Submission 202

Attachment A

Negative benefits of a Voltage Reducing Device (VRD)

Not complying with the general rule, set out by OH&S. remind workers to turn equipment off when not
in use (each time the arc is broken)
Reduced voltage when not welding

Power source output is never switched off.

Voltage is reduced between 12 and 30 Volts meaning the welding cables are always energised (live).
Present electrical hazard at all times.
Suitable for stick welding Category. A only.

Risk of electric shock exist

Even with reduced voltage at the handpiece, low body impedance can allow harmful currents to
flow through the operator. Electrical hazard exists.
VRD does not protect the user during the welding process.

Not all Fail Safe device

The VRD senses an increased resistance to reduce the output, which can sometimes take
seconds, which is enough time for an electrocution to occur.
If a resistance lower than 200 ohms is present then the OCV output will not reduce and will have
a cyclic operation (ON-OFF-ON) with full OCV present.
Self start device.
High failure rate.

Difficult to strike an arc

Contact below 200 ohms is required to switch to full Open Circuit Voltage (OCV)
Difficult to strike an arc on rusty or scaly workplace and with Celluloid or Low nitrogen
electrodes (require minimum OCV of 95V to start).
Electrode wastage and damage (chipping) while trying to start arc.
Increased hazard due to excessive use of power tools to prepare surface (<200 Ohms) for welding
(waste power, grinder, grinding discs and time).
Changes performance of the power source by introducing a time delay before full OCV is applied
(cold start)
Forces the operator to use both hands to scratch the surface with the electrode to strike an arc.

Voltage can be accidentally applied

Flashes can occur when electrode accidentally touches the work piece. This presents a blindness
hazard to the operator or assistant.
A small current (few mA) leakage between the work and return leads may turn the power source on to
full OCV.
Dropped and swinging electrode holder could hit flammable area (gas pipe) and consequences
could be catastrophic

Observer needed

Where an observer is required for Category B & C Environments, Confined Space or Underwater

Submission 202
Attachment A
Welding; the observer must remain in close proximity to the deadman switch reducing the ability
to maintain visual contact.
The observer has the ability to reset the deadman switch without the knowledge of the welding
operator
Observer reaction time is slow The observer must physically switch the deadman switch in 0.3
second according AS Standard

May require bypassing

A VRD bypass switch is required on multiprocessor machines such as Plasma, Tig HF, Gouging, and
Mig.
High maintenance
Requires regular operational testing of device and constant maintenance, inspection for high resistance on
welding leads, connections, electrode holder and earth clamps. (max. 200 Ohms required for operation)