, use to avoid user confusion and to
thoroughly present guidelines for the supplement and reinforce the written
minimum required information, method of message.
presentation, signal words, color use, and NEMA EW6 standard provides a list of
label format. symbols and minimum symbol size for labels
along with complete information regarding
DEFINITION their use and application.
Graphic symbols are pictures sometimes
called pictographs, pictograms, or pictorials HOW TO USE THE SYMBOLS
used in place of, or as a supplement to, • Use the symbols to show the associated
written words. These symbols provide non- hazard.
verbal communication about the possible • Take standard symbols from NEMA EW6.
hazard. They represent or symbolize the • Follow a building block approach.
hazard. • Select a base symbol—often it is used alone
such as the fire symbol.
RATIONALE FOR GRAPHIC SYMBOLS • Choose additional symbol element(s) to fully
Pictures may convey information better than show the hazard.
words. Therefore, the next logical evolution of • Combine the chosen symbol element(s),
precautionary labeling adds graphic symbols such as the stick electrode symbol, with the
to show the major welding or cutting hazards. base symbol, such as fumes and gases.
The use of symbols on precautionary labels is • Carefully review all symbols on this Fact
optional and is recommended for the Sheet and in NEMA EW6.
following reasons: • Follow the design methods and standard
• Symbols may show and help to explain the way of incorporating symbols onto the
hazards quickly—fast concept transfer—and safety label according to EW6.
use visual (not verbal) recognition.
• Symbols address nonreaders as well as
readers.
• Symbols may be multilingual and usually
translate directly into all languages.

- 20 -
 . Connection HYOSUNG

1. Safety Instructions

STYLE GUIDELINES FOR

SAFETY AND HEALTH DOCUMENTS

INTRODUCTION the consequences as well as how to avoid

Style for welding and cutting documents them. The stylistic features are as follows:
means two things: matter and manner; form • Use the active voice.
and content; style and format. Style refers not • Use strong, clear, action verbs in the
only to what is said, but also how it is stated imperative mood.
and presented to the reader. • Use short, direct sentences.

EARLY STYLE METHODS AND EATURES USE OF PRECAUTIONARY LABELING

The style and format for welding and cutting SIGNAL WORDS
documents have evolved with time. Ten or There are three signal words used to identify
fifteen years ago documents contained the the levels of hazard in ANSI Z535.4—
following features: DANGER, WARNING, and CAUTION.
• Commands or directives telling what to do Wherever possible, reserve these words for
without explaining the consequences of use on labels only. Avoid the use of signal
not doing it. words in prose. Use the word “precautionary”
• Frequent use of the passive voice rather instead of signal words for text.
than active voice.
• Use of underlining for emphasis. CURRENT STYLE EXAMPLES
• “Use a checklist. Do not skip any items.
EARLY STYLE EXAMPLES Omitting steps can cause personal injury or
• “A check off list should be used by the equipment damage.”
welding operator.” • “Use proper quality control procedures to
• “Proper quality control procedures should be meet intended performance requirements
used.” and to minimize costs.”

BACKGROUND OF CURRENT STYLE

REASONS FOR NOT USING EARLY STYLE
The current writing style evolves from
The AWS Safety and Health Committee
precautionary labeling practices and arises
recommends the early method not be used
from the obligation to users found in
for the following reasons:
standards and codes, as well as from an
• The older style of writing does not give or
industry-wide concern for the well-being of its
imply the consequences of the failure to act
customers. The writing method needs to warn
as directed.
and instruct the reader about the normal
• The older style does not tell how to avoid
use and reasonably foreseeable misuse
the consequences when it is possible to do
and abuse of a product or process as is used
so.
in current precautionary labeling practices.
CURRENT STYLE METHODS AND The instruction literature which accompanies
FEATURES a product, or process, is considered as part of
Currently, it is recommended that that practice.
documents state the hazards and include

- 21 -
 . Connection HYOSUNG

1. Safety Instructions

STYLE GUIDELINES FOR

SAFETY AND HEALTH DOCUMENTS

• The warn part of the requirement is met by

a statement of the hazard and • Use enough ventilation or exhaust at the
consequences of the failure to act as arc to keep fumes and gases from your
specified. breathing zone, and the general area.
• The instruct part of the requirement is met • Wear correct eye, ear, and body
by explaining how to avoid the hazard and protection.
consequences. • Read and follow the manufacturer’s
• It is not mandatory to have a particular instructions, employer’s safety practices,
order to the statements. It can be warn and and Material Safety Data Sheets
instruct or instruct and warn. Either (MSDSs).
sequence is satisfactory, though warn and
instruct is preferred.
• This order preference is based on current FEATURES OF THE CURRENT METHOD
precautionary labeling practices which • Use simple, clear, precise words.
warn first and instruct second. • Use the active voice instead of the passive
• For all safety and health information voice in sentence structure.
published by the American Welding Society, • Use the imperative mood of the verbs to
try to follow the warn and instruct give commands or directives.
requirements for the normal use as well as
for the foreseeable misuse and abuse of SUMMARY
the product or process. Remember the primary purpose of any
instructions, but especially those containing
FORMAT SUGGESTIONS safety or health information;
• Several formats satisfy these requirements. • Quickly get to the point to keep the reader’s
The two most popular are the following: attention and save time.
• Put all information in one or two sentences. • Be clear, direct, and simple in
• Use an entry statement containing the communicating all the reader needs to know.
warning (statement of hazard and its • Use easy-to-read short lists to follow the
consequences) followed by a list of simple preferred method.
instructions telling how to avoid the hazard
like the following typical example from NEMA
EW6:

