STICKMATE LX - Pdfstream.manualsonline.com
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1. 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 29 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 speed Table 6 6 Burn Through Burn Through weld metal melting com pletely through base metal resulting in holes where no metal remains 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 base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique2. Table 6 8 Distortion Distortion contraction of weld metal dur ing welding that forces base metal to move Base metal moves 31 x 2 a f 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 OM 950 Page 30 Notes Q HOBART INSTITUT Start Your Professional Vb LE DAMEN Over 80 000 Welding Career Now 90 Trade Square East Troy Ohio 45573 trained since 1930 1 800 332 9448 www welding org OM 950 Page 31 SECTION 9 PARTS LIST gt Hardware is common and not available unless listed 802 245 F Figure 9 1 Main Assembly AC DC model illustrated OM 950 Page 32 Item Dia Part No Mkgs No Description Quantity Figure 9 1 Main Assembly US eus 224 794 LABEL gen precautionary electrode 1 p AA 217 732 LABEL Warning General Precautionary En Fr Vert 1 mom 4210309 s WRAPPER cidcm eu den ptt o o de o oe recto e meme 1 9 S2 190079 SWITCH secondary 2 position AC models 1 3 S2 225647 SWITCH secondary 4 position w jumpers AC DC models 1 4 T1 1901
3. Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin 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 Research 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 lec triques 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 conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM
4. NZ OM 950 218 245B WELDERS HS Processes Stick SMAW Welding Description AC DC Models cc AC Models cc Arc Welding Power Source STICKMATE LX SED www HobartWelders com 235 AC And 235 160 AC DC OWNER S MANUAL 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 N do every power source Hobart is registered to the you may need to fix the problem Warranty and from Hobart is backed by ISO 9001 2000 Quality service information for your particular model the best warranty in the System Standard business are also provided 150 9001 2000 QUALITY SYSTEM Protect Your Investment Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Ho
5. Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage II reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l ou on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s avere n Le soudage g n re des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v
6. blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du cote oppose de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits 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 boites antistati ques pour stocker d placer ou exp dier des cartes PC 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 provoquer 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 personnes ou toute pi ce m canique en enga geantle fil de soudage AN 2 4 Proposition californienne 65 Avertissements A Les qui
7. 5 LES RAYONS D ARC peuvent entrai ner des brulures aux yeux et 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 provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ 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 tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une
8. 950 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou a Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance 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 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les p
9. DS ma Ashe Bas Go 190 599 EA EIS Ts idest qd cee tue is culter NO 1 T ads 215 248 KIT electrode holder amp gnd clamp 1 Noc TROU OE ES LABEL brand Identity order by model and serial number 1 AO EE ee 207 074 HANDLE switch ie oes dre ES BEDE FIR Re ee SUE Bae SSR Re ed taen 1 o p ES 111 644 BUSHING strain relief 370 430 ID X 875 mtg hole 2 or TRENT 494 907 SCREW K50 x 20 pan hd trx stl pld thread forming 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 OM 950 Page 33 Notes Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST 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 Assistance Visit the Hobart website www HobartWelders com HOBART sal WARRANTY Effective January 1 2005 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a seria
10. Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power 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 e If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s 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 ar
11. 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 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body B m m 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 before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes LN WE zf Ce groupe de symboles signifie Avertissement Attention Risques 2 1 i Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci
12. explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologu es e Ne pas souder dans un endroit ou des tincelles peuvent tomber sur des substances inflammables e Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e 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 e Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des condui
