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AC Models - Tractor Supply Company

1. 802 246 A OM 950 Page 18 SECTION 5 OPERATION 5 1 Controls A Controls For AC DC Models gt E fer ch E RATED WELD OUTPUT AC v T AC DC E EA VOLTS 25 300704 I AMPS 225 150 CAC of DUTY CYCLE 20 MAX OCV 80 150 235A l ON WARNING ELECTRIC HO Ey 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 Q O FF 3 2 ACCU SET AMPERAGE CONTROL 5 Lef 1 ELECTRODE y 30 WORK 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of DC output Electrode Posi tive DCEP or Electrode Nega tive DCEN For AC Weld Output Use mode switch to select AC low range or high range output Ref 190 600 B 802 105 D OM 950 Page 19 f 1 Amperage Adjustment Control 9 SH TA kr 2 Power Switch B Controls For AC Models 3 Mode Switch M Use mode switch to select AC low range or high range output RATED WELD OUTPUT ACI AC AC VOLTS 150 235A 30 170 A AMPS dee DUTY CYCLE 20 ri MAX OCV 80 a WARNING ELECTRIC O ch Eil SHOCK CAN KILL Seege POWER l j DO NOT USE AC
2. EP ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted too high If electrode sticks to work piece use a quick twist to free it Tapping Technique Bring electrode straight down to 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 OM 950 Page 26 8 4 Positioning Electrode Holder ER SE q Ag ar e 1 End View Of Work Angle fas isa SE Xi 2 Side View Of Electrode Angle c Groove Welds we 10 30 i 3 VS Fillet Welds S 0060 8 5 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration O E ND S 0053 A 8 6 Good Weld Bead Characteristics MX b RE i er e 1 Fine Spatter gt eh Wy ee IR 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into
3. Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If 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 To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the weldi
4. lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser 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 Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le cable de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 950 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup 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 PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l qui
5. EMF can affect ImplantedMedical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating 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 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
6. En cas 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 c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements 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 mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants gt Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation gt Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent OM 950 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nit
7. as close to the weld as possible F Always wear appropriate per sonal protective clothing 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Section 8 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before making another weld pass Stick 2010 02 151 593 OM 950 Page 25 8 2 Electrode and Amperage Selection Chart Si 9 MEC Ex AMPERAGE RANGE ELECTRODE DIAMETER 100 150 200 250 300 350 ELECTRODE POSITION PENETRATION A DEEP ALL DEEP MIN PREP ROUGH HIGH SPATTER ALL LOW GENERAL ALL MED SMOOTH EASY FAST ALL MED LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL EP ALL LOW CAST IRON 308L
8. moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle 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 provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil 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 revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur pui
9. 4 T1 190170 TRANSFORMER 8 SHUNT including 1 D WEE 190242 SCREW le ad shunt cernere aaa 1 os do 190 150 Ee ETC H REECH 1 Patent ass 147 907 SCREW 5 16 18 x 1 75 w loctite 4 Biron date 080 522 BLOCK anti noise shunt 4 9 Z1 190145 STABILIZER AC DC models 1 10 SR1 190 303 RECTIFIER AC DC models 1 TL eed ST e 124511 SWITCH iis ieu EE eee A Gah a eae te 1 12 RAS 225 857 CASE SECTION ua peed Peg eA ead e a ue RA GR 1 13 5 PLG 0889 2977 CORD SET a de geod eegene 1 Is 111 443 BUSHING strain relief 1 UE 185759 LABEL warning escocia a bee abe ELE AUER EEN EE AA RARE 1 ux EE 217 733 LABEL Warning Electric Shock amp Input Power En Fr 1 2016 FM 190234 MOTOR ant ee odode cea A Reg 1 TE ley Sie OO Gap BLADE fan c IEEE SE seine ade eds 1 18 iet edic LABEL Control Output order by model and serial number 1 T9 te etu 190 296 GEAR RIDO 2o uoo hel eae a EL ees odis UE id delt wea ida 1 QO erie de 190 295 55 GEAR PON a erg RER th degen dee 1 2 eee 190241 HANDLE control current 1 Doa 190 538 2 LEAD LIS TA iaa 1 23 ai 215248 KIT electro
10. 6 LE SOUDAGE peut provoquer un 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 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 e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de 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 Surveiller tout d clenchement d incendie et tenir un extincteur proximit 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
