HEALTH & SAFETY
Those that are not in use or are left unattended must be switched off and disconnected from the power supply. Devices must always be operated in accordance with the protection class shown on the rating plate—in compliance with the relevant operating instructions. Devices in protection class IP21 may
only be used in dry indoor areas. A protection class of IP23 is required as a minimum for outdoor use. Return lead cables should be connected as close as possible to the welding area—either directly to the workpiece or to its support. In the event of faults, the power supply
Drawing 3: Break in ground conductor: electrode holder lying uninsulated on the welding machine
must be disconnected immediately, either by switching off the device or removing the mains plug. Any damage to welding machines, mains leads, or hosepacks must be reported to the welding supervisor immediately. Under no circumstances may defective devices be used again or opened without authorisation—especially not by removing the protective cover.
Hazards due to stray welding current Improper handling of welding machines can result in considerable risks. Incorrectly connected return lead cables or carelessly placed electrode holders are particularly critical aspects. Faults of this type can cause interruption of the ground conductors, welding machines, or other electrical devices. As breaks in protection are not usually evident from the outside, they pose a considerable risk for anyone working with damaged devices. Carelessness and inattention are
Drawing 4: Break in ground conductor: power hand tools lying on the welding tables are connected to the mains
The employer’s duty to protect and inform Effective protective measures can
prevent workplace accidents, and the employer is responsible for making sure these are implemented. International standards and regulations—such as those published by the ISO (International Organization for Standardization), ASME (American Society of Mechanical Engineers), AWS (American Welding Society), and DIN (German Institute for Standardization)—form the basis for safe working conditions. Welding specialists must be informed of the potential hazards in all cases.
The distance between the welders must be selected so that simultaneous contact with two welding torches or electrode holders is ruled out. If this is not possible, the work areas must be separated by insulating partitions. In addition, appropriate measurements need to be taken to ensure that the total voltage does not exceed the maximum permissible open circuit voltage.
What needs to be taken into account during welding? Before starting work, welding specialists
must ensure that the welding machines they are using are in perfect condition.
28 / WELDING WORLD MAGAZINE - ISSUE 04 - AUGUST 2025
the most common causes of breaks in the ground conductor and resulting accidents. Typical examples might include uninsulated electrode holders that are set down on the welding machine or power hand tools left on the welding table during welding work (drawings 3 and 4). However, those who pay attention to
the protective measures stipulated by the applicable standards can ensure they are effectively protected against stray welding current. The welding current return cable (ground) should be connected directly to the workpiece or its support—by clamping it or using adhesive magnetic poles. Other parts such as metal poles, chains, or crane ropes must never be used as return cables. If, in exceptional cases, workpieces have to be welded while suspended from
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