WARNING: ELECTRIC SHOCK can

kill:
FUMES AND GASES can be
hazardous; ARC RAYS can injure
eyes and burn skin.
• Do not touch live electrical parts.
• Keep your head out of the fumes.
• Wear dry insulating gloves and
clothing.
- 22 -
 . Connection HYOSUNG

1. Safety Instructions

PACEMAKERS AND WELDING

DEFINITION • Keep the weld cables as close together as

Pacemakers are devices which are implanted possible by twisting or taping them.
in cardiac patients to ensure proper heart • Connect work clamp to workpiece as close
rhythm. Since these devices are electrical in to the weld as possible.
operation, their ability to function can be • Arrange cables to one side and away from
affected by strong electromagnetic fields. the operator.
• Keep welding power source and cables as
WELDING AND ELECTROMAGNETIC far away as practical.
FIELDS • Do not weld with rapidly repeated short
Electric arc welding and cutting processes spurts—wait about 10 seconds between
produce intense electric and magnetic each weld.
(electromagnetic) fields. Persons with a • If you feel sick, stop welding immediately
pacemaker should not go near welding or and get medical attention.
cutting operations until they have consulted • Do not work alone.
their doctor and obtained information from the
manufacturer of the device. TALK TO THE DOCTOR
If you are getting a pacemaker and will be
STEPS TO REDUCE EXPOSURE working with or around welding, talk with your
Pacemaker wearers should observe the doctor. Inform him of your occupation.
following precautions: Discuss your work clearly with him.
• Do not use current settings higher than Pacemakers differ, and your doctor can select
necessary. one that is less likely to be affected by
interference.

ELECTRIC AND MAGNETIC FIELDS (EMF)

INTRODUCTION .occur whenever there is current flow.

Electric and magnetic fields are often referred
to as “electromagnetic fields,” or EMF. There HOW DO I MINIMIZE EXPOSURE?
is concern that EMF may affect your health. • Do not place your body between the torch
and work cables. Route cables on the
HOW IS EMF PRODUCED? same side of your body.
Voltage is the difference in electric potential • Route the welding cables close together.
between two points. This voltage creates Secure them with tape when possible.
and electric field between those points. Now • Connect the work cable to the workpiece as
suppose that an electric connection is made close to the weld as possible.
between those two points, so that there is an • Keep the welding power source and cables
electric current. This current produces a as far away from your body as possible.
magnetic field. Magnetic fields • Never coil the torch or work cable around
your body.

- 23 -
 . Connection HYOSUNG

1. Safety Instructions

CADMIUM EXPOSURE FROM WELDING AND ALLIED

PROCESSSES

INTRODUCTION • Conclusions from the International Agency

Fumes are poisonous and can kill. for Research on Cancer (IARC Group 2B):
Overexposure may cause death. Some (1) there is limited evidence in humans for
fume and dust from welding processes the carcinogenicity of welding fumes, and
(including brazing, soldering, and thermal (2) there is inadequate evidence in
spraying) may contain cadmium or cadmium experimental animals for the carcinogenicity
oxide compounds. The specific form and of welding fumes. (The IARC classification
concentration of cadmium present in the 2B means that the agent is possibly
fume and dust are dependant on the carcinogenic to humans. By contrast, a 2A
composition of the filler metal, base metals, designation would mean that the agent is
metal coatings, atmosphere, flux, and the probably carcinogenic to humans.)
welding process.
OVERALL EVALUATION
ACUTE (SHORT TERM) EFFECTS OF • Overexposure to cadmium may cause
OVEREXPOSURE TO CADMIUM death.
• Similar, but much more severe, to the • Cadmium exposure is possibly arcinogenic
effects produced by fume and dust from to humans (IARC Group 2B).
other metals.
• Inhalation exposure to high concentrations HOW TO PROTECT AGAINST
of fume may cause symptoms such as OVEREXPOSURE
nausea, headaches, dizziness, • Comply with OSHA regulations for
nervousness, lung complicatons, and death. cadmium.
• Identify composition of all base metals,
CHRONIC (LONG TERM) EFFECTS OF
coatings, and consumables; substitute
OVEREXPOSURE TO CADMIUM
non–cadmium containing materials wherever
• Long term exposure to cadmium oxide
possible.
fume and dust has caused severe chronic
effects, kidney failure, and may, with longer • Read and follow the Material Safety Data
exposure and/or higher concentrations lead Sheets (MSDS’s) for cadmium containing
to severe respiratory disease and death. products.
• Inhalation of cadmium by smokers may • Do not breathe fumes and gases. Avoid
accelerate the development of respiratory even brief exposure to high concentrations.
diseases. • Keep your head out of the fumes.
• There is evidence that long term exposure • Use enough ventilation, exhaust at the arc,
to cadmium may cause lung cancer. OSHA or both, to keep fumes and gases from your
has defined cadmium as a carcinogen with breathing zone and the general area.
no further categorization. Observations are • If ventilation is questionable, use air
difficult to interpret because of inadequate sampling to determine the need for
data and confounding factors. corrective measures––air supplied
respirators may be required.