11. 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM 9 SECTION 3 DEFINITIONS sy ul EEN REPRE REGE Re pete teense NN IET Ee ek 11 3 1 Symbols And Definitions 11 SECTION 4 INSTALLATION EN ENN RI a aa EEN ENN te Ref c queri EPOR 12 4 1 Specifications re os ERE Rb Er hor GR DER QURE QUEUE E RR IS D Reg ds 12 4 2 Duty Cycle Chatls re os Ee E DER LEV etr GR pe QUE QUE QM AE Acme eus 13 4 3 Volt Ampere CUIVES ii Uer YR a E e E NIME EE PUE ER CO Ame Y p 14 4 4 Serial Number And Rating Label Location 15 4 5 Selecting A Locatii Rr Re ORO Ree E EE EEN GU EE Y ERE 15 4 6 Installing Electrode Holder And Work Camp 16 4 7 Weld Output Cables tre ete A ex Wa ea XOU AR e ES eee 17 4 8 Electrical Service Guide 17 4 9 Connecting Input POWE erus MENO a ECC X Y A UC ERR 18 SECTION 5 OPERATION sie umi RUM entre ida 19 Sak cGofittolss nsa euis RENE B RR eae Rooter mt ASA Ier cA sana dsl 19 SECTION 6 MAINTENANCE amp TROUBLESHOOTING eeeeeeee nn 21 6 1 Routine Maintenance ssec bx E Het eases reed ee cancer FARO E e Rd 21 6 2 Lubricating Shunt Block And Anti Noise Adjustment 21 6 3 Reinstalling Amperage Adjustment Indicator 22 6 4 Troubleshooting c Ne EES NEIE EEN Bea eed
12. Base Metal S 0052 B OM 950 Page 27 8 7 Conditions That Affect Weld Bead Shape T Correct Angle L pm D Too Short Normal Arc Length rs AE Travel Speed IE Weld bead shape is affected Angle Too Small Py 10 30 Angle Too Large Electrode Angle SE ammm cm d prag Spatter prt Too Long pd by electrode angle arc length travel speed and thick ness of base metal Slow Normal Fast S 0061 8 8 Electrode Movement During Welding 7 SM CS Normally a single stringer Au Wy Me M N bead is satisfactory for most e narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple 1 2 stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the elec trode Do not let weave width ex 3 ceed 2 1 2 times diameter of oH electrode MIT DN S 0054 A OM 950 Page 28 8 9 Groove Butt Joints lt T ES 1 1 Tack Welds Prevent edges of joint from draw ing together ahead of electrode by tack welding the materials in posi tion before final weld 2 Square Groove Weld Good for materials
13. Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 950 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine ex
14. Definitions Do Not Switch A Amperes 1 FAG Single Phase Q gl Urid r Load Input On O Off gt Output H Z Hertz mw SM e A Electrode Positive B E A Electrode Negative Direct Current e O P Welding Arc V Volts gr an Work IN Electrode LA LA OM 950 Page 11 4 1 SECTION 4 INSTALLATION Specifications A AC DC Models c gare ey a Rated Welding Amperage Open i i Mode Output Range Circuit Single Phase Weight Voltage 230 V 225 A 25 Volts AC AC 20 Duty Cycle 60 Hz VEU pd 80 VAC 1596 Duty Cycle amp 50 Hz gn Vue 47 5 150 A 25 Volts DC 2 3 47 kg DC 20 Duty Cycle 60 Hz 30 160 80 VDC 15 Duty Cycle 50 Hz Overall Dimensions Height 18 3 4 in 476 mm Width 12 3 4 in 323 mm Depth 17 1 2 in 445 mm While idling B AC Models Amperes Input at Rated Load Max Open Output 50 Or 60 Hz Rated Welding Output AUR Circuit Single Phase Weight ange Voltage 230V 225 A 25 Volts AC 20 Duty Cycle 60 Low 30 150A 47 5 85 Ib Hz High 40 235A 80 VAC 2 3 39 kg 15 Duty Cycle 50 Hz i Overall Dimensions While idling Height 18 3 4 in 476 mm Width 12 3 4 in 323 mm Depth 17 1 2 in 445 mm OM 950 Page 12 4 2 Duty Cycle Charts A For AC DC Models Duty Cycle is percentage of 10 minutes y that unit can weld at rated load wi
15. ERG Qe nelle tee ee eke ewes 23 SECTION 7 ELECTRICAL DIAGRAMS 24 SECTION 8 STICK WELDING SMAW GUIDELINES eesssses 25 SECTION S PARTS LIST enea 2 50 lli iR APA HESE E ANNE EE EENS 33 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2010 03 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text A Indicates a hazardous situation which if not avoided A DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 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 ELECTRIC SHOCK can kill Touching live ele
16. a separate cable e Do nottouch 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 e 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 in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns i OM 950 Page 1 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
17. electrical parts e I 7 e Disconnect input power or stop 230 N engine before servicing Do not operate with covers removed VOLT EA en hd ELECTRIC Have only qualified persons install ONLY NA SHOCK HAZARD use or service this unit GAN lt PRI 900090090 SR1 es 2233333233 ET SE 4 my We e Ee Z1 4 AV al L Leg AC HIGH O AC LOW q e e e S2 me DC EP o 9 DC EN O i WORK O O ELECTRODE 191 364 Figure 7 1 Circuit Diagram For AC DC 230 Volts Models 1 230 VOLT 5 Gre ONLY wn amp WARNING e Do not touch live electrical parts GRN S Disconnect input power or stop ST 3 engine before servicing PRI Do not operate with covers removed 00600000007 ELECTRIC Have only qualified persons install T1 SHOCK HAZARD use or service this unit PLG1 SEC OM 950 Page 24 S2 e AC HIGH AC LOW O WORK O O ELECTRODE 191 362 Figure 7 2 Circuit Diagram For AC 230 Volts Models SECTION 8 STICK WELDING SMAW GUIDELINES 8 1 Stick Welding Procedure PY 3 1 gf se Tools Needed l Equipment Needed Constant Current Welding Power Source A Weld current starts when electrode touches work piece A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp
18. rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles 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 cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service G LA CHUTE DE L EQUIPEMENT peut provoquer des blessures 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 c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage
19. the fumes Do not breathe the fumes 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 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 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 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 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 Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding
20. up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 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 S 0062 8 10 Lap J oint En E m e 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength S 0063 S 0064 8 11 Tee Joint EN 1 Electrode 2 Fillet Weld Keep arc short and move at defi nite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 8 8 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 950 Page 29 8 12 Weld Test SSC 2 To 3 in 51 76 Dir 6 4 mm AS 1 4 in _4 gt 2 BS e 1 Vise 2 Weld Joint 3
