Standard Bots Welding User Manual

2 Welding & Equipment Safety

2.1 General Welding Hazards

Welding involves serious hazards that can cause injury or death if proper precautions are not followed. Before operating this system, make sure all personnel working in or around the welding cell understand the following risks.

Electric Shock — The welding circuit is electrically live whenever the power source output is on. In MIG welding, the wire, wire drive, and all metal parts in contact with the welding wire are energized. Never touch live electrical parts. Always disconnect input power before performing any maintenance on the power source or wire drive.

Arc Radiation — The welding arc produces intense ultraviolet and infrared radiation that can burn skin and cause permanent eye damage. Never look at the arc without proper eye protection. Even brief unprotected exposure can cause “arc flash” — a painful burn to the surface of the eye.

Fumes & Gases — Welding generates fumes and gases that are hazardous to health. Ensure adequate ventilation in the welding area. If welding in an enclosed or confined space, use forced ventilation or a supplied-air respirator. Review the Safety Data Sheet (SDS) for the welding wire and shielding gas being used.

Fire & Explosion — Sparks and spatter from welding can travel significant distances and ignite flammable materials. Remove all flammable materials from the welding area or shield them with fire-resistant covers. Never weld on containers that have held flammable substances unless they have been properly cleaned and purged. Keep a fire extinguisher rated for Class ABC fires within reach of the welding cell.

Burns — The workpiece, torch, and surrounding fixtures remain extremely hot during and after welding. Allow parts to cool before handling, and always wear appropriate gloves when working near recently welded components.

Noise — Depending on the welding process, wire feed speed, and shielding gas, the arc may produce significant noise. Hearing protection may be required depending on the environment.

2.2 Personal Protective Equipment (PPE)

All personnel operating or working near the welding cell must wear the following:

• Welding helmet with auto-darkening lens rated to a minimum of Shade 10 (Shade 11–13 recommended for higher amperages).
  
• Safety glasses with side shields, worn under the welding helmet.
  
• Flame-resistant clothing — long sleeves, full-length pants, and a welding jacket or FR coveralls. No synthetic fabrics.
  
• Welding gloves — leather gauntlet-style gloves rated for MIG welding.
  
• Steel-toed boots — leather, fully enclosed. No canvas or mesh shoes.
  
• Hearing protection — if the environment exceeds 85 dB.

2.3 Workspace Requirements

Ventilation — The welding area must have adequate airflow to remove fumes and gases from the operator’s breathing zone. Use local exhaust ventilation (a fume extraction arm or hood) positioned near the weld zone whenever possible. If welding indoors without local extraction, ensure the room has general mechanical ventilation.

Fire Prevention — Maintain a minimum 35-foot (10 m) clearance from flammable materials, or use fire-resistant barriers (welding curtains or screens). A Class ABC fire extinguisher must be accessible within the immediate work area. Inspect the area for flammable materials before each shift.

Welding Screens — Use welding curtains or screens around the cell to protect bystanders from arc radiation. Screens should be rated for welding use and positioned to block line-of-sight to the arc from all accessible angles.

Flooring — The floor in the welding area should be dry and non-flammable. Concrete is ideal. Avoid welding on or near painted, coated, or oiled surfaces that could ignite or release fumes.

Grounding — The workpiece, welding table, and fixture must be properly grounded. The work clamp from the Industrial MIG 4/0 kit must make clean, direct metal-to-metal contact with the workpiece or fixture. Poor grounding causes erratic arcs, increased spatter, and potential shock hazards.

Electrical — The Auto DeltaWeld 350 requires either 208/230/460V three-phase or 230V single-phase input power at 60 Hz. Verify that the facility circuit breaker and wiring are rated for the power source’s input current requirements. Refer to the Miller owner’s manual for detailed electrical specifications.

2.4 Robot-Specific Welding Safety

Robotic welding introduces hazards beyond those of manual welding. The robot does not inherently know when a person has entered the work area, and the welding torch is live and in motion during operation.

Risk Assessment — Before operating the welding cell, a comprehensive risk assessment must be completed in accordance with ISO 10218-2 and ISO/TS 15066. The risk assessment should evaluate the complete cell, including the robot, welding equipment, fixtures, workpiece, and any ancillary equipment. The risk assessment determines what safety devices (light curtains, area scanners, safety-rated fencing) and robot safety settings (speed limits, force limits) are required.

Torch Hazard — The welding torch is both an electrical hazard (live welding circuit) and a thermal hazard (hot nozzle, spatter buildup). Treat the torch as energized and hot whenever the power source is on, even if no welding is actively taking place.

Unattended Operation — Never leave a running welding routine unattended unless the cell has been fully safeguarded per the risk assessment. If the cell is safeguarded, ensure all safety devices are functional before starting the routine.

Protective Stops — The RO2’s collision detection and protective stop features remain active during welding. If the robot detects an unexpected force or collision, it will stop and the weld arc will extinguish. Refer to the RO2 User Manual, Chapter 4, for details on configuring safety settings.

Payload Configuration — The combined weight of the torch, gun mount, insulating disc, and wire drive (if arm-mounted) must be entered as the robot’s payload mass in the RO2 safety settings. Incorrect payload configuration affects the robot’s collision detection sensitivity and braking performance.

2.5 Emergency Procedures

E-Stop — Pressing any E-stop button in the cell (robot E-stop on the control box or any cell-level E-stop wired into the RO2’s safety I/O) will immediately stop the robot and cut power to the welding arc. The power source output is disabled when the E-stop is active.

Recovery After E-Stop:

1. Identify and resolve the cause of the E-stop.
   
2. Reset the E-stop button.
   
3. On the RO2 interface, reset the E-stop condition and unbrake the robot.
   
4. Jog the robot away from the workpiece if needed before resuming.
   
5. Inspect the weld and workpiece before restarting the routine.

In Case of Fire — Use the Class ABC fire extinguisher to suppress any fire. Do not use water on an electrical fire. Disconnect input power to the welding system if it is safe to do so.

In Case of Electric Shock — Do not touch the person if they are still in contact with the energized circuit. Disconnect power immediately. Call emergency services. Begin CPR if the person is unresponsive and not breathing.

In Case of Arc Eye (Flash Burn) — If a person has been exposed to the welding arc without proper eye protection, they may experience symptoms (pain, tearing, sensitivity to light) within several hours. Seek medical attention.