- 24 -
 . Connection HYOSUNG

1. Safety Instructions

FLUXES FOR ARC WELDING AND

BRAZING: SAFE HANDLING AND USE

INTRODUCTION • Fumes containing chromium or nickel

Fluxes are used in various arc welding compounds may irritate the skin and
processes, such as Submerged–Arc respiration tract and cause Metal Fume
Welding (SAW) and Electroslag Welding Fever (see Fact Sheet Number 25).
(ESW). Fluxes are also used in most • Flux products containing both fluoride and
brazing applications. Fluxes are available in hydrogen compounds may produce corrosive
various forms such as granules, powder, and toxic hydrofluoric acid which can
paste, or liquid. There are hazards when cause irritation to skin, eyes, and the nose
dealing with fluxes. and throat.
• Swallowing or breathing barium oxide dust
HAZARD OVERVIEW or fume can result in abdominal pain,
The possible hazards associated with vomiting, paralysis, and death.
handling and using fluxes include the
following: CHRONIC (LONG TERM) EFFECTS OF
• Inhaling toxic or corrosive flux dust OVEREXPOSURE
• Breathing welding fumes and gases Long term overexposure to inhalable welding
• Getting flux on the skin and in the eyes fumes may lead to their accumulation in
• Swallowing toxic or corrosive flux or dust the body. The effect is cumulative, depending
on concentration and time of exposure.
• Breathing and swallowing flux particles
The accumulation, evident from x-ray
during recovering and grinding.
examination, may or may not result in
The makeup and amount of these hazardous
reduced lung function or disease. Smoking
materials varies depending on the flux and the
or other non-welding exposure to hazardous
process. Individuals with pre-existing physical
particules may cause or aggravate this type
conditions, such as allergies or lung diseases,
of lung accumulation condition. Chronic
may react to levels below allowable exposure
fluoride absorption can cause calcium loss
limits and have symptoms that normal,
from the bones and can discolor or spot the
healthy adults do not experience.
teeth. Prolonged exposure to manganese
oxides may affect the central nervous
ACUTE (SHORT TERM) EFFECTS OF
system, causing tiredness, fatigue, sleepiness,
OVEREXPOSURE
muscular weakness, emotional disturbances,
Overexposure to flux may cause the
and uncontrolled movements while
following symptoms:
walking (muscle spasms). Chronic
• General overexposure may cause overexposure
irritation, to respirable crystalline silica may
burning, and bleeding of the exposed result in silicosis, a disabling lung disease,
tissue, headache, dizziness, and shortness and also a suspected carcinogen to the
of breath. lungs. Nickel and chromium VI compounds,
• Dust, fumes and gases may irritate the
skin, eyes, and respiratory system.
• Toxic, corrosive, or oxygen–depleting
gases can cause fluid in the lungs,
suffication, and death.
- 25 -
 . Connection HYOSUNG

1. Safety Instructions

FLUXES FOR ARC WELDING AND

BRAZING: SAFE HANDLING AND USE

when present, and when inhaled over long HOW TO PROTECT AGAINST
periods, are carcinogenic. Nickel fumes may OVEREXPOSURE
also cause fibrous masses and fluid in the • Wear proper hand, face, and body
lungs. protection when handling or when otherwise
exposed to fluxes and their dust,
OVERALL EVALUATION OF POTENTIAL fumes and gases––this means protective
HAZARDS (leather, rubber) gloves, goggles, and full
Fluxes are safe and useful when handled clothing with long sleeves and long pants
and used properly and when recommended (not shorts).
safety procedures are followed. The major • Avoid breathing the dust or fumes and
hazards to avoid are overexposure by gases. Keep your head out of the fumes,
breathing, swallowing, or inhaling the dust or dust, and gases. Use enough ventilation,
fumes and gases, especially those containing exhaust at the arc, or both, to keep fumes,
respirable crystalline silica and fluorides. dust, and gases from your breathing zone
If the application recovers used flux, as is and the general area. When necessary,
common in Submerged–Arc Welding (SAW), wear an approved mask or respirator.
and then reuses or grinds the flux for reuse,
• Do not consume food or beverages in
overexposure to dust happens quickly if
areas where flux dust or fumes or gases
precautions are not taken.
may be generated or may be present.
Some submerged arc welding fluxes may
contain very small quantities of naturally • During brazing, do not overheat the fluxes.
occurring radioactive material (NORM). Flux Follow the manufacturer’s recommended
materials containing sufficiently low procedures. Overheating results in the
concentrations of NORM are not subject to generation of, and potential exposure to,
federal radiation control regulations. These excessive fumes and gases.
fluxes do not present an environmental or
health hazard. Contact the flux manufacturer
for further information.

