Hot Max AC300 Operator's Manual

Operator’s Manual

Model AC300

ARC Welder

WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual
and the safety precautions and warnings illustrated in this manual.

KDAR Company Tel: [phone]

1 Mulch Lane Fax: [phone]
St. Louis, MO 63044 Web Site: www.hotmaxtorches.com

SAFETY PRECAUTIONS AND WARNINGS

PLEASE READ BEFORE USING EQUIPMENT

WARNING

ELECTRIC SHOCK CAN KILL.

 The input circuits are live and hot when the power is on
 Do not touch live electrical parts
 Wear dry, hole free insulated work gloves and body protection when operating
 Do not touch torch components if in contact with the work piece or ground
 Always turn off power before cleaning, checking, or changing parts
 Properly ground this piece of equipment per state and federal requirements
 Inspect and replace any worn or damaged torch cables or leads
 Keep all panels and covers securely in place
 Do not touch any part of the welding electrodes (rods) when welding
 Ground the metal or work piece to the ground cable (Earth Clamp)
 Never dip the tip into water to cool or attempt to use cutter in or under water
 This equipment holds a lot of power in the off position, before touching, make sure voltage is near

zero on input capacitors before touching any parts.

 Keep children away from this equipment

 Protect your self and others from possible injury
 Pacemaker wearers should consult with their doctor before operating
 Read and follow all instructions in this manual before operating
 All installation, operation, and maintenance procedures are performed

only by qualified individuals

ARC RAYS CAN BURN SKIN AND EYES

 Arc rays when cutting produce intense ultraviolet and infrared rays that can burn skin and eyes
 Where face protection, either helmet or shield when operating with ANSI Z49.1 approved #10

shade (minimum) recommended for all welding currents less than 300 amperes. The lens should

conform to ANSI Z87.1 standards for testing.

 Wear approved safety glasses with side shields under the face protection
 Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect

other workers in the area from the arc while operating

 Wear flame resistant gloves, clothing, and shoes when operating

FUMES AND GASES CAN BE HAZARDOUS

 ARC welding produces fumes and gases and breathing these gases is hazardous to your health
 Keep your head out of the fumes and do not breath the fumes while welding
 Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied

respirator. Fumes from welding can deplete the oxygen supply and can be harmful. Always be
sure there is ample breathing air

 Read the MSDS sheets and the instructions from manufacturers for metals to be cut, coatings,

cleaners, and welding electrodes

 Do not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or spraying

operations. The heat and rays can react with solvent vapors to create a gas phosgene, a very toxic
gas, as well as other irritating gases

 Do not weld coated metals, such as galvanized, lead, or cadmium plated steel. Before welding, all

plating must be removed. The area must be well ventilated or an air supplied hood must be used.
The coatings and chemicals when burned cause highly irritating and toxic fumes.

 Do not cut containers with toxic, flammable, or reactive elements stored in them. They must be

emptied and properly prepared before cut. They must be cleaned and prepared to cut by the AWS
F4.1 guidelines for cutting containers or tubes

KDAR Company 1

CUTTING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION

 Remove all flammable materials from the welding area
 Always have a charged fire extinguisher available in the cutting area
 When not welding make sure the welding electrode is not grounded, this causes a heat build up and

possible fire

 Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns and cables
 Sparks and hot metal fly out from the arc when welding, wear approved safety glasses with side

shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear
plugs to keep sparks from entering the ears

CYLINDERS CAN EXPLODE IF DAMAGED

 Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-

ploding. Gas cylinders are a major part of metalworking and must be treated with care.

 Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
 Always keep cylinders in an upright position securely fastened to a fixed support
 Valve protection caps should always be in place and hand tight except when the cylinder is in use
 Keep all cylinders away from any cutting or electrical circuits
 Never allow the arc from a welder to contact a cylinder
 Never cut any type of pressurized cylinder, an explosion could result
 Always turn your face away from the valve when opening the cylinder
 Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-

lication P-1 listed in the Safety Standards before using

WELDING ARC CAN INJURE

 The heat from the welding arc is very intense and forceful and can burn through protective clothing

and pierce skin causing serious burns

 Check your protective clothing for holes, tears, or worn spots before welding. Replace any clothing

that is worn or damaged

 Do not hold or grip the material being welded too close to the weld pool
 Always wear protective clothing when operating the welder, cover all exposed body areas
 Turn off power source and unplug unit when dis-assembling electrode holder or ground clamp

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

 Electric current used in welding create Electric and Magnetic Fields (EMF)
 Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to

contact their doctors before operating this type of equipment

 Exposure to EMF during operation of this equipment may have other health effects which are not

yet known

 Route the work and ground cables together and not around your body
 Do not place your body between the work and ground cable. They both need to be on the same side

of your body when operating

 Do not work next to the cutting or welding machine. Provide 3 feet of space between you and the

machine

ELECTRICALLY POWERED EQUIPMENT

 Disconnect power source or turn off the circuit breaker before working on any equipment
 Only install equipment using the US National Electrical Code, all local codes, and the manufactur-

er’s recommendations

 Ground the equipment in accordance with the US National Electrical Code

KDAR Company 2