13. stored electrodes Noise and vibration from shunt block Lubricate shunt block and or tighten adjustment screws see Section 6 2 OM 950 Page 21 SECTION 7 ELECTRICAL DIAGRAMS A WARNING e Do not touch live electrical parts e e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install use or service this unit 0250235537 oM voy voy cV AE N SEC 4 lt 09 09 JN 191 364 A WARNING e Do not touch live electrical parts e e Disconnect input power or stop 5 engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit WORK O O ELECTRODE 191 362 Figure 7 2 Circuit Diagram For AC 230 Volts Models OM 950 Page 22 SECTION 8 WELDING METHODS amp TROUBLESHOOTING A Welding Methods mod5 1 9 92 8 1 Shielded Metal Arc Welding SMAW Procedure V Tools Needed YH 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Electrode A small diameter electrode requires less current than a large one Follow recommendations of electrode manufacturer when setting weld amperage see 8 2 4 Insulated Electrode Holder 2 d 2 eee 151 593 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electro
14. sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut
15. 5 Principales normes de S curit s simus ssa Gite Karta tae st kirin Galt ac DA pp acr an 8 2 6 Information EMP i243 caua hui Rex whale coeds REX EE EXAUDIRI bee RUE eu ei sg 8 SECTIONS D FINITIONS use beso Era Pu ME GU DA EROR Gene te cee RS a 56 9 dk oymbolsAAnd Dellnitloris cur SERE DEE A RE DEER DR Dr AR Oe eie ND IE ds wed ei id 9 3 27 M nufaclurers Rating Labels capi ed e beh Ron UR contd Gare Na do baute a Cane e 9 SECTION 4 INSTALLATION dime B anum ERE SE DE BESEER OE EE MEE A an e oo 10 ze secet T rec Ed 10 4 2 Duty Cycle Chans ssa n 453 K t ROC RR ARA don eee BEG EE eG ee D MA 11 423 Molt Ampere CUIVOS ui EX Ge EUER AE RA eee EN EE Ge EL TEES PL WE n 12 4 4 Selecting A Location se GE ER ES EE N ER RE RE GE GE RE EO RE AAA PR AA 13 4 5 Installing Electrode Holder And Work Clamp ss SE cece e 14 4 6 Weld Output Gables zer Id m RE RE ee REG N wate GE EE GE AR REG SEP E em 15 4 7 Electrical Service GUIAS is Ed c wie ede ae e Rc dr nd eu ewe deen ee ds DOE dg 15 4 8 Connecting Input Power o osx s s cee kr s ner DER RE EER CR ers o E A ON S wae RR RR 16 SEETIONS OPERATION 5 20 55 SERE RE E HE Rates auc EDS BEE SEGE SE DS VES EO GE vad ae wees 17 ly CONUS EE AE He AE GEL SE Kes e AR OE rc 17 SECTION 6 MAINTENANCE amp TROUBLESHOOTING se ese ese kaak ae Rae ees 19 6 1 Routine Maintenance sucs aires abe enc DS oye kaa KE KKK Sole aes eh PE EEN eee eee 19 6 2
16. 70 TRANSFORMER amp SHUNT including 1 TE ETE 190 242 SCREW lead shunt 2 ees os EE SR ek e a xs 1 EL EKT eee 190186 oe SEPIE vs ito Set ae dit erga sl ee EE Waar es alin ED eee 1 SU ee ee ee 147907 SCREW 5 16 18 x 1 75 w loctite 4 UE KEET EUN 080522 BLOCK anti noise shunt 1 4 s9 see ZA anu 190 145 STABILIZER AC DC models 152500000 dE Eg Ud erbe se Pr ie ttes 1 gt 10 se SAL se 190 308 RECTIFIER 4AC IDG models us ee sa m dae E Dee a e eee 1 11 Ed ss EA BI o OWOH ss ti pU eU EXE TIA ee DERE diner eee ras 1 NS N 225 857 CASE SECTION eresie ici E A in ET 1 ca lt n PEGI 4 2 088297 SORD SER 2 cual li da aa da 1 EU MM DD 111 443 BUSHING straln relief 2222 A n RC Ca re Ne tt cute 1 LTD said 185 799 LABEL WARNING tata dat aetna ace tid ee ae 1 RAO EE Med 217 733 LABEL Warning Electric Shock amp Input Power En Fr 1 16 FM 190 234 MOTOR Tall 35 kammi tte God nan ee Sek Sumea 1 us ua as 905 656 BLADE fan iran Med der Keys ot Mee ee a eee 1 PRES OER o LABEL Control Output order by model and serial number 1 NEL A 190 296 x GEA PINION s e static nues e eta dione iu cerros EE 1 JAD n Ease 190295 3 GEAR pointer 2 55 topa BR ee ae rend sata Sa Kota et isen ea oil ni seo 1 cu PR dtu eco 190241 HANDLE control current llle eee eee ees 1
17. 70 A A AMPS 225 150 of dc output Electrode Posi AC v MU 20 tive DCEP or Electrode Nega 160259 0 ON tive DCEN For AC Weld Output Use mode switch to select ac low S range or high range output WARNING ELECTRIC Oi Ly g g g p SHOCK CAN KILL DO NOT USE AC OUTPUT IN DO NOT SWITCH POWER 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 3 Q OFF 2 ACCU SET AMPERAGE CONTROL 50 E M d WORK ELECTROD Ref 190 600 B 802 105 D OM 950 Page 17 B Controls For AC Models CACA AC 150 235A 30 170 A e O DO NOT SWITCH WARNING ELECTRIC SHOCK CAN KILL DO NOT USE AC OUTPUT IN DAMP AREAS IF MOVEMEN UNDER LOAD IS CONFINED OR IF THERE IS A DANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE WELDING PROCESS 3 A RATED WELD OUTPUT AC VOLTS 25 AMPS 225 DUTY CYCLE 20 MAX OCV 80 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac low range or high range output ON ACCU SET 1 AMPERAGE CONTROL N ELECTRODE A 30 WORK OM 950 Page 18 Ref 190 599 A 802 105 D SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power before maintaining Amd 3 Months ET Replace ON A oe Sql Unreadable JN c p Labels A ra
18. EQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y 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 WELDERS hobart warr 2 05 YA Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date
19. Lubricating Shunt Block And Anti Noise Adjustment 19 6 3 Reinstalling Amperage Adjustment Indicator 20 9 4 oublestiGOlllit ux ecd kie ede toe does oe er la ee ole re LA das eae does g 21 SECTION 7 ELECTRICAL DIAGRAMS seeks ek ae kaak eee ae N KEN hh RM ek ke N ke 22 SECTION 8 WELDING METHODS 8 TROUBLESHOOTING ese ese ese kaak ae Raak sek seke 23 8 1 Shielded Metal Arc Welding SMAW Procedure 23 8 2 Electrode And Amperage Selection Chart skn 24 837 OMIKING ARAFO acerco a RT NO HOE di Sa ad 25 8 4 Positioning The Electrode Holder is ccc ccc cee eee IIR III hn 25 8 5 Weld Bead Characteristics SEE EE Es Es Ese es ee se es ee se hh hr rrr 26 8 6 Conditions That Affect Weld Bead Shape 0 ccc ccc Ese ek ee ke es ee ee ee ee 26 8 7 Electrode Movement During Welding 2 27 0 0 Bull JOS in EE EE ER EG N oe SE SENERE m s RE a E UN SM EN Re ES EER Ed 27 89 E Iordlelri arta PTT 28 910 TOS OMS os ETE tus inanis O das te a dtd da tatoo N N N RE mt E nhe 28 SECTIONS PARTS HS Paie cite bara pede re s ett Sie ee dec wae ERR oae eR EE e ene 32 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 A Warning Protect yourself and others from injur