- 26 -
 . Connection HYOSUNG

2. Caution in handling

The following points are explained for handling the machine safely.
Please read it through before handing. The following caution mark is placed on the partition where a special
care should be taken or any hazard to human body can be expected;-

STYLE GUIDELINES FOR SAFETY AND HEALTH

DOCUMENTS

2.1 Arrangement of the machine

The welding power source should be placed more than 20cm from wall or 50cm more in case
of any heating material placed nearby.

2. 2 Working wear and protector

A proper working wear and protector should be used for safety.

2. 3 Ventilation
Welding fume and CO2 gas is harmful. Please arrange any ventilation whenever the machine may be
used.

2. 4 Removal of the covers of welding power source

Inside the welding power source, there are high voltage loaded portions
Do not operate the machine with removing the top cover or side panels, except repairing and
inspection time.
When the machine-inside is inspected, do the inspection work at 3 minutes or longer later after the
power switch having been turned off.

2. 5 Fuse
When any fuses are checked or exchanged, turn off the power switch of the welding machine.

2. 6 Gas heat consent

The A.C. 100V consent located at rear side is exclusively for CO2 gas heating.
Do not use it for any other purpose.
The rated capacity is 190W. When a heavy capacity gas regulator is used, use another power supply.

2. 7 Remote control consent

There is remote control consent in the front cover of the welding power source. By connecting optional
cable to it, the welding condition can be set remotely far from welding power source. Please note that
the remote control cannot be used when a welding wire feeder and a welding power source have been
connected.

- 27 -
. Connection HYOSUNG

3. Constitution of Product

3.1. Standard constitution of product

This welding machine is constituted as follows.

Item Specification Q’TY Remarks

Welding power source PDC350G 50/60Hz 200V 1
Wire-Feeder EF-R350FA DC42V 1
Welding Torch F-R35H M2011 1
Control cable MS 3106A 18-19S 1
Wire-Feeder Power cable DWA0600020H008 1
Cable Set Earth cable DWA0600020H008 1
Gas Hose 1
Conduit cable 9/16UNF-18 Coupler 1
Option
Wire Reel Stand WR-R300S 1

3.2. Components

Welding Power Source Wire-Feeder Torch

Manual L-wrench Contact tip
Hose band Gas nipple

- 28 -
. Connection HYOSUNG

4. Rating

4.1. Rating

Type PDC350G Remarks

Rated primary input voltage AC 200V, 50/60Hz 3 phase
Rated input 16KVA, 15KW
Rated output Current(A) 40 ~ 350A
range Voltage(V) 12 ~ 36V
Rated duty cycle 60%
Dimension(W×D×H) W290 x H 630 x D 540 mm
Mass 60kg

4.2. Power Source Facility

Power source facilities(transformer, molded-case circuit
breaker, fuse, cable, etc.) need to be installed by electrical
certificate holders and use power source facilities suitable for a
rated capacity.

Forms PDC350G Remarks

Input power AC 200V 50/60Hz 3phase
Rated capacity 16kVA
Fuse/breaker capacity 50A
Input cable 10㎟ or more
Output cable
50㎟ or more
(Secondary)

● Don’t use triple or more rated capacity when an engine generator is used.
● Install each switch for one welding power source and use a fuse of a regulated specification.
● A permissible range of variation of the input voltage of the welding power source is ±10%.
● Use a short-circuit breaker for inverter in case of using the short-circuit breaker.

- 29 -
. Connection HYOSUNG
5. Installation of Product

5.1. Wirings

There is in danger of electrical shock.

● Never fail to turn off a power source of the switch before wirings of the product.
● Take wirings so as to prevent leakage of gas or a contact failure of a conductor.
● Never fail to insulate the conductor in which a spiral is exposed with an insulator
other than an insulation tape
● Connect the power source to U and W phases in case of using single-phase input power.

5.2. Wrings, Switches, and Machine Parts

(1) (+)-output cable connection socket (latch)

The output cable is connected (electric feeder).
(2) (-)-output cable connection socket (latch)
The earth cable is connected.
(3) Electric feeder control cable connector
An electric feeder control cable is connected.
(4) External equipment connector
An arc welding robot, automation equipment, a digital remote controller,
and an analog remote controller are connected.