21. 7 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des cables de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 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 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 Regul
22. G SPARKS can injure e Wear a face shield to protect eyes and face e e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards SS N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure 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 r MOVING PARTS can injure e Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer
23. Hammer Strike weld joint in direction shown A good weld bends over but does not break 2 To 3 in D 51 76 mm E x S 0057 B 8 13 Troubleshooting Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 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 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
24. NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds N 3 n L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT pa e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal po nd 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 TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir o cuits imprim s SIS 25 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 antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 950 Page 7 Les PIECES MOBILES peuvent causer 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 g chette
25. OM 950 218 245C Se Zi 2010 04 coal Processes WELDER S H2 Stick SMAW Welding Description AC DC Models ce AC Models ae Arc Welding Power Source STICKMATE LX SHEIK Online Forum www HobartWelders com 235 AC And 235 160 AC DC OWNER S MANUAL File Stick PA SMAW 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 list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular model are also provided IS0 9001 REGISTERED QUALITY SYSTEM Hobart is registered to the ISO 9001 Quality System Standard Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor to re
26. 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 Q O FF 3 ACCU SET 1 AMPERAGE CONTROL pi ELECTRODE 50 uo 30 WORK Ref 190 599 A 802 105 D OM 950 Page 20 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance pow A Disconnect power before maintaining Maintain more often Q Inside Unit ae during severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent NZ cmn E a ERL EJ p Every e 0 n e 2 Ze VA Pa 3 Fr Months e Unreadable Labels Weld Terminals Weld Cables Every 6 Months 6 2 Lubricating Shunt Block And Anti Noise Adjustment IL pin Dl 0 C Tools Needed 5 16 3 8 in A Turn Off welding power 1 Remove wrapper 2 Shunt Block Do not grease screw threads 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 H shunt becomes noisy tighten adjustment screws 1 4 turn Install wrapper turn On unit and check for shunt noise Repea
27. SS 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 hobart_warr 2010 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original
28. action of weld metal during welding that forces base metal to move 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 31 Notes Start Your Professional H eg Over 80 000 Welding Career Now 40 Trade Square East Troy Ohio 45373 trained since 1930 1 800 332 9448 www welding org OM 950 Page 32 SECTION 9 PARTS LIST 5 Hardware is common and not available unless listed 802 245 F Figure 9 1 Main Assembly AC DC model illustrated OM 950 Page 33 Item Dia Part No Mkgs No Description Quantity Figure 9 1 Main Assembly lisent 224 794 LABEL gen precautionary electrode 1 Duerme 217732 LABEL Warning General Precautionary En Fr Vert 1 2 fmt sra 210 309 WRAPPER cos carr cian ER UR EERSTEN Du A 1 3 82 190079 SWITCH secondary 2 position AC models 1 3 82 225647 SWITCH secondary 4 position w jumpers AC DC models 1
29. ales ou autres probl 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 com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z8
30. ass RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps 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 17 4 9 Connecting Input Power ar A Disconnect and lockout tag out input power before instal ling receptacle A Have only qualified persons make this installation See rating label in Section 4 5 and be sure to supply correct in put power 1 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 8 Conductors must comply with applicable codes 3 Over Current Protection Select type and size of over current protection using Section 4 8 4 Plug NEMA 6 50P hie 2 Connect plug to properly installed receptacle GND PE Earth Ground Close and secure door on discon nect device Remove lockout tagout device and place switch in the On n RE position
31. ations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 950 Page 9 OM 950 Page 10 SECTION 3 DEFINITIONS 3 1 Symbols And
32. avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PIECES MOBILES peuvent causer des blessures 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 e Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LI LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur E e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et
33. 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 Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LO