20. able 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 EP 14mm Tu 6mm SS Ref 802 251 A 802 105 D 4 6 Weld Output Cables For weld output cable replacements or extensions contact your Factory Authorized Service Agent 4 7 Electrical Service Guide 50 60 Hz Single Phase Input Voltage 230 Input Amperes At Rated Output 47 5 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker Time Delay 2 50 Normal Operating 3 70 Min Input Conductor Size In AWG 4 12 Max Recommended Input Conductor Length In Feet Meters 87 26 Min Grounding Conductor Size In AWG 4 12 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 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 cla
21. al distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 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 4 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 Eq
22. as d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de cables blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 950 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org
23. bart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 Hobart1 or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 ORARI AS Hob_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MBO US AO O ae ae ER ae ee hae tad li db ane een ade eae 1 152 Are Welding Hazardo EE o oe EE kaa Ae de a oa alee deu aie ee A qua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 3 1 5 Principal Safety Standards si sind de duna k ctc RD c o S edad nanan ee A 4 156 EME IBITOFITIS BOTE rita d i Dar ti a Sinker n c acr d o Dot a a bd ed aika d is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS USES e span rcv rd ate en free a od eh dnce o ee Dalee EED RERUM een en 5 2 2 Dangers relatifs au soudage l arc 2 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2
24. cked ZA Cables 6 Months juw 12 Months Blow Out Or Vacuum Inside Lubricate Shunt Block During Heavy Service See Section 6 2 Clean Monthly A Turn Off welding power source and disconnect input power 1 Wrapper Hemove 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 your nearest Factory Authorized Ser vice Agent if noise continues A Install wrapper before turning On power Tools Needed Jr 1 2 in C ER 5 6 3 8 in 802 248 D OM 950 Page 19 6 3 Aw Amperage Adjustment Indicator 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 fr
25. de to the workpiece A short arc with correct amperage will give a sharp crackling sound A Welding current starts as soon as electrode touches the workpiece 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before making another weld pass OM 950 Page 23 8 2 Electrode And Amperage Selection Chart AMPERAGE DIAMETER Ly O a E O IY TT 564 Lye ie 5 32 po ze ES EEUM 18 gi Lugar A POSITION BEI PENETRATION ELECTRODE 600 EP ALL DEEP VIN PREP ROUGH DEEP HIGH SPATTER Low GENERAL SMOOTH EASY EPEN Y ies ican FAST LOW HYDROGEN FLAT 7024 EPEN V HORIZ Low SMOOTH EASY FILLET FASTER NI CL 308L STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref 087 985 A OM 950 Page 24 8 3 Striking An Arc 1 Electrode Scratch Start Technique 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 Tap Start Technique workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0049 S 0050 8 4 Positioning The Electrode H
26. dessous concernant les mesures prendre pour supprimer gt Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en e l quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Nepas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus completes fournies ou mal piss s sakea cl ae maa de dans la Section 2 5 Lireet amp Ne pas enrouler les c bles autour du corps id pa i e Sila piece soud e doit tre mise a la terre le faire directement avec un A Seul un personnel qualifi est autoris a installer faire fonction c ble distinct ner entretenir et r parer cet appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendantle fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l apparei
27. ea the area is well ventilated and 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 an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 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 glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection T 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 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where
28. elmet 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 Do not touch hot parts bare handed e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e 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 physical damage 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 c
29. et ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester distance e Les porteurs d un stimulateur cardiaque doi vent 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 endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es 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 e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage
30. flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e 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 sparks 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 e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E 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 h
31. ine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 OM 950 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com 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 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 Weldi
