Hobart Welding Products 500 Welder User Manual
Contents
1. 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 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 making2. Set Switch Select Amperage Range In Example Range Selected 45 to 250 DC Maximum Amperage Selected 100 DC Min 45 DC Max 100 DC 2 Max 100 DC T Min 45 A DC Select Maximum Amperage SD Adjust Remote Control 4 4 Power Switch 1 Power Switch Use switch to turn unit t On and Off OM 201 444 Page 21 4 5 Ammeter And Voltmeter Optional 1 Voltmeter Voltmeter displays voltage at the weld output terminals but not nec essarily the welding arc due to cable resistance poor connec tions etc 2 Ammeter Ammeter displays weld amperage output of unit SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance A Disconnect power before maintaining Replace Repair or Clean and unreadable replace tighten weld labels cracked pa terminals weld EN cable ll 6 Months Blow out or vacuum inside Sealed A Bearings During heavy service clean d uio Es monthly p WE p OM 201 444 Page 22 5 2 Overload Protection 1 Circuit Breaker CB1 CB1 protects the welding power source control circuit from over load If CB1 opens weld output drops to the minimum of the range selected Press button to reset circuit break er Ref ST 800 040 Trouble Remedy No weld output unit completely inoperative Place line disconnect switch in On positio
3. OM 201 444 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin
4. 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 OVERUSE can cause OVERHEATING INN e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit Le STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em 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 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126
5. 9 Overcurrent Protection Select type and size using 3 11 Install into deenergized line discon nect device fused disconnect switch shown ssb2 4 1 94 ST 800 042 A OM 201 444 Page 19 SECTION 4 OPERATION 4 1 Controls Power Switch Amperage Adjustment Control see Section 4 2 Remote Amperage Control Receptacle See Section 3 10 Circuit Breaker CB1 See Section 5 2 Remote Amperage Switch See Section 4 3 VOLTS AMPERES MAX OCY DUTY CYCLE MAX OUTPUT NEMA CLASS 1 00 122 043 1 Amperage Adjustment Control Use control to adjust amperage within range for Negative Weld Out put terminal see Section 3 9 Use A inner scale for low amper age range and B outer scale for high amperage range OM 201 444 Page 20 4 3 Remote Amperage Switch A Arcing can damage switch A Do not change Remote Am perage switch position while 1 power is on Arcing inside switch can damage con tacts causing switch to fail A 1 Remote Amperage Switch cS 2 Remote Amperage Control Use switch to select way of control ling amperage adjustment Example Combination Remote Amperage Control 400 Ampere Non CE Model Shown For front panel control place switch in the Panel position For remote control place switch in the Remote position and connect remote amperage control to remote amperage control receptacle see Section 3 10 See example below A m B 25 50 500A O A 9
6. Wf 7 ST 018 370 D Figure 7 3 Panel Rear w Components 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 OM 201 444 Page 29 Replace Coils At Factory Or Authorized Service Stations Service Distributors Item Dia Part Quantity Figure 7 4 Transformer amp Amplifier Power Main 50 Hz Fig 7 1 Item 7 Listed below as Amplifier eer ee ea ee ee ae 093 931 TRANSFORMER AND AMPLIFIER consisting of 1 bob Saat ares 052 995 22 3 9 TABIBIZEEPU cuiu acertado doe a iS ab Rae a VD NET ne 1 kw A tos IVA T soa 052 204 AMPLIFIER magnetic consisting of 1 DM Nue 033 691 COIL CONtroOlde see d techo dextero a QM deccm eed 1 hits Onda ani douce 033690 GOIL COH OL BO uri dad UNE Ere dio Res 3 TUE PUN EMU 093 932 TRANSFORMER power main consisting of 1 ped 093 587 COIL PSC siia dieere E RH Re OI te tente 1 D E 093 588 COL Oil SCC Com atrasada din ia 1 C O in 093 589 COIN Secar testear a dba de 1 eo n 018 873 BAFFLE p canoa ela 1 ST 802 611 Figure 7 4 Transformer amp Amplifier Power Main 50 Hz BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORD
7. of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local to receive the latest full line catalog or gt distributor Your distributor TP can also supply you with individual catalog sheets To locate your nearest Welding Process Manuals such as SMAW GTAW distributor or service agency call 1 577 Hobartl GMAW and GMAW P WELDING PRODUCTS The following terms are used interchangeably throughout this manual MIG GMAW 4 amp WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS 1 SEINE A a dd as dei 1 12 ATC Weding Hazards satis A a an a a Oaks ia 1 1 3 Additional Symbols for Installation Operation and Maintenance 3 1 4 Principal Safety Standards 0 0c ccc eee tenet teen tenes 3 1 9 EMF AMONMAUON Vitec eee oe eS tae eee Se Mee eG Sl ead ot iride mu us 4 SECTION 1 CONSIGNES DE SECURITE 4 5 11 Significa