- 30 -
. Connection HYOSUNG
5. Installation of Product

5.3. Devicenet connector connection

MS3102A 18-11S-X
Key direction: "X" Type

- 31 -
. Connection HYOSUNG

6. Operation of Product

Never fail to wear appropriate clothes and protectors

before welding.

6.1. Front Window, Remote Controller

Power source

(1) Power indication LED

(2) During welding indication LED
(3) Error indication LED
(4) The main switch
The power of the welding power source is turned on/off.

- 32 -
. Connection HYOSUNG

6. Operation of Product

6.2. Key combinations – special functions

Press both buttons for approximately 5 seconds to use the following specific functions.

(1) A software version is displayed on a display window of the front panel of the welder
for approximately 5 seconds (welder front panel).

+
(2) The welding parameter is changed to an initial value (factory initial setting value)
(welder front panel).

(3) The internal welding parameter enters a change mode.

+ Press the same key combination for approximately 5 seconds to

cancel the change mode.

(4) An analog current adjustment dial use mode of a push-pull type welding torch (EF350MA,
EF350MW only) is entered.

Press the same key combination for approximately 5 seconds

+ to cancel the change mode.

- 33 -
. Connection HYOSUNG

6. Operation of Product

6.3. Changes of Internal Parameters

(1) The setting value is changed by turning the adjustment dial after selecting a desired parameter by
pressing buttons “A” and “V”.

Parameter
Code
value
Selecting code Selecting code
(up 1 level) (down 1 level)

Changing the
parameter

Code No.
Important!
When a CAN communication mode is used, the buttons and dials of
the front panel of the welder and the remote control unit are not operated.
The Devicenet communication mode can be changed by setting a JC1 (jumper Pin) of
a main P.C.B. (PR1).
- Short-circuit of JC1 (jumper Pin): Setting CAN communication mode,
cancellation of short-circuit of JC1 (jumper Pin): Cancellation of CAN communication mode
- Never fail to carry out the operation for changing the communication mode while turning off
the power source of the welder.

- 34 -
. Connection HYOSUNG

6. Operation of Product

(2) Refer to the following internal welding parameter and code table

Mark
Code No. Description of parameters Initial value
name
0
36 Cooling type COL 0: air cooling
1: water cooling
General welding parameters
51 Start current stA 100
52 Start current time stT 10
53 Deposition prevention voltage WEV 100
54 Deposition prevention time WPA 0.02
55 Gas pre-flow WET 0.02
56 Gas after-flow WST 0.5
57 Welding end time ctT 0.1
58 Wire projection length WL 100
59 Wire slow-down WSD 100
Special welding parameters
Cautions!
When the parameters are incorrectly set, a welding operation may be performed.
71 Delay time SDT 1
72 Slope level SSL 100
73 Slope SSC 100
74 Arc level arL 100
75 Bridge current BRA 100
76 Bridge time BAT 1
77 Arc current MAA 100
78 Arc time MAT 5
79 Short-circuit cancellation current AgA 100
81 Short-circuit detection voltage SDV 100
82 Arc detection voltage ADV 100
85 Down slope DSC 100
87 Down slope time DST 10

- 35 -
. Connection HYOSUNG

6. Operation of Product

6.4. Weldig mode

(1) 2 step mode

Welding sequence
ON OFF
Torch
switch
Parameter
pre aft
Code
Welding
Welding current
current
Parameter WEV, WET, ctT,
Code WL

(2) Crater mode

Welding sequence
ON OFF ON OFF
Torch
switch
Parameter
pre aft
Code

Welding Welding current

current
WA,WV,
Parameter WEV, WET, ctT,
WVL,WPA,
Code WL
WRC

(3) 4 step mode

Welding sequence
ON OFF ON OFF
Torch
switch
Parameter
pre aft
Code

Welding
Welding current
current

WEV,
Parameter
WET, ctT,
Code WL

- 36 -
. Connection HYOSUNG

6. Operation of Product

(4) Initial start mode(aluminium welding start up)

Welding sequence
ON OFF
Torch
switch
Parameter
pre aft
Code

Welding Welding current

current
WST,
Parameter WA,WV, WEV, WET, ctT,
Code WVL,WPA, WL
WRC

6.5. Welding process

6.5.1. CO2, MIG/MAG welding

(1) Repeatedly press the process (gas) button to select a desired process.
(2) Repeatedly press the welding material selection button to select a desired material.
(3) Repeatedly press the welding material diameter selection button to select a desired diameter. The SP
can be used when a welding database of the welder is valid.
(4) Repeatedly press the welding mode selection button to select a desired mode.
(5) Select a desired welding parameter, and operate the adjustment dial to change the parameter setting
value.

