Hobart CYBERTIG 180 SD User's Manual
Contents
1. 1 192 451 COVER LED diffuser 2 na ra 1 iat 16 PCT S tes 190 772 CIRCUIT CARD ASSEMBLY control w hardware 1 PEGS 115 092 CONNECTOR amp SOCKETS 1 PLG6 115 091 CONNECTOR amp SOCKETS 1 PLG20 115 093 CONNECTOR 4 SOCKETS 1 PLG10 131 052 CONNECTOR 4 SOCKETS 1 455 ake 192 279 ENCLOSURE circuit card assembly 1 ETNE o 111 634 CAPACITOR ASSEMBLY 1 Si uis 128 755 SWITCH tgl DPST 40A 600VAC 1 10 C5 6 188 273 PANEL front 1 ET 175 952 PLASTIC handle 1 ter 169713625 BIN harndle itti a aaa etd 1 174 992 KNOB pointer 840 DIA 250 ID 1 185 703 RECEPTACLE Twistlock assembly 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain2. 10r Stick MIN Stick MAX 10 STICK MIN 0 i 0 0 50 100 150 200 250 300 350 0 50 100 150 200 250 AMPERES AMPERES ssb1 1 10 91 ST 188 277 ST 188 278 2 7 Weld Output Terminals And Selecting Cable Sizes ARC WELDING can cause Electromagnetic Interference 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 electronic 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 welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding gt 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m Or Less 51 60m 70m 90m 105 m 120 m 10 60 60 100 Weld Output Welding Duty Duty 10 100 Duty Cycle Terminals Amperes Cycle Cycle 100 4 4 4 3 2 1 1 0 1 0 ps 150 3 3 2 1 1 0 2 0 3 0 3 0 Work 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 Ref ST 802 238 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere S 0007 D OM 355 Page 11 2 8 Remote 14 Receptacle NOTE
3. TET Fed re 1 4 Principales normes de 1 5 Information sur les champs lectromagn tiques SECTION 2 5 1 2 1 Included wrth Your Unit och cree etre ve an Ss wel eae PCS Can Fe EY e 2 2 Selecting A Location wr ES REN E ERE VINO HUNGER 2 3 Dimensions And 5 2 4 Specifications gt Medea dk Mees Aie des BR dub eese EA recibe eg 2 5 Duty Cycle Chart be oe ee PR TEE wed Ae ute RUE 2 6 Volt Ampere Curves 222 2 2 2 2 2 7 Weld Output Terminals And Selecting Cable Sizes 2 8 Remote 14 Receptacle erensia e xS Ve ee ED RE a 2 9 Shielding Gas Connections 2 10 Electrical Service 2 11 Connecting Input SECTION 3 OPERATION eue ane Done tin de PEERS 3 1 SOS pee meme Nene thie qe pak co tee E 3 2 Example of Front Panel Amperage Control 3 3 Example of R
4. re 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 9 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 355 Page 35 SECTION 10 PARTS LIST 15 Hardware is common and not available unless listed Figure 10 1 Main Assembly 9 355 36 Item Dia Par u Mkgs No Description Quantity Figure 10 1 Main Assembly 1882706 v COVER Pa er dima ln tin e itl nus 1 Tm T4 sise 190 332 COILE Coupllng 4 edes kein LES DIT 1 LE pep 190 436 HOLDER HF coil 1 O G1 199 854 SPARK GAP ASSEMBLY consisting of 1 199855 BASE uisu sieht ollie eae ewe ra od PE ture ME 199 856 HOLDER ites ese L
5. Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 9 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 mak ing another weld pass stick 12 96 ST 151 593 OM 355 Page 28 9 2 Electrode and Amperage Selection Chart AMPERAGE RANGE ELECTRODE DIAMETER 100 150 200 250 300 350 ELECTRODE POSITION PENETRATION DEEP ALL DEEP MIN PREP ROUGH HIGH SPATTER ALL LOW GENERAL ALL MED SMOOTH EASY FAST ALL LOW LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER y y A V y ALL LOW CAST IRON 308L ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLA
6. gt Remote control device has complete control of amperage at all times when connected to Remote 14 receptacle Socket Socket Information 24 volts DC