8. 42A 33A s oozeva TEN 24 CEA 200 176 B 2 6 Symbols And Definitions Note 3 Some symbols are found only on CE products Protective Earth Ground Voltage Control Panel Percent Amperes Output A A Negative A B Negative Weld Output Termi Weld Output Termi 45 250A nal Low Range 60 550A nal High Range Negative Weld Output Terminal Direct Current U Rated No Load Conventional 0 Voltage Average Load Voltage nace a M Current 1 Primary Current Rectifier D Degree Of Alternating Protection Current OM 201 444 Page 11 SECTION 3 INSTALLATION 3 1 Specifications Amperes Input at Rated Load Output 50 or 60 Hz Three Phase Rated Welding Amp Range Max OCV DC Model Output DC IP Rating 220 V 380 V 440 V KVA KW A Low 500 A 40 Volts 45 250 SRH 500 DC 50060 Hz 290 75 23M B Ad 2 2 r 35 Duty Cycle B High i 60 500 While idling 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min RATED OUTPUT utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty SRH 500 WELD AMPERES DUTY CYCLE 3596 Duty Cycle At 500 Amperes 3 1 2 Minutes Welding 6 1 2 Minutes Resting Overheating A gt s OR Minutes Reduce Duty Cycle duty1 4 95 201 171 OM 201 444 Page 12 3 3 Volt Ampere Curves
9. File a claim for loss or damage during shipment 2000 Hobart Welding Products 1 00 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 WELDING PRODUCTS
10. 3 12B 220 VOLTS 380 VOLTS 440 VOLTS FAR o o ARAN o o ARAN o o ooo o AA o o o o AA o o o o AA of Bo o o o Alo o o o A o o o L1 L2 L3 L1 L2 L3 L1 L2 L3 S 021 148 A ssb5 1 2 92 Ref ST 800 042 OM 201 444 Page 18 B Connecting Input Power SA Jo SEEN CON CO Connect 9 Conductor First eetet pololefeleies tolol HX Tools Needed C xA 3 8 7 16 1 2 in Connect GND PE Conductor First peu Jf 9 Have only qualified persons make this installation Open rear panel access door 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using 3 11 Conductor rating must comply with national state and local electrical codes Use lugs of proper amper age capacity and correct hole size 4 Strain Relief Connector Insert conductors through strain relief 5 Input Terminal Board 6 Line Terminals 7 Welding Power Source Ground Terminal Connect grounding conductor to ground terminal first Then connect input conductors to line terminals 8 Disconnect Device Ground Terminal Install and connect grounding conductor and input conductors in conduit or equivalent to deener gized line disconnect device Connect grounding conductor first then line input conductors Be sure grounding conductor goes to an earth ground Close rear panel door
11. an authorized Hobart 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 option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart authorized service facility as determined by Hobart 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 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 WARRANTY 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 IS EXCLUDED AND DISCLAIMED BY HOBART 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
12. 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 som nd 4 98 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 Repair 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 capacito
13. 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 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 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard
14. que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s 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 irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 201 444 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l bl
15. Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re sear
16. DC VOLTS 3 4 Selecting A Location Movement Location And Airflow Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown SRH 500 LOW RANGE HIGH RANGE 200 300 400 500 600 700 800 900 DC AMPERES va _curvel 4 95 201 172 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Plate Label 4 Rating Label Use rating label to determine input power needs Label located on rear access door see Section 2 5 5 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref ST 800 402 A ST 139 445 C OM 201 444 Page 13 3 5 Dimensions And Weights 1 2 Dia 13 Dia 6 Holes 6 Holes Weight 755 lb 342 Kg ST 800 039 A Be careful when placing or moving unit over uneven surfaces OM 201 444 Page 14 3 7 Selecting And Preparing Weld Output Cables 1 Weld Output Cable Determine total cable length in weld circuit and maximum welding am peres See Section 3 8 to select proper cable size Use shortest cables possible Do not use damaged cables 2 Terminal Lug O Use lugs of proper amperage capacity and hole size for connect ing to work clamp e
17. ERING REPLACEMENT PARTS OM 201 444 Page 30 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 WARRANTY Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio 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 will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart must be notified in writing within thirty 30 days of such defect or failure at which time Hobart will provide instructions on the warrant