Welding current

Wire feeding speed

Wire feeding speed

Welding voltage (individual)

Welding voltage (synergic)

Arc feature

** Welding voltage (synergic)

Setting value < 100(Min.50) : Short arc length
Setting value = 100 : Reference arc length
Setting value > 100(Max.150) : Long arc length

** Arc feature
Setting value < 100(Min.0) : Soft arc
Setting value = 100 : Reference arc
Setting value > 100(Max.255) : Hard arc

- 37 -
. Connection HYOSUNG

6. Operation of Product

(6) Open a valve of a protection gas cylinder.

(7) Set a flow of the protection gas.
(8) Press a torch switch to start welding.

Important!
** When the LED of the remote controller is lightened, the welding parameters (welding current,
feeding speed, welding voltage) can be adjusted by only external devices (remote controller, arch
robot, automatic welding JIG).
** When the CAN communication mode is used, the buttons and dials of the front panel of the
welder and the remote control unit are not operated.
** In the CAN communication mode, all of the welding parameters can be operated by a robot
teaching pedant.

- 38 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

There is in danger of electrical shock.

Please make the following inspection and maintenances work to keep the machine
under the proper condition: -

7.1 Regular check-up (once every 3 to 6 months depending on use frequency)

Checking locations Checking points Repairing methods

Checking electric wire connection state
Input switch Refer to facility capacity
Check an appropriate fuse
Checking electric wire connection state Fastening bolt or
Input/output terminal
Checking appropriate fuse coupler of wiring part
Checking insulation of
Torch switch Insulation state from power cable
each onnector
Replacing existing roller
Feeding roller Accumulation of dust, abrasion
with new roller
Checking deformation of torch liner, Cleaning clogged part or
Wire feeding path
whether foreign materials is attached replace wire feeding path
Inside of Remove dust with
dust
welding power source dry wind

7.2 Causes and Measures by Occurrence of Errors

The causes and measures of the occurrence of errors which may occur while using the welder are shown.
Contact an A/S officer of out company when errors which are not described in the following table occur.
When the error content is described, write a relevant error code or error content to transfer the content to
the A/S officer of our company at the time of contacting the A/S officer.

Error codes Error causes Checking points

E10 Input power voltage decreases Check the input power voltage (within
The input power voltage is lower 10%)
than an allowable reference
range.
E11 A frequency of the input power Check the input power voltage
voltage is out of the allowable frequency (within 2%).
reference range.
E13 Input power voltage is Check the input power voltage (within
excessive 10%).
The input power voltage is
higher than the allowable
reference range.

- 39 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

E20 An abnormal welding parameter Initialize the welding parameter.

is input. When the phenomenon repeatedly
occurs, contact an A/S team of our
company.
E24 Battery voltage on the main Replace the battery.
control P.C.B. decreases.

E61 A primary circuit side of the Cool the welder

welder is overheats. Check whether a cooling fan operates.
Use product according to the use rate
of the product.
Set a usage environment of the welder
at a temperature of 40℃ or lower.
E60 A water cooling sensor operates. Check a water cooling device.
Check a connection state and
connection directions (inlet and outlet)
of a hose connected to the electric
feeder.
E62 Overcurrent is detected at a Appropriately select a welding wire.
secondary circuit side of the Prevent the second circuit side
welder. (contact tip, + output cable) of the
welder and a base material (or, -
output cable) from short-circuiting.
E63 Overload of a feeding motor is Check whether the torch liner is
detected. deformed (bent) and remove dust in
the liner.
A hole size of the contact tip is smaller
than the wire diameter. Use a contact
tip having an appropriate size.
Adjust a brake strength of the wire
spool to be low.

E64 A power unit module is Contact the A/S team of our company.
A mina power source is in damaged.
ON state, when the torch
switch is pressed, the wire
is fed and the gas is
ejected, but secondary
current and voltage are not
generated.
E65 The power unit module is Contact the A/S team of our company.
damaged. Connect the control cable or (+)
The control cable or (+) output output cable.
cable is not connected. Connect the (-) voltage detection line
A (-) voltage detection line or (-) or (-) output cable.
output cable is not connected.

E66 The welder and the output cable Correctly connect the (+) output cable
are incorrectly connected. and the (-) output cable to the output
terminal of the welder.

- 40 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

E98 The digital remote controller and Check the connection state of the
Related to the case of using an inter-welder control line control line.
the digital remote controller connection state are faulty. Prevent the digital remote controller
The digital remote controller from short-circuiting from the (-) side
short-circuits from a (-) side of of the base material.
the base material. When the same phenomenon is
continued, contact the A/S team of our
company.

E99 The Devicenet communication Check a connection state of a

with the robot controller is not Devicenet communication cable.
achieved. Replace the cable when the cable is
damaged.
Turn on a power source of the robot
controller.
Select the selection of the welder as a
product of out company in the robot
controller.
Short-circuit the JC1 of the main
P.C.B. of the welder.
A main power switch is The fuse is damaged. Contact the A/S team of our company.
turned on, but the welder The main control P.C.B. is
does not operate (an damaged.
indication lamp is not
lightened)

The breaker (N.F.B.) The power unit module is Contact the A/S team of our company.
operates damaged.