34. ceive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 877 Hobart1 or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 2009 09 5 31 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com Ga NUI THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Let Symbol Usage ge dete ER AAA hea ea eG 1 1 27 Arc Welding e Ee EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 0 cece nett eee 4 1 6 EMP formations sis vie re a nn rm px dE a di nee le e P 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Sy Mboles utiles wees hae itane tate ht oath sited n Ve E e dk een had arit 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements
35. ctrical 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 Additionalsafety 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
36. curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit gt Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr a la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ques en contact avec le fil sont sous tension lectrique Un quipement install ou mis a la terre de mani re incorrecte ou impropre constitue un danger A Fe Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e 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 Ne pas se servir de source lectrique courant lectrique dans les zones hu
37. customer Distributor Address City State 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 ORIGINAL INSTRUCTIONS PRINTED IN USA O 2010 Hobart Welding Products 2010 01 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 Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se KA HOBART tHe
38. de com munication les services de s curit et les ordi nateurs 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 ap pareil 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 distan ce 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 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 Veiller 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
39. de holder amp gnd clamp 1 24724 S TASSE est LABEL brand Identity order by model and serial number 1 Oh ani aus 207 074 HANDLE switch 1 20 osse oen 111 644 BUSHING strain relief 370 430 ID X 875 mtg hole 2 CI RSR 494 907 SCREW K50 x 20 pan ha 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 34 Warranty Questions Call 1 800 332 3281 7 AM 5 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 S WELDERS HOBART 331 WARRANTY Effective January 1 2010 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive
40. e Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 OM 950 Page 2 La Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT 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 BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS
41. e SCRs diodes and discrete rectifier modules Reactors Stabilizers Transformers 2 3 Years Parts and Labor Drive Systems Idle Module PC Boards Rotors Stators and Brushes Solenoid Valves Spot Welder Transformer Switches and Controls 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Accessories Batteries Trek 180 Only Contactors 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 Flowgauge and Flowmeter Regulators No Labor HF Units MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Regulators Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Water Coolant Systems 4 Engines batteries except Trek 180 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 contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified
42. ectrode 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 XT 14mm 6 mm Ref 802 251 A 802 105 D OM 950 Page 16 4 7 Weld Output Cables For weld output cable replacements or extensions contact your Factory Authorized Service Agent 4 8 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 50 60 Hz Single Phase Input Voltage V 230 Input Amperes A At Rated Output 47 5 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 2 50 Normal Operating Fuses 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 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL cl
43. haust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 48rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power s
44. ll securing screw through han dle into threaded hole in shunt shaft Tighten securely Reinstall wrapper o Tools Needed SS pP 720 Torx EI 5 16 3 8 in 804 293 A Ref 802 248 D Ref 190 599 A OM 950 Page 22 6 4 Troubleshooting R x e PREA o Trouble Remedy No weld output fan does not run Be sure line disconnect switch is in On position see Section 4 9 Check and replace line fuses if open Reset breakers if necessary see Section 4 9 Fan does not run weld output okay Be sure nothing is blocking movement of fan If fan does not run freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry properly stored electrodes Shorten arc length Reduce amperage setting see Section 5 1 Electrode freezing to work Increase amperage setting see Section 5 1 Increase arc length Use dry properly stored electrodes Noise and vibration from shunt block Lubricate shunt block and or tighten adjustment screws see Section 6 2 OM 950 Page 23 SECTION 7 ELECTRICAL DIAGRAMS amp WARNING e Do not touch live
45. mides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants F Indique des instructions sp cifiques cal Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e C
46. ng machine using shielded cables using line filters or shielding the work area OM 950 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 749 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor
47. 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 Indicates special instructions e Le This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill 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
48. or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection WELDING can cause fire or explosion es 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 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 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 Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 se
