AC Models - Hobart Welders
Contents
1. 2 xad usas 494 907 SCREW K50 x 20 pan hd trx stl pld thread forming 1 Mog 216361 LABEL electrode amperage selector not included with EN FR model 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Return To Table Of Contents OM 950 Page 31 Warranty Questions Call 1 877 HOBART1 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART RS WELDERS HOBART EL WARRANTY Effective January 1 2003 5 3 1 WARRANTY applies to all Handler 125 135 and 175 models Airforce 250 250A 375 400 and 625 models and Champion 4500 and 10 000 models Beta Mig 1800 Champ 1435 2060 8500 models Ironman 210 and 250 models Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial No KK200262 and newer This limited warranty supersedes all previous Hobart warranties and is exclusive wi2. F I rs YS T 3 EE LI IS ETES emer j _ f eases Ss em eses po ae Ses Ss ell 802 246 Return To Table Of Contents OM 950 Page 15 SECTION 5 OPERATION 5 1 Controls R AK a R ES OS ous A Controls For AC DC Models 1 Amperage Adjustment Control 2 Power Switch J Ge 3 Mode Switch For DC Weld Output RATED WELD OUTPUT AGIDG Use mode switch to select polarity 25 225 150 of dc output Electrode Posi DC j SN MAX OCV A l ON tive DCEN AC ZA 30 170A 2 Kc A CACJ es DUTY CYCLE e tive DCEP or Electrode Nega 1 dt For AC Weld Output Use mode switch to select ac low S range or high range output WARNING ELECTRIC Qa K 9 9 9 p SHOCK CAN KILL DO NOT USE AC OUTPUT IN DO NOT SWITCH POWER c DAMP AREAS IF MOVEMENT UNDER LOAD IS CONFINED OR IF THERE IS A DANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE WELDING PROCESS O OFF 3 2 ACCU SET AMPERAGE CONTROL D 70 I 0 50 E ELECTROD 40 Ref 190 600 B 802 105 C OM 950 Page 16 Return To Table Of Contents B Controls For AC Models 1 Amperage Adjustment Control 2 Power Switch UL OUTPUT 8 Mode Switch ACA AC AC Use mode switch to select ac low 150 235A 30 170 A MES 5 range or high range output DUTY CYCLE 20 Cu Py MAX OCV 80
3. 15 Duty Cycle 50 Hz Overall Dimensions Height 18 3 4 in 476 mm Width 12 3 4 in 323 mm Depth 17 1 2 in 445 mm While idling AC Models Amperes Input at Rated Load Max Open Output 50 Or 60 Hz Rated Welding Output gen Circuit Single Phase Weight ange Voltage 230 V 225 A 25 Volts AC 20 Duty Cycle 60 on ja BERTE am 5 E 15 Duty Cycle 50 Hz d Overall Dimensions Height 18 3 4 in 476 mm Width 12 3 4 in 323 mm Depth 17 1 2 in 445 mm While idling OM 950 Page 10 Return To Table Of Contents 4 2 Duty Cycle Charts A For AC DC Models Duty Cycle is percentage of 10 minutes RY that unit can weld at rated load without overheating gt A 20 Duty Cycle at 225 Amperes Ex ceeding duty cycle can damage unit and void warranty 2 Minutes Welding 8 Minutes Resting For 115 230 230 And 460 Volt Models 225 150 Amperes 300 ET SS per een E Eh een L RT LL LT SR o TS ul 150 ES 9 tr KH IT H 1 CT 13 E NT 3 NJ 00 Sur fa Lech 9 E 1 LL L LI LI KKH ul LI I et oe 1 ae DS CE L Yt l wo o L ee SON RRG ER 0 15 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE These models have a 15 duty cycle when used with 50 Hz input power 086 727 B For AC Models Duty Cycle is percentage of 10 minutes EN m that unit can weld at rated load wi
4. Figure 9 1 Main Assembly pm 134 464 LABEL gen precautionary 1 ou ET heechiueris 217 732 LABEL Warning General Precautionary En Fr Vert 1 I E 2103309 4WRAPPER a2 sc aceite naan cs ekked rue ENEE SERERE ne owe 1 9 82 190079 SWITCH secondary 2 position AC model 1 9 82 190080 SWITCH secondary 4 position AC DC 225 model 1 RP 190 977 BUS BAR jumper AC DC 225 model 2 T 190 978 BUS BAR jumper AC DC 225 model 1 Tp C 191 122 BRACKET base reinforcing 2 7 T1 190170 TRANSFORMER amp SHUNT 230V 225A model consisting of 1 3 EE 190 242 SCREW lead shunt 1 m 190150 ssa SHUNT ciu vince c bia ete bet Len Bho ans E NS AMI one 1 P O ta 147 907 SCREW 5 16 18 x 1 75 wiloctite 4 ze WA ase ees 080 522 BLOCK anti noise shunt 4 12 Z1 190145 STABILIZER AC DC 225A model 1 18 SR1 190303 RECTIFIER AC DC 225A model 1 14 S1 124511 SWITCH all 225A models 1 25 715 see vows aa 190086 CASE SECTION isieiles ide dod REIR GRE