No Prog Welding synergic data is not Select synergic data registered with
registered. welding data.

The main power source is The control cable is damaged or Connect the control cable.
turned on and the indication not connected. Replace the control cable.
lamp is also lightened A torch cable is damaged. Replace the torch.
When the torch swtich is
pressed, the torch does not
operate.

The protection gas is not The gas is fully consumed. Charge gas or replace a gas tank.
ejected. A gas pressure regulator is Replace the gas pressure regulator.
All other functions are damaged. Connect or replace the gas hose.
normally operated. The gas hose is not connected
or damaged. Replace the torch.
The torch is damaged. Replace the solenoid valve.
A solenoid valve is damaged.

- 41 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

Weldability is poor. Setting the welding parameter is Check the setting of the parameter.
inappropriate. Certainly connect the earth cable to
Connection of the earth cable is the base material.
inappropriate. Check the connection states of the
The protection gas is not gas pressure regulator, the gas hose,
sufficient or is not ejected. the solenoid valve, and the torch.
The protection gas leaks from Replace the torch.
the torch. Replace the contact tip.
Selection of the contact tip is
inappropriate or the contact tip is Check the wielding wire and the base
excessively worn out. material, and select appropriate
Selection of the welding wire or synergic data.
selection of the diameter is Select appropriate protection gas.
inappropriate.
Selection of the protection gas
depending on the welding wire is
inappropriate.
The feeding speed of the The brake strength of the wire Adjust the brake strength.
wire is irregular. spool is set to be too high.
The hole size of the contact tip Use the appropriate contact tip.
is too small.
The liner of the torch is Check whether the torch liner is
damaged. deformed (bent) and remove dust in
the liner.
The selected diameter of the Select the same diameter of the
feeding roller does not match feeding roller as the wire.
the wire diameter or the feeding Adjust the pressing setting of the
roller is worn out. feeding roller.
Pressing setting of the feeding
roller is inappropriate.

- 42 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

7. 3 Part list

- 43 -
. Connection HYOSUNG

7. Check-up and Maintenance of Product

Symbol Part name Part Number Specification Q’TY Comment

T1 Transformer 200V 1
T2 Transformer 175VA 1
T3 Transformer 168VA 1
L0 Inductor PDC350G 1
L5 Inductor PDC350G 1
L1,L2
Filter T2915 4
L3,L4
Q1,Q2 I.G.B.T. 200A/1200V 2
D1 Diode 60A/1600V 1
D2,D3,D4,D5 Diode 200A/400V 4
NFB CP 50A 1
MS1 Contactor 30A 1
CT1 Current transformer 300A/4V 1
CT2 Current transformer J&D 800T 1
FAN1,2 Fan AC200V 2
F1 Fuse 60A 1
FU1 Fuse 5A 1
TH1 Thermal relay NC75 1
PR1 P.C.B. HSW-086-03 1
PR2 P.C.B HSW-115-00V1 1
PR3 P.C.B HSW-113-00V1 1
PR5 P.C.B HSW-068-01 1
PR7 P.C.B HSW-114-00V3 1
PR8 P.C.B HSW-057-A 2
C1 Capacitor 4700uF 1
C3,C4 Capacitor 2.2uF 2
C5~C8 Capacitor 0.0047uF 4
C11,C12 Capacitor 0.01uF 2
C15 Capacitor 0.22uF 1
C16,C17 Capacitor 0.01uF 2
C19 Capacitor 0.01uF 1
R1 Resistor 80N150FW 1
R2 Resistor 40W10K 1
R5~R8 Resistor 40W200J 4
R11~R12 Resistor 40W200J 2
R15 Resistor 40W3R0 1
MC1 Connector MS3102A 18-19P 10PIN 1
MC6 Connector MS3102A 18-11S-X 1

- 44 -
. Connection HYOSUNG

8. Circuit diagram

8.1 PDC350G

- 45 -
. Connection HYOSUNG

9. Outline Dimensions

9.1. PDC350G

- 46 -
. Connection HYOSUNG

10. WIRE FEEDER

10.1 Rating

Type EF-R350FA 備 考
Roller size 1.2(1.4), 1.6
Feeding speed 0.8 ~ 20 m/min
Control method Encoder pulse
Dimension(W×D×H) 173x288x192
Mass 5.8kg

10.2 Connection

Wire feeder EF-R350FA

(1) 4-roll drive system

(2) Welding torch connector
A welding torch is connected.
(3) Protection gas connector
A protection gas hose of the welding torch is connected.
(4) (+)-output cable connection (one-touch latch type)
A (+)-output cable from the welding power source is connected.
(5) Electric feeder control cable connector
The electric feeder control cable connector from the welding power source is connected.
(6) Protection gas connector
The gas hose from a gas cylinder is connected.
(7) Welding wire induction pipe connector
The welding wire induction pipe connector is a connector of an induction pipe for feeding
a wire from the welding wire spool to the electric feeder.