49. ouper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l
50. ource or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2010 03 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s
51. pement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures 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 une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs 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 oxyg ne provoquant des blessures ou des accidents mortels S assurer 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 for mer des gaz hautement toxiq
52. 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 endom mag 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 excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits 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 e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult
53. rust paint coatings slag and dirt from work surface before welding OM 950 Page 30 CP EY Lack of Penetration Good Penetration Lack Of Penetration shallow fusion between weld metal and base metal 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 wile Excessive Penetration Good Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 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 technique Base metal moves in the direction of the weld bead Distortion contr
54. rves shown 80 t B HIGH RANGE 70 60 50 AC Volts 0 50 100 150 200 250 300 AC Amperes H 4 4 Serial Number And Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 5 Selecting A Location A 1 Hand Cart Use cart or similar device to move unit 2 Line Disconnect Device Locate unit near correct input power A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 460 mm 18 in 18 in 460 mm 460 mm 804 292 A 802 105 D OM 950 Page 15 4 6 Installing Electrode Holder And Work Clamp 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 Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from electrode holder Insert electrode cable through barrel into end of el
55. ssance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES E SALETES peuvent provoquer des blessures dans 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 volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial 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 Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des
56. t procedure until noise stops Do not overtighten Call your nearest Factory Authorized Ser vice Agent if noise continues A Install source and disconnect input power Wrapper on shunt block block vibrates and wrapper before turning On power 802 248 D OM 950 Page 21 6 3 Reinstalling Amperage Adjustment Indicator SN For 225 A models X 2 1 2 in X ACCU SET AMPERAGE CONTROL 90 110 ELECTRODE p Y I 6 WORK Proper alignment of pointer and crank handle A Turn Off welding power source and disconnect input power 1 Wrapper Remove wrapper from unit 2 Crank Handle 3 Shunt Shaft 4 Transformer And Shunt Located Inside Unit Insert crank handle onto shunt shaft protruding through front panel and turn crank handle to adjust shunt to the proper vale of X de pending on model see detail of transformer and shunt Remove crank handle 5 Pinion Gear Install pinion gear onto front panel making sure anti rotation pins are in holes on front panel 6 Pointer Gear Install pointer gear overtop of pinion gear and rotate so pointer is indicat ing 130 Amps on AC Low Range scale see example Install crank handle overtop the sta tor pinion gear assembly with the handle straight down It may be necessary to turn the handle slight ly so vertical alignment is possible 7 Securing Screw Insta
57. thout overheating 3 NOTICE 20 Duty Cycle at 225 Amperes Exceeding duty cycle can damage unit and void warranty 2 Minutes Welding 8 Minutes Resting For 235 160A Models d WELD AMPERES v 2 25 30 40 50 60 70 80 90 100 DUTY CYCLE These models have a 15 duty cycle when used with 50 Hz input power 086 727 B For AC Models Duty Cycle is percentage of 10 minutes Nw that unit can weld at rated load without overheating NOTICE 20 Duty Cycle at 225 Amperes Exceeding duty cycle can damage unit and void warranty 2 Minutes Welding 8 Minutes Resting For 235A Models WELDING AMPERES 15 20 26 30 40 50 60 70 80 90 100 DUTY CYCLE These models have a 15 duty cycle when used with 50 Hz input power 001 836 4 OM 950 Page 13 4 3 Volt Ampere Curves A For AC DC Models DC Volts 80 70 60 50 40 30 20 10 For 235 160A Models AC Volts 90 0 50 100 150 200 250 300 350 AC Amperes 50 100 150 200 250 DC Amperes The volt ampere curves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown 193 509 193 510 OM 950 Page 14 B For AC Models The volt ampere curves show the For 235A Models minimum and maximum voltage and amperage output capabilities 90 Curves of other settings fall be A LOW RANGE tween the cu
58. ues 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 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 LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque 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 sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 950 Page
59. when cylinder 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 A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure 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 e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Followthe guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment nn d t OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle dd e Reduce current or reduce duty cycle before MES D starting to weld again e Do not block or filter airflow to unit N FLYIN
60. 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 delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to includ

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