5. C OM 950 Page 14 Return To Table Of Contents 4 7 Electrical Service Guide Input Voltage 230 47 5 Input Amperes At Rated Output 67 Max Recommended Standard Fuse Or Circuit Breaker Rating 70 In Amperes 100 Min Input Conductor Size In AWG Kcmil a Max Recommended Input Conductor Length In Feet Meters 87 GH Min Grounding Conductor Size In AWG Kcmil 12 10 Electrical Service Requirements For 300 200 AC DC And 300 AC Models Reference 1997 National Electrical Code NEC Ref S 0092 J 4 8 Connecting Input Power Per Disconnect and lockout tag out input power before con necting input conductors from unit Have only qualified persons make this installation See rating label in Section 4 4 and be sure to supply correct in put power Line Disconnect Device Input And Grounding Conductors For Models Not Supplied With Plug See Section 4 7 for fuse size and ratings Size and ratings must comply codes 3 Plug 4 Proper Receptacle User Supplied conductor and with applicable TN 2 He 1 91 ra SRE GE d TET agn dr L2 NNNM i L1 Install conductors into a deenergized line A Sam ma R JET disconnect device conductor first GND PE f l j i 5 E
6. Dr ERG E E RR te 1 16 PLG1 088297 CORD SET 230V 225A model 1 ne IP a 111 443 BUSHING strain relief 230V 225A model 1 Dn EE 185759 LABEL warning 1 d 217 733 LABEL Warning Electric Shock amp Input Power En Fr 1 19 FM 190234 MOTOR fan 1 ux sei xus 005 656 2 BLADE fati eek gane e Cate scu etu e Re b eu je 1 qud csse exu 193289 LABEL Control Output AC 235 Amp 1 ei 21 suis 193291 LABEL Control Output AC DC 235 160 Amp 1 uA uelis ee 218246 LABEL Control Output AC 235 Amp EN FR 1 eee ee 218 247 LABEL Control Output AC DC 235 160 Amp EN FR 1 m 190296 GEAR pinion men 1 cx ideis 190295 GEAR pointer soises eie siui ienaa hn 1 oe P sors 190241 HANDLE control current 1 m Roe 190 538 LEAD LIST AEN ER ERR LER ERIT EE EIU PE De RH qr RR ad 1 ga AO ag eeu hve 215248 KIT electrode holder amp gnd clamp 1 one casia 192872 LABEL brand Identity Stickmate LX 1 Vu ether race 217981 LABEL brand Identity Stickmate LX EN FR 1 One e pm 207 074 HANDLE switch 1 ee ae 190 243 CLAMP weld cable
7. EEA ex d 20 SECTION 7 ELECTRICAL DIAGRAMS 21 SECTION 8 WELDING METHODS amp TROUBLESHOOTING 22 8 1 Shielded Metal Arc Welding SMAW Procedure 22 8 2 Electrode And Amperage Selection Chart 23 8 3 Striking An ANG 424 ossis eus mal eee Gate Mone ete ete tobe heat dent T S RES 24 8 4 Positioning The Electrode Holder 4204222 24 8 5 Weld Bead Characteristics 25 8 6 Conditions That Affect Weld Bead Shape 25 8 7 Electrode Movement During Welding 2 26 8 0 BUJONS i tae ae t EUROPE D Ae Sasa tape dani egg hie Sa PNE gain Saws 26 8 95 EAD TONS c S dE SEET den Eed NEE erre C e e ANUS p ats 27 8 10 Tee Joints oer weve x et eR wes oe E Sad EE REN ea sab E EUREN NE RE XR aD ET wey 27 SECTION 9 PARTS LIST i oe eiii hee SE NNN EE NN DSE EE NEE KEN Pria 30 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Haza
8. Install securing screw through han dle into threaded hole in shunt shaft Tighten securely Reinstall wrapper 5 16in 802 248 C Return To Table Of Contents OM 950 Page 19 6 4 Troubleshooting PER Trouble Remedy No weld output fan does not run Be sure line disconnect switch is in On position see Section 4 8 Check and replace line fuses if open Reset breakers if necessary see Section 4 8 Fan does not run weld output okay Be sure nothing is blocking movement of fan If fan does not run freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry properly stored electrodes Shorten arc length Reduce amperage setting see Section 5 1 Electrode freezing to work Increase amperage setting see Section 5 1 Increase arc length Use dry properly stored electrodes Noise and vibration from shunt block Lubricate shunt block and or tighten adjustment screws see Section 6 2 OM 950 Page 20 Return To Table Of Contents SECTION 7 ELECTRICAL DIAGRAMS S1 o To 230 VOLT a o p Fog de ONLY NED GRAN lt PRI 900090090 SR1 in
9. MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 950 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phon