18. OM 201 444 August 2000 Processes Stick SMAW Welding a Air Plasma Cutting and Gouging Air Carbon Arc CAC A Cutting and Gouging Submerged SAW Welding WELDING PRODUCTS Description C3 y E Arc Welding Power Source Betastick 500 im 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 ME 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 gt Z installation and operation quick and easy With Hobart you can count on years of reliable service with proper WARRANTY maintenance And if for some reason the unit Working as hard as you l E do every power source Hobart is registered to the needs repair there s a Troubleshooting section from Hobart is backed by ISO 9001 Quality System that will help you figure out what the problem the best warranty in the Standard business is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTEHED QUALITY SYSTEM Hobart Welders manufactures a full line
19. Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans 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 Theuseris 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 equipmentat 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
20. c shock from welding electrode or wiring can kill Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label f 2 4 mb OM 201 444 Page 9 2 2 Input Connection Label S 179 290 2 4 Nameplate Safety Symbols OM 201 444 Page 10 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before w
21. 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 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 201 444 Page 4 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 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles i ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci so
22. celles et des arcs Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimen
23. ch Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 201 444 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 General Precautionary Label 1 96 Warning Watch Out There are possible hazards as shown by the symbols 1 Electri
24. coartada oe eas ees ead 20 As COMMONS saasaa NH 20 4 2 Amperage Adjustment Control 1 ic eus aiment ey ER one 20 4 3 Remote Amperage Switch vae d ss du nes HAN E as 21 4 4 PONT SWITCHED s e E Reid XR a LOE ia 2E 21 4 5 Ammeter And Voltmeter Optional 5 22 ia rr TRIS E IELSPSUE EFIE IA 22 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 22 5 2 Overload ProlectiOn 5s Pew vaso aeu prevede bas utopia uu adds 23 SECTION 6 ELECTRICAL DIAGRAM 9599 acia 24 SECTION 7 PARIS LIST iaa 26 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 Er Means Note not safety related 1 2 Arc Welding Hazards 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 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away Lr ELECTRIC SHOCK can kill
25. d le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine som nd fre 4 98 Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce 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 c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus p
26. ecessary OM 201 444 Page 23 SECTION 6 ELECTRICAL DIAGRAM D t o a o o c o 2 o c o 2 o w o c o aea e A WARNING e Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK_ HAZARD 70 pi rT TE1 d E De 220 440 220 D 380V PTT O Q Q O miu T1 J7 Sd CT a R1 H 33 a RN MAY 2 N V AZ a CW on ra FORA ra PEA PEA C A O C O C C O O O O cd O po pH a n El B y MR OUY 0009 J MEN 0 VV Q GR GROUND B BRASS C COPPER REMOTE CONTROL OPT FRE VUV 709090 9 709090 9 b O LOW NEGATIVE O HIGH O POSITIVE 086 018 D ircuit Diagram Figure 6 1 C OM 201 444 Page 24 Notes OM 201 444 Page 25 SECTION 7 PARTS LIST E Hardware is common and not Ki available unless listed Ref ST 139 447 F OM 201 444 Page 26 Item No ONES 1116 888 deta Sci Fig 7 3 TE1 038 138 rachet 038 618 BASE Fig 7 2 176 254 Part NO Dia Mkgs 199 311 2 SR2 035704 Fig 7 4 026 627 Rude t 040 075 METER amp dc 50MV 0 600 scale METER volt dc 0 100 scale 191 833 191 834 006 016 006 890 Jab c TIPIERSSEdIOde da UO ctu E UON a Description Figure 7 1 Main A
27. 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 lf 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 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 201 444 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will
28. g 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 a FLYING METAL can injure eyes e Welding chipping wire brushing 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 201 444 Page 2 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 e Pacemaker wearers keep away Wearers should consult their doctor before going
29. invisible ultraviolet and infrared rays a 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 f WELDING can cause fire or explosion 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 contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e 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 ceilin