32. 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 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 Toreduce 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 If 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 A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines A Diesel eng
33. k 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 5 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 OM 950 Page 27 8 9 Lap Joints 1 Electrode door Dess 2 Single Layer Fillet Weld 30 Or Less BET Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a larger fillet is needed Remove slag before making another weld pass Weld both sides of joint for maximum strength 2 Single Layer Fillet Weld Multi Layer Fillet Weld S 0063 S 0064 8 10 Tee Joints 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface 45 For maximum strength weld both Or Less gt sides of upright section 2 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 Table 6 1 Porosity Porosi
34. l e Ne pas toucher des porte lectrodes connect s deux machines en N gt m me temps cause de la pr sence d une tension vide doubl e UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel en bon tat R parer ou remplacer sur le OI entrainer la mort champ les pieces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes electrigues sous tension peut e Porter un harnais de s curit si l on doit travailler au dessus du sol Provoquer ugs ees dents moles ou dec DE e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est E EES R sous tension lorsque le courant est d livr a la PES ui i sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de facon a obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique a la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse
35. l number preface LF or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with 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 Internation
36. ng 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 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 OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of
37. older Groove Welds End View Of Work Angle Side View Of Electrode Angle Fillet Welds End View Of Work Angle Side View Of Electrode Angle OM 950 Page 25 8 5 Weld Bead Characteristics Poor Weld Bead Good Weld Bead 8 6 Conditions That Affect Weld Bead Shape Electrode Angle Angle Too Small Correct Angle di 10 30 I GE 3 Arc Length N n lt Too Short Normal Travel Speed TR EE 3 Normal OM 950 Page 26 Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S 0053 A Fine Spatter Uniform Bead 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 Angle Too Large lt Spatter Too Long 8 7 Electrode Movement During Welding Stringer Bead Steady Move ment Along Seam Weave Bead Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode ISA 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 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tac
38. ont 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 f necessary to turn the handle slight s ly so vertical alignment is possible For 225 A models X 2 1 2 in 7 Securing Screw Install securing screw through han dle into threaded hole in shunt shaft Tighten securely Reinstall wrapper ACCU SET AMPERAGE CONTROL A ELECTRODE 6 Tools Needed ES P 1 20 Torx CO 5 16 3 8 in Proper alignment of pointer and crank handle 804 293 A Ref 802 248 D Ref 190 599 A OM 950 Page 20 6 4 Troubleshooting 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
39. or AC DC Models OM 950 Page 12 DC Volts 80 70 60 50 40 30 20 10 The volt ampere curves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown For 235 160A Models AC Volts 90 80 70 N 60 N 40 30 20 0 50 100 150 200 250 300 350 AC Amperes 50 100 150 200 250 DC Amperes 193 509 193 510 B For AC Models The volt ampere curves show the For 235A Models minimum and maximum voltage and amperage output capabilities Curves of other settings fall be 90 A LOW RANGE tween the curves shown 80 B HIGH RANGE 70 60 50 40 AC Volts 30 100 150 AC Amperes 193 508 4 4 Selecting A Location 1 Rating Label See Section 3 2 Locate unit near correct input power Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 804 292 A OM 950 Page 13 4 5 Installing Electrode Holder And Work Clamp OM 950 Page 14 p ELECTRODE A Turn Off unit and disconnect input power before installing electrode holder or work clamp Removing Barrel From Electrode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through access hole and slide barrel away from electrode holder Installing Electrode Cable and Barrel onto Electrode Holder 5 Electrode C
40. orteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS 3 1 Symbols And Definitions Do Not Switch A Amperes 1 AG Single Phase G E nder Load lt Input On O Off gt Output H 7 Hertz Alternating AN A et Ki EA Electrode Positive EA Electrode Negative Direct Current E J Welding Arc V Volts D aa Work AN Electrode 3 2 Manufacturer s Rating Labels Rating Label For EN FR Machines Rating Label For All Other Machines INPUT SERIAINO R3 sock no VOLS AMPERES V A KW KW TV Hz PHASE HERTZ 5071 LR5071 P c ys EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY AA TOUTE ALT RATION DE L TIQUETTE ANNULLE LA GARANTIE EVIDENCBFLABELTAMPERINGOIDSNARRANTY 217 652 A 165 371 A OM 950 Page 9 SECTION 4 INSTALLATION 4 1 Specifications AC DC Models Maximum Amperes Input at Rated Load Output 50 Or 60 Hz Rated Welding Amperage Open Mode Output Range Circuit Single Phase Welght Voltage 230 V 225 A 25 Volts AC AC 20 Duty Cycle 60 Hz ai mk 80 VAC 15 Duty Cycle 50 Hz gn 1 475 04 Ib 150 A 25 Volts DC D Ge 47 kg DC 20 Duty Cycle 60 Hz 30 160 80 VDC 15 Duty Cycle 50 Hz O