10. Rated Welding AG iuret E IN Electrode Positive a N Electrode Negative 2 Current X Duty Cycle Direct Current d io Line Connection U 2 Bere Fond Rated Supply Cur U 1 Primary Voltage 1 rent Input Volts Rated No Load Welding Arc TOME EN He U Q Voltage Average E 3 2 Manufacture s Rating Labels Rating Label For AC EN FR Machines MILLER ELECTRIC MFG CO APPLETON WI USA LR5071 XXX21 Hz XX10 A 1 DD U X48V U x06V EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE ALT RATION DE L TIQUETTE ANNULLE LA GARANTIE 217 854 A 217 855 A 165 371 Rating Label For AC DC EN FR Machines MILLER ELECTRIC MFG CO APPLETON WI USA ET EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE ALTERATION DE L ETIQUETTE ANNULLE LA GARANTIE Rating Label For All Other Machines INPUT SERIAINO STOCK NO VOOS AMPERES KW PHASE LR5071 HERTZ e US EVIDENCBFLABELTAMPERINGOIDSNARRANTY Return To Table Of Contents OM 950 Page 9 SECTION 4 INSTALLATION 4 1 Specifications AC DC Models Amperes Input at Rated Load Maximum Mode Rated Welding Amperage Open EE is EL 60 Hz Weight Output Range Circuit Ing e F nase g Voltage 230 V 225 A 25 Volts AC AC 20 Duty Cycle 60 Hz d cec 80 VAC 15 Duty Cycle 50 Hz 2 TS 47 5 47 kg 150 A 25 Volts DC 23 DC 20 Duty Cycle 60 Hz 30 160 80 VDC
11. Sila Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil e Faire r guli rement contr ler et entretenir l installation e Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique e Pour r duire la possibilit d interf rence maintenir les cables de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel e Encasd interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS
12. air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 950 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion p Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental conta
13. et un masque e Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu E P vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 950 Page 6 a LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr z LES PI CES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e lis doivent consulter leur m decin avant de s appro cher d un lieu ou on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut a
14. it 2 ee Po oe S 0049 S 0050 8 4 Positioning The Electrode Holder 10 30 Groove Welds NN 907 90 3 d End View Of Work Angle Side View Of Electrode Angle End View Of Work Angle OM 950 Page 24 Return To Table Of Contents Side View Of Electrode Angle Fillet Welds S 0660 8 5 Weld Bead Characteristics Poor Weld Bead 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 4 5 Poor Penetration 5 S 0053 A Fine Spatter Uniform Bead Good Weld Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration Into Base Metal Ref S 0052 B 8 6 Conditions That Affect Weld Bead Shape Electrode Angle Angle Too Small Correct Angle Angle Too Large 10 30 i fl ee eS OTN 5 ES Drag Arc Length Spatter a pt Rn e 5 5 Too Short Normal Too Long Travel Speed dili c d oA Slow Normal Fast S 0061 Return To Table Of Contents OM 950 Page 25 8 7 Electrode Movement During Welding e 3 zt EC MAN 1 Stringer Bead Steady Move ment Along Seam 2 Weave Bead Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the ele
15. ne doi vent tre confi s qu des personnes qualifi es A Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants LES DECHARGES ELECTRIQUES peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger e Ne jamais toucher aux pi ces lectriques sous tension e Porter des gants et des v tements de protection secs et exempts de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre e Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber e Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige e Sil tilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip e
16. of electrode manufacturer when setting 7 Slag weld amperage see 8 2 Use a chipping hammer and wire brush to remove slag Remove 4 Insulated Electrode Holder slag and check weld bead before making another weld pass OM 950 Page 22 Return To Table Of Contents 8 2 Electrode And Amperage Selection Chart AMPERAGE DIAMETER LL a O tc o LI LI scs ul p Se us sao za RE L A8 us 316 DEEP MIN PREP ROUGH D HIGH SPATTER L GENERAL SMOOTH EASY FAST 6011 6013 HH PENETRATION TU ALL ALL ALL LOW A ME LOW HYDROGEN LOW STRONG N r wool e 7018 ALL FLAT SMOOTH EASY 7024 EP EN mus LOW FASTER Low CASTIRON Low STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref ST 087 985 A Return To Table Of Contents OM 950 Page 23 8 3 Striking An Arc Scratch Start Technique Tap Start Technique 1 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was A 2 lifted too high If electrode sticks to workpiece use a quick twist to free
