In this video, I issued a crucial warning about the potential dangers of using off-brand gray arc welders for permanent jewelry. These welders, originally designed for the dental industry, are extremely powerful and can discharge even after being turned off, posing significant safety risks that could lead to severe injuries.
A Real Incident: Customer Experience
A concerned customer, who had purchased this off-brand welder as part of a training package, sent me a video that starkly illustrates the dangers involved. While practicing, she and her husband suffered burns from the welder. This wasn’t just a minor incident; it was a frightening experience that highlighted the potential hazards of using such equipment.
She filmed the video as evidence to show her course instructor and the manufacturer, who initially accused her of lying. In the video, we can clearly see the gray arc welder set to a low power setting of 2. Despite being turned off, the welder discharged a powerful weld that broke a piece of chain. This incident is alarming and underscores the importance of using safe and reliable equipment.
Understanding the Issue: Expert Insights
To understand why this off-brand welder posed such a danger, I contacted a certified electrician and an electrical engineer. Their insights were invaluable in shedding light on the issue. Arc pulse welders have powerful capacitors inside that hold a charge even after the machine is turned off. Typically, a safety mechanism, such as a resistor or relay, discharges these capacitors safely over several seconds to prevent accidental discharges.
According to the electrical engineer, in safe and well-designed machines, there is usually a shunt resistor that discharges the capacitors when the machine is turned off. Alternatively, a relay acts as a switch to short the outputs and discharge the capacitors safely. However, it seems this off-brand welder might lack these critical safety features, which could explain the dangerous discharge after it was turned off.
Expert Advice and Potential Solutions
The electrical engineer suggested a workaround for this problem: using a large resistor, around 1k ohm, to discharge the built-up electrical charge. After turning off the machine, the user should short the welder tip to the ground tip through the resistor. This method can safely discharge the capacitors and prevent accidental discharges.
He provided a detailed diagram to illustrate this solution. However, I must emphasize that I do not recommend attempting this yourself. While this method might work, it involves significant risks and potential liability issues. Instead, I advise contacting the manufacturer to inquire about proper safety measures and solutions.
A Safer Alternative: Sunstone Engineering Micro Welders
In my videos, I exclusively use micro welders from Sunstone Engineering, based in Utah. These welders are designed with built-in safety mechanisms that prevent such dangerous discharges. Unlike the off-brand welders, Sunstone’s machines do not energize the welder tip until they sense that the pieces are in contact. This feature prevents accidental discharges and shocks, ensuring a safer working environment.
Common Complaints and Issues
Numerous users have reported complaints about the gray arc welder, particularly regarding high voltage and unstable discharges. Many have experienced the electrode discharging even before making contact with the jewelry, leading to potential injuries. This is a stark contrast to the Sunstone welders, which only send power to the tip when the pieces are in contact, ensuring controlled and safe welding.
Additionally, there have been reports of the stylus handle shocking users. The suggested solution from the manufacturer was to wrap electrical tape around the stylus, which is far from a safe or professional fix. This kind of advice raises serious concerns about the safety standards of the off-brand welder.
The Importance of Safety in Jewelry Making
While the allure of saving money by purchasing cheaper equipment is strong, especially for those just starting in the jewelry-making business, safety must be the top priority. Using non-certified equipment can lead to severe injuries and invalidate insurance coverage, particularly in Canada and most EU countries where CSA certification is required.
Investing in certified, safe equipment might require a larger initial outlay, but it is crucial for long-term business success. Certified machines like those from Sunstone Engineering come with built-in safety features and reliable performance, reducing the risk of injuries and potential lawsuits. This investment not only protects you but also ensures the quality and safety of the products you create for your customers.
Insurance Implications
It is important to note that in Canada and many EU countries, insurance companies often insist on using CSA-certified equipment. Any accidents that occur while using non-CSA certified equipment will likely invalidate your insurance, leaving you unprotected in case of a mishap. Always read the fine print of your insurance policy to understand these requirements and ensure you are compliant to avoid costly repercussions.
Encouraging a Safe Community
I encourage everyone in the jewelry-making community to share their experiences and thoughts. Have you used this or other off-brand welders? If you’ve tried rigging up your own resistor, how did it work out? What has been your experience with this welder or any other brand?
Sharing our experiences can help others make informed decisions and avoid potential dangers. By fostering a community focused on safety and quality, we can ensure that everyone benefits from our collective knowledge and expertise.
Conclusion
In conclusion, the dangers of using off-brand gray arc welders for permanent jewelry are real and significant. The potential for severe injuries and the lack of built-in safety features make these machines a risky choice. Investing in certified, reliable equipment is crucial for ensuring safety and long-term success in the jewelry-making business.
Always prioritize safety over cost, and don’t hesitate to reach out to manufacturers and experts for advice and solutions. By doing so, you protect yourself, your business, and your customers, ensuring a safe and successful jewelry-making journey.
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