- 47 -
. Connection HYOSUNG

10. WIRE FEEDER

10.3 The treatment method

(1) Component confirmation about the welding wire.
① Feeding roller
Place welding wire in the center of outer groove of the feed roller.
(2) Center of Wire Reel
Confirm the direction of wire feeding and
lock the lever located at the center of wire reel.

When install a welding wire,

Be careful not to be jammed between feeding roller and gear.

(3) Inching Feeding of wire

Come down a pressure handle to the right side and raise a

pressure arms upward.

Straighten welding wire and put through inlet guide

to outlet guide.

Lock the pressure arm to the center by the pressure handle.

Push an inching switch to feed

a welding wire.

- 48 -
. Connection HYOSUNG

10. WIRE FEEDER

10. 4 Maintenance and check period

(1) Check period
① Inlet guide
Once a week, remove the dust in an inlet part.
② Feeding roller
Exchange in the case of the change of angle or the wear of the groove.
(check once for 2~3 months)

10.5 Part List

Symbol Part name Part Number Specification Q’TY Comment

1 Motor bracket - 2Roll driven geared 1
2 Drive roller - V groove 2
3 Torch connection - Standard 1
4 Wire inlet - R-standard 1
5 Nipple - 9/16’’ UNF 2
M Motor - KSV 5035-755 1
PR5 P.C.B. - HSW-068-02 1
MC1 Connector - MS3102A 18-19P 10PIN 1

- 49 -
. Connection HYOSUNG

10. WIRE FEEDER

10.6 Outline Dimensions

10.6.1 Wire feeder EF-R350FA

- 50 -
. Connection HYOSUNG

10. WIRE FEEDER

10.6.2 REEL STAND

Item Type Specifications Remarks

Wire Reel Stand WR-R300S W195x H340x L450mm

- 51 -
. Connection HYOSUNG

11. TORCH

11.1 Rating

Item Specifications Remarks

Type F-R35H M2011
Rated current 350A
Rated duty cycle 350A 100% ( CO2)
Cable length 50sq 1.1m
Cooling Mode AIR

11.2 An utility attention subject

A welding wire can cause the wound or injury.

Do not operate a torch(gun) switch before execute the welding.

Do not operate the torch(gun) toward others body.
Do not pass by the wire at different part beside the welding basic material.

(1) Confirm the content of the follow at least before using.

 The tip and nozzle, spring liner is the expendable supplies.
Prepare at the work center before work.
 Is the tip suitable to the welding wire to use, and tighten?
 Does the feed roller set for welding wire to be used?

(2) Once a week, clean a spring liner with compressed air.

 Wire feeding is unstable if there are the impurities such as iron powder.
 When a spring liner has a short trace and deformation,
exchange necessarily to the new one.
 When attach and take off a spring liner, straight a torch cable.
Be careful not to bend a spring liner when you install.

- 52 -
. Connection HYOSUNG

11. TORCH

(3) It is important that a torch cable must not be crooked while in use.
 If the bending of a torch cable is extreme,
It may cause welding defect and damage on the machine
due to unstable feeding.
 Refer the picture on the right side.
(4) When a spring liner is protruding outside, push a spring
liner with spinning a torch to seal spring liner 0-ring.
 When a spring liner exchanges, a projection length
should be 8~10mm.
 In case of cutting a spring liner,
Grind to remove burr and rough surface.
(5) The distance between the nozzle and basic material is
10~20mm according to the welding current.
(6) Set gas flow rate based on the 10 times of the inner dia.
of gas nozzle.
( 12ψ : 12ℓ/min or more, 16ψ : 16ℓ/min or more )
(7) Remove the spatter attached to the tip and nozzle.
You can prevent attach of the spatter if you use the anti-spatter.
(8) The case of a welding wire sticking to contact tip,
cut the wire at feeder side prior to removing tip.
(9) Check the insulation state of a torch switch line and
power cable.
If an insulated state is bad, a 1A fuse of the feeder is
disconnected
so it can cause malfunction of machine.
(10)Spring liner is designed to fit our company product for enhancing feed ability.
We recommend using our spring liner to exchange in order to

- 53 -
. Connection HYOSUNG

11. TORCH

11.3 Part list

Torch F-R35H

(1) Robot
(2) Robot mount base
Robot mount base attach the feeder to the robot. It is joined by four places in the M6 bolts. .
(3) WIRE FEEDER
Wire feeder is attached to the Robot mount base. It is joined by four places in the M6 bolts
(4) Robot torch cable
(5) Robot torch

- 54 -
. Connection HYOSUNG

11. TORCH

11.4 Outline Dimension

11.4.1 Robot torch

- 55 -