17. other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 877 Hobart1 AC TAAS THO Hob Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Tsis 2Symbol USagez es 9 Kae oie pets Seah te oett de vet eie rd edema exe Ae 1 1 2 Are Welding Hazards o hee vetet er ge xe e t See EEN sex 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 1 6 HEME Norma ON eg ed den tee cated e Ale een OLAS sc du ss co Sh A EN 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DERINITIONS serie eiie ru xr Rare ae
18. responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects a
19. utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Ne travailler dans un espace clos que s il est bien ventil ou porter un respirateur a adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moins que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 950 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures ocu
20. your nearest Factory Authorized Ser vice Agent if noise continues A Install wrapper before turning On power Tools Needed T E 1 2 in Ll 5 16 in 802 248 C OM 950 Page 18 Return To Table Of Contents 6 3 Reinstalling Amperage Adjustment Indicator For 225 A models X 2 1 2 in ACCU SET AMPERAGE CONTROL ELECTRODE p M I E WORK Proper alignment of pointer and crank handle C ZH Tools Needed SS P T 20 Torx A Turn Off welding power source and disconnect input power 1 Wrapper Remove wrapper from unit 2 Crank Handle 3 Shunt Shaft 4 Transformer And Shunt Located Inside Unit Insert crank handle onto shunt shaft protruding through front panel and turn crank handle to adjust shunt to the proper vale of X de pending on model see detail of transformer and shunt Remove crank handle 5 Pinion Gear Install pinion gear onto front panel making sure anti rotation pins are in holes on front panel 6 Pointer Gear Install pointer gear overtop of pinion gear and rotate so pointer is indicat ing 130 Amps on ac Low Range scale see example Install crank handle overtop the sta tor pinion gear assembly with the handle straight down It may be necessary to turn the handle slight ly so vertical alignment is possible 7 Securing Screw
21. 8 03 AEN Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance I y a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de connaitre les me sures prendre pour viter tout danger e N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de fa on obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e Ne pas connecter plus d une lectrode ou plus d un cable de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimentation lectrique Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUMEES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou
22. C ESD can damage PC boards P e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards N De MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Return To Table Of Contents E MOVING PARTS can cause injury e Keep away from moving parts such as fans C e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is
23. Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout cable d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou mal piss s Ne pas s enrouler les cables autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un cable distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine Revenez la table des mati res som fre
24. NI OM 950 218245A Een December 2003 C Processes H2 Stick SMAW Welding Description AC DC Models ce AC Models cc Arc Welding Power Source STICKMATE LX WELDERS 235 AC DC And 235 AC de OWNER S MANUAL Visit our website at www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source SE ig ten Aid N you may need to fix the problem Warranty and from Hobart is backed by i i i 1 1 the best warranty in the System Standard service information for your particular model y business are also provided IS0 9001 2000 QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on
25. National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 950 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Ch
26. RANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart retail 8 03 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Alwa
