I have two welding set-ups: an oxyacetylene (gas) and an arc welder (electric). Although welding equipment doesn’t require a lot of maintenance, following a few basic rules concerning the components will keep things working safely.
The primary items for the oxyacetylene unit are bottles of compressed oxygen and acetylene. To these the individual regulators are connected, then the hoses and finally a selection of torches for either cutting or welding. Maintenance is quite simple but important. Attaching the regulators to the tanks is pretty straight forward. The use of pipe dope is not permitted as it can permit over tightening. It isn’t needed as the fittings are self sealing.
The hoses should be checked regularly for tightness and signs of digression as these are usually dragging on the floor, stepped on and the recipient of sparks of molten steel. They are also the weak link in the system being tugged on they should be checked regularly for tightness to the regulators. The torches both welding and cutting should be examined for any signs of digression and the tips cleaned after use with a tip cleaner (which is a kit of fine files to fit each tip size).
After use, I follow this procedure upon shutdown:
1. shut the acetylene tank off
2. open the acetylene torch valve and leave open
3. dial the acetylene regulator to zero
Next I repeat the same procedure for the oxygen leaving both torch valves open. This sequence will allow the acetylene to be released first and then purge everything with the oxygen leaving the system accelerant free.
The arc welder, a Lincoln AC, came with cables that would reach 12 feet and a 220 volt plug about four feet long. At a welding shop I purchased two cable connectors and 100 feet of welding cable. The welder sits in the back end of the shop and with the extension cables, 50 feet each, can be used all the way to the front door. The only repair I’ve had to do to this unit in its life was the replacement of the cooling fan which consisted of removing the back, unbolting the fan, disconnecting the wires and then doing the reverse for install.
Maintenance to the AC welder is also pretty minimal; keeping things clean and keeping a watchful eye on the cables for digression is pretty well it and the support equipment is mostly care related.
My protective apparel consists of an auto adjust welder’s helmet, welder’s cap, leather gloves, leather apron and leather safety boots all of which offer protection from the UV rays, heat and burns. The gloves should be high cut, heavy and kept dry to prevent electrocution, burns and cuts and they should be examined regularly for any holes.
The leather apron is checked for rips and burns to the straps which are nylon. The helmet that came with the unit was one of the old timers with a small two by six inch fixed # 10 lens mounted into a fiberglass hood on a hinged headband which had to be hinged down just before the arc was struck. I replaced it with an auto darkening unit and was amazed at the immediate improvement to my welding ability. I need only to wipe the protective lens clean after each use to remove residue from the fume plume. As an addition to this I let the helmet sit in daylight for 10 minutes before engaging in activity allowing the photocell to charge.
Clothing should be loose fitting and wool or cotton fabric, never synthetics which can melt unless they have been fire protection treated and shirts or pants should not have cuffs where sparks can get caught. Basically, the clothes worn should be layered, shirt over top of pants, pants over top of boots, and when possible all should be free of flammable substances such as oil or grease.
As with the clothing, it is paramount that the rods be kept clean and dry; moisture is a welder’s nightmare causing unsuccessful arc strike, inconsistent burn, overall poor results and most of all, frustration.
I have my set-up mounted on a cart, the oxyacetylene tanks on top with the Lincoln underneath. Oxyacetylene rods are stored in a holder on the side and the arc rods in a box mounted on the back.
At the end of the day when the hoses have been wiped off and spooled back on their holder or the cables wiped and wound back in place the unit is covered in a drop sheet and wheeled to its storage spot in the shop — out of sight, out of mind and protected from dust and dirt and any oil that can ignite with a spark.
Note: the results of breathing the fume plume from arc welding which contains solid particles, can range from irritating to fatal depending on what you are welding, so knowing what you are engaging in is extremely important. If your welding area is smoke clear your risk of respiratory problems is minimal. Anything above that requires air exchange, either natural or man made. Two extremes are: galvanized pipe that emits zinc which if inhaled can cause metal fume fever (a temporary condition similar to symptoms of flu) and breathing the fume plume from Cadmium (used as a protective coating on army/navy (AN) bolts) which can be fatal.
The welder is an essential tool around the farm and when cared for properly it is a pleasure to use. Used safely, your welder can be an asset for years.
Welding area including anvil, forge, steel welding bench with vice backed with fireproof brick against steel siding on wall and spark proof exhaust hood with lighting.
- Dan Kerr