41. pements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es a enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut p
42. r airflow to unit 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 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 E 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts 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 responsible for having a qualified electrician prompt ly correct any interference problem resulting from the
43. r et abaisser le niveau d oxygene provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulverisation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl NY ment toxiques et irritants e Toujours verifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccord e une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les e En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 950 Page
44. round 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 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 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 If 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 Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present 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 e 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
45. rovoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil 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 un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiler ce que tout l quipement de la zone de soudage soit compatible 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 quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En c
46. rself 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 e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Owners 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 g
47. ss H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 950 Page 15 4 8 Connecting Input Power OM 950 Page 16 1777777 A O r KL oo NS a N jw N GND PE Earth Ground A Disconnect and lockout tag out input power before instal ling receptacle A Have only gualified persons make this installation See rating label in Section 4 4 and be sure to supply correct in put power Proper Receptacle NEMA 6 50R User Supplied Receptacle must comply with appli cable codes 2 Input And Grounding Conductors See size and length using Section 4 7 Conductors must comply with applicable codes 3 Over Current Protection Select type and size of over current protection using Section 4 7 4 Plug NEMA 6 50P Connect plug to properly installed receptacle Close and secure door on discon nect device Remove lockout tagout device and place switch in the On position 802 246 A SECTION 5 OPERATION 5 1 Controls A Controls For AC DC Models 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output co AO RATED WELD OUTPUT AC v Wu a Use mode switch to select polarity 30 1
48. tements mouill s sur des structures m talliques telles que e Alint rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC a fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur e Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l ai
49. tes gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque e Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux pw re e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 950 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu DES PIECES CHAUDES peuvent provoquer 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 pistol
50. ty 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 idibus all grease oil moisture rust paint coatings slag and dirt from work surface before welding OM 950 Page 28 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 Possible Causes 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
51. uipment that has been modified by any party other than Hobart Miller 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 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 CONS
52. verall 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 Essa Circuit Single Phase Weight Voltage 230 V 225 A 25 Volts a d Duty Cycle 2 60 L ow 30 150 A sane 47 5 85 Ib 15 Duty Cycle 50 Hz High 40 235A 2 3 39 kg 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 4 2 Duty Cycle Charts A For AC DC Models Duty Cycle is percentage of 10 minutes that unit can weld at rated load without 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 235 160A Models RATED OUTPUT WELD AMPERES 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 that unit can weld at rated load without 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 235A Models RATED OUTPUT Y m tr TT Q 2 lt 2 J m 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 OM 950 Page 11 4 3 Volt Ampere Curves A F
53. which equipment was delivered to original customer Distributor Address City otate Zip Resources Available Always 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 C 2005 Hobart Welding Products 6 05 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call 1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 HOBART Sa
54. y read and follow these precautions 1 1 Symbol Usage i 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 gt 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 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 m 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 you
55. ylinder 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 oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance 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 IX 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 e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filte
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