27. SS e Mettre un bracelet antistatique AVANT de mani puler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage PAL Revenez la table des mati res N LES ORGANES MOBILES peuvent causer des blessures CE e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de S curit et les ordinateurs e Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation e
28. a WARNING ELECTRIC D SA L SHOCK CAN KILL DO NOT USE AC OUTPUT IN DO NOT SWITCH POWER DAMP AREAS IF MOVEMEN UNDER LOAD em IS CONFINED OR IF THERE IS ADANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE WELDING PROCESS O O FF 3 ACCU SET 4 AMPERAGE CONTROL Ref 190 599 A 802 105 C Return To Table Of Contents OM 950 Page 17 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Lay we A Disconnect power before maintaining Bess 3 Months WARNI fm gt l ee Repair Or Replace Unreadable up t Labels zx Cables md 12 Months During Heavy Service Clean Monthly See Section 6 2 Blow Out Or Vacuum I Inside Lubricate Shunt Block 6 2 Lubricating Shunt Block And Anti Noise Adjustment A Turn Off welding power source and disconnect input I power 1 Wrapper Remove wrapper 2 Shunt Block Do not grease screw threads on shunt block Apply light coating of high tempera ture grease to shaded areas of both shunt blocks Turn amperage con trol handle to spread grease evenly 3 Noise Adjustment Screws If shunt block vibrates and becomes noisy tighten adjustment screws 1 4 turn Install wrapper turn On unit and check for shunt noise Repeat procedure until noise stops Do not overtighten Call
29. actors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed impro
30. any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Return To Table Of Contents 1 3 Additional Symbols For Installation Operation And Maintenance Ki FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit UM OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit Ram an e 7 STATI
31. ct of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding SESCH FLYING METAL can injure eyes e Welding chipping wire b
32. ctrode Do not let weave width exceed 2 1 2 times diameter of electrode A single stringer bead is satisfactory for most narrow groove weld joints For wide groove weld joints or bridging across gaps a weave bead works better S 0054 A 8 8 Butt Joints OM 950 Page 26 1 16 in 1 6 mm Return To Table Of Contents o 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 through 3 4 in b 19 mm thick Cut bevel with oxyacetylene or plasma cutting equipment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 8 9 Lap Joints 1 Electrode 2 Single Layer Fillet Weld 30 Or Less alan B Move electrode in circular motion 30 Or Less Pd 3 Multi Layer Fillet Weld Weld a second layer when a larger i 1 s 1 filletis needed Remove slag before making another weld pass Weld both sides of joint for maximum strength 2 3 Single Layer Fillet Weld Multi Layer Fillet Weld S 0063 S 0064 8 10 Tee Joints 1 Electrode 1 2 Fillet Weld Ke
33. d CEET TTT SER r gt L b d b d 0 Z1 AV J e L L Leem OAC HIGH 0 r 4 AC LOW O e e gt a S2 9 DC EP S 9 DC EN o WORK ELECTRODE 191 364 Figure 7 1 Circuit Diagram For AC DC 230 Volts Models EN Ge 230 VOLT amp o qu ONLY No amp WARNING e Do not touch live electrical parts Le e Disconnect input power or stop RN A G PRI 3 engine before servicing e Do not operate with covers removed 00600000007 ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit T1 PLG1 SEC es e acHIGH AC LOW O WORK O ELECTRODE 191 362 Figure 7 2 Circuit Diagram For 225 230 Volts Models Return To Table Of Contents OM 950 Page 21 SECTION 8 WELDING METHODS amp TROUBLESHOOTING mod5 1 9 92 A Welding Methods Fe erm 8 1 Shielded Metal Arc Welding SMAW Procedure Tools Needed ST 151 593 1 Workpiece 5 Electrode Holder Position Make sure workpiece is clean before welding 6 Arc Length 2 Work Clamp Arc length is the distance from the electrode to the workpiece A Place as close to the weld as possible Short arc with correct amperage will give a sharp crackling sound 3 Electrode A Welding current starts as soon as electrode touches the workpiece A small diameter electrode requires less current than a large one Follow recommendations
34. e 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Counc
35. ed Table 6 6 Burn Through Burn Through weld metal melting com pletely through base metal resulting in holes where no metal remains L Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode with lower amperage Increase and or maintain steady travel speed Table 6 7 Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by Sm base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique Table 6 8 Distortion Distortion contraction of weld metal dur ing welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds Return To Table Of Contents OM 950 Page 29 SECTION 9 PARTS LIST Hardware is common and not available unless listed 12 802 245 E Figure 9 1 Main Assembly AC DC model illustrated OM 950 Page 30 Return To Table Of Contents Item Dia Part No Mkgs No Description Quantity
36. ep arc short and move at definite 1 rate of speed Hold electrode as shown to provide fusion into the Sag corner Square edge of the weld T Sal surface 45 For maximum strength weld both Or Less 7 sides of upright section 2 2 r 3 Multi Layer Deposits Weld a second layer or more when a larger fillet is needed Use any of the weaving patterns shown in Sec tion 8 7 Remove slag before mak ing another weld pass S 0069 S 0058 A S 0061 B Welding Troubleshooting D Ad Table 6 1 Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Gees all grease oil moisture rust paint coatings slag and dirt from work surface before welding Return To Table Of Contents OM 950 Page 27 Table 6 2 Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage Table 6 3 Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead a Possible Caus
37. es Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Table 6 4 Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion be tween weld metal and base metal Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed OM 950 Page 28 Return To Table Of Contents Table 6 5 Excessive Penetration Excessive Penetration weld metal melt ing through base metal and hanging un derneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel spe
38. ffecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes e D tourner la t te lorsqu on ouvre la soupape d une bouteille e Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m
39. icago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended Return To Table Of Contents SECTION 2 CONSIGNES DE S CURIT A LIRE AVANT UTILISATION 2 1 Signification des symboles A identifie un message de s curit particulier Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc A Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apr s ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes L installation l utilisation l entretien et les r parations
40. il a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiques pendant le soudage ou le coupage OM 950 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus Revenez la table des mati res SECTION 3 DEFINITIONS 3 1 Symbols And Definitions D Single Phase d 1 1v Single Phase n Transformer AC amp A Amperes 1 N Single Phase D Transformer GD DIE Rectifier DC Power Source On O Off gt Output H Z Hertz Alternating oi B
41. laires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage e Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit RAR CH LE SOUDAGE peut causer un incen die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et prot ger les tier
42. les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit Revenez la table des mati res 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que l anneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil nw t i L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L EQUIPEMENT lt e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage Ne pas obstruer les orifices ou filtrer l alimentation en air du poste e LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s P amp A
43. nd other reproductive harm OM 950 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the
44. pecial installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 151 556 217 855 A 4 5 Weld Output Cables NOTE gt For weld output cable replacements or extensions contact your Factory Authorized Service Agent Return To Table Of Contents OM 950 Page 13 4 6 Installing Electrode Holder And Work Clamp A Turn Off unit and disconnect input power before installing electrode holder or work clamp Removing Barrel From Electrode Holder 1 Electrode Holder E 2 Barrel ES 3 Access Hole 4 Set Screw ELECTRODE Loosen set screw through access hole and slide barrel away from electrode holder Installing Electrode Cable and Barrel onto Electrode Holder 5 Electrode Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from electrode holder Insert electrode cable through barrel into end of electrode holder and tighten ter minal screw securely Move barrel toward electrode holder and tighten set screw to secure barrel in place Installing Work Cable onto Work Clamp 7 Work Clamp 8 Work Cable From Unit Has Ring Terminal on End 9 Mounting Bolt Route work cable through work clamp as shown and install onto mounting bolt using supplied hardware Tools Needed oF 14mm 6 mm E Bi Ref 802 251 A 802 105
45. perly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WAR
46. pete se Meee ea ete QS ete 9 3 1 Symbols And Definitions 9 3 2 Manhufactures Rating Labels iex ob eA Y ee AEN E CLE eC ada Rs 9 SECTION A INSTALLATION 2 2 x v9 I Rx DER DEER MER SNE NEEN un ieee one DEER EEN des 10 4 1 Specifications iweLi tive Ate br a ee Pe EE 10 4 2 Duty Cycl Charts 259 iene itl dead deat eL ben er e edad s 11 4 32 Volt Ampere Curves fen sede vena eR Yaad cate esp ases a Pe Vous RR aad oe te vane RR 12 434 Selecting A Location roii RE DE vais PANNI E IM de aa wee vane Na 13 45 Weld Output Cables ivi eyed Rd ste ya where ya LEE TR PE V ERN PYTH 13 4 6 Installing Electrode Holder And Work Clamp 14 47 Electrical Service Guide esee UE AR NUN CAE IN RENI RENE d 15 4 8 Connecting Input Power Au SIE Rt RU bey SOR EUN MER ed ee EUR RE 15 SECTION 5 OPERATION 1 0 ei Tex ee ee eee ee ee ede eds ee eee ee 16 el Gonttols 25 5 sede ong Rie as EROR ERES RUSSIE REDI de Ee RR SU ME 16 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 18 6 1 Routinie Maintenance os s cene iere pute eR RE ete Ser put etes Rule DS me Re e ne TE ele d 18 6 2 Lubricating Shunt Block And Anti Noise Adjustment 18 6 3 Reinstalling Amperage Adjustment Indicator 2 19 6 4 Troubleshooting de IRR x hve ENEE there eed dene eA be eee eee ee eee
47. r or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing
48. rds A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away be e ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use
49. remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body Return To Table Of Contents som 8 03 e wv T i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repai
50. rushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 950 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch
51. s de la projection d tincelles et de m tal chaud e Ne pas souder un endroit ou des tincelles peuvent tomber sur des substances inflammables e Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t e Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes
52. th no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Re
53. thout overheating A 20 Duty Cycle at 225 Amperes Ex ceeding duty cycle can damage unit and void warranty 2 Minutes Welding 8 Minutes Resting For 115 230 And 230 Volt Models 225 Amperes 300 250 200 150 WELDING AMPERES 15 20 26 30 40 50 60 70 80 90 100 DUTY CYCLE These models have a 15 duty cycle when used with 50 Hz input power 001 836 A Return To Table Of Contents OM 950 Page 11 4 3 Volt Ampere Curves A For AC DC Models DC Volts 80 70 60 50 40 30 20 10 For 115 230 230 And 460 Volt Models 225 150 Amperes AC Volts 90 0 50 100 150 200 250 300 350 AC Amperes 50 100 150 200 250 DC Amperes The volt ampere curves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown 193 509 193 510 OM 950 Page 12 Return To Table Of Contents B For AC Models The volt ampere curves show the For 115 230 And 230 Volt Models 225 Amperes minimum and maximum voltage and amperage output capabilities 90 Curves of other settings fall be A LOW RANGE tween the curves shown 80 tk B HIGH RANGE 70 60 50 40 AC Volts 30 0 50 100 150 200 250 300 AC Amperes 193 508 4 4 Selecting A Location 1 Rating Label See Section 3 2 Locate unit near correct input power A S
54. ys provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 9 2003 Hobart Welding Products 1 03 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se ZN HOBART tHe
Download Pdf Manuals
Related Search