30. l Receptacle RC1 2 Keyway To connect remote amperage con trol to receptacle insert plug and turn clockwise until tight Ref ST 800 040 3 11 Electrical Service Guide 50 Hertz Models 500 Amp Model Input Voltage 220 380 440 Input Amperes At Rated Output 103 60 51 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 100 60 50 Normal Operating 3 125 70 60 Min Input Conductor Size In AWG Kcmil 4 8 8 Max Recommended Input Conductor Length In Feet Meters ae ES Abs Min Grounding Conductor Size In AWG Kcmil 6 8 10 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 201 444 Page 17 3 12 Connecting Input Power Jumper links allow operation on dif Tools Needed ferent input voltages and are facto ry set for the highest input voltage Check input voltage available at site Open rear panel access door to check jumper links 1 Input Voltage Label Only One Is On Unit Look at jumper links and compare link position with unit label 2 Input Voltage Jumper Links Move links to match input voltage For example use 230 volts position when 230 volts input power is avail able Close door or go on to
31. lectrode holder O and weld output terminals O 3 Insulated Electrode Holder Install according to manufacturer s 2 instructions O 8 o 4 4 Work Clamp Install onto work cable Z 10 ft 3 m For Example Vi Total Cable Length In Weld Circuit 20 ft 6 m 10 ft 3 m Tools Needed sb6 1 11 92 S 0653 OM 201 444 Page 15 3 8 Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft males 45m 60m 70m 90m 105m 120m Welding 10 To 60 60 Thru 100 O Amperes Duty Cycle Duty Cycle 10 Thru 100 Duty Cycle Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes S 0007 E 3 9 Connecting To Weld Output Terminals Positive Weld Output Terminal A Negative Weld Output Terminal Low Range B Negative Weld Output Terminal High Range For DC Electrode Positive DCEP connect work cable to negative terminal that supplies desired am perage range Connect electrode holder cable to positive terminal For DC Electrode Negative DCEN reverse cable connec tions Use ONLY one negative weld output terminal at a time Tools Needed LE 3 4in Ref ST 800 040 OM 201 444 Page 16 3 10 Remote Amperage Control Receptacle 1 Remote Amperage Contro
32. m of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Hobart 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 or equipment that has been improperly installed improperly 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 option 1 repair or 2 replacement or where authorized in writing by Hobart in appropriate cases 3 the reasonable cost of repair or replacement at
33. n see Section 3 12B Check and replace line fuse s if necessary or reset circuit breaker see Section 3 12B Check for proper input power connections see Section 3 12B Check for proper jumper link position see Section 3 12A No weld output Clean and tighten all weld connections see Section 5 1 Unit provides only low or minimum weld output Check for proper line voltage Check for open line fuse s and replace if necessary Check and replace circuit breakers See Sec tion 3 12B Clean and tighten all weld connections see Section 5 1 Place Remote Amperage switch in correct position see Section 4 3 Select correct size weld cables see Section 3 8 Low weld amperage Amperage Ad justment does not control amperage Reset circuit breaker CB1 if necessary see Section 5 2 Maximum weld output Have Factory Authorized Service Agent check Amperage Adjustment control Erratic or improper weld output Check for proper input power connections Clean and tighten all weld connections see Section 5 1 Use proper size and type electrodes Excessive line current or line fuse s open repeatedly Check for proper input power connections see Section 3 12B Check for proper jumper link position see Section 3 12A Fan not operating and or over heating Check for and remove anything blocking fan movement Replace fan motor if n
34. ngageant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appa reil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veille
35. nt identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants RN e UN CHOC LECTRIQUE peut tuer ne Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension des que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l 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 Des mat riels mal install s ou mal mis la terre pr senten
36. orking on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring and exposed weld terminals can kill Close door before turning on unit 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 2 5 Manufacturer s Rating Labels For CE Products Match label to one on EN 60974 1 unit See Section 3 4 E 45AJ12V 500A 30V 2V 500A 30V sex son EIE Re en EXT Gm EAS ES 100 MONES 103A 84A 65A 60A 48A 37A 51A
37. ouissement demander aux autres personnes de ne pas re garder l arc Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds gt LE SOUDAGE peut provoquer un PER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger AA Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables D 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 homologu s Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le so
38. r ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures 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 uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS 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 201 444 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI 249 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and
39. r s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer
40. rs 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 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 201 444 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and
41. sionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT 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 recommancer le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en e
42. ssembly PANEL side COVER NI A E RECTIFIER integ 40A 800V TRANSFORMER amp AMPLIFIER power main GASKET lifting eye GROMMET rbr 1 500 ID x 1 750mtg hole PANEL rear w components TERMINAL pri term assy pri 3ph 3v consisting of Jumper link PANEL front wlcomponents LABEL general precautionary 50 Hz Parts For Optional Equipment METER KIT consisting of One grommet center is included with the Amplifier Transformer Stabilizer Assembly Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Quantity OM 201 444 Page 27 Item Dia Part No Mkgs No Description Figure 7 2 Panel Front wComponents Fig 7 1 Item 13 CUL erent eee en X017 207 2 PANEL WOM o id eo eMe ao oe eine ta dese nies 1 2 CB1 083432 CIRCUIT BREAKER man reset 10A 250VDC 1 3 RC1 089607 RECEPTACLE twlk 3P3W 20A 250V 1 epos DE ne 605 797 PLUG twik 3P3W 20A 125V Arrow Hart 6312 ibus 52 3 011 6092 SWITCH tol SPDT ASA 125VAG iios A Ad 1 os dune RI 030653 RHEOSTAT WW 150W 15 ohm 1 m Diui S1 045835 SWITCH tgl 3PST 60A 600VAC screw term 1 ioo Sn
43. t un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e 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 En effectuant les raccordements d entr e fixer d abor
44. tion des SVIMDOIES dex uxausceos ket neal a es Rede eee ERA EM SR ME 5 1 2 Dangers relatifs au soudage l arc 2 6c6 eee lade Rh ewes ees 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement ertaunainterali6e e Seiren aonane aaa A sas E pL Sees 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS iocus dre iREREREE FL REESE TOn di eas 9 2 1 General Precautionary Label 2222 9 2 2 Input Connection Label scada al 10 2 3 Electric Shock And Airflow Label curia rettet ee Div sms li sat 10 2 4 Nameplate Safety Symbols 10 2 5 Manufacturers Rating Labels For CE Products 11 SECTIONS INSTALLATION ocurra ERROR RC era Ca ba xc C Red acie d d 12 3 2 Duty Gycle And Overhedlillg u a aoe dans nadia a 12 9 4 Selecting ALOCO eds AAA AA 13 Soest 14 3 7 Selecting And Preparing Weld Output Cables 15 3 9 Connecting To Weld Output Terminals 16 3 10 Remote Amperage Control Receptacle 17 3 12 Connecting IMNPUEPOWE s 5245 ads ard e leet ETSES INIA 18 SECTION 4 OPERATION
45. udage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial
46. ue 181 245 TERMINAL pwr output red 1 oN NO ram reine 181 246 TERMINAL pwr output black 2 Ue pU eo NAMEPLATE order by model and serial number 1 o P 097 926 KNOB DOMED z 2s obere tete be ed eR edd iie Rie ede bark te 1 When ordering a component originally displaying a precautionary label the label should also be ordered BE SURE TO PROVIDE MODEL AND SEHIAL NUMBER WHEN ORDERING REPLACEMENT PARTS L5 Hardware is common and not available unless listed p 1 Y aa Ws Y 7T 227 Ps gt x UN Q 77 Y 2 1 7 y v Q AS 9 ST 018 369 G Figure 7 2 Panel Front w Components OM 201 444 Page 28 Item Dia Part NO Mkgs NO Description Quantity Figure 7 3 Panel Rear w Components Fig 7 1 Item 10 A ee FM 116 190 MOTOR 1 12HP 230V 1550RPM 50 60Hz 1 5A 1 E A A edad tn aes 124274 BRACKET mtg fan motor 1 NS PT wed ee 173283 CHAMBER plenum 14 in 1 TI IMMUNE 180 165 BLADE fan 14 in 3wg 28deg 375 bore CCW 1 vou dO aeu stc dite Po 018 144 PANEL Fear omn o oe e ab tide c a ton Re RU Io s 1 uou D Re ee 179 290 LABEL warning electric shock input connections 50 Hz models 1 L5 Hardware is common and not available unless listed YU
47. 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 WELDERS hobart standard 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Avallable Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks
48. y claim procedures to be followed Hobart 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 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 8 Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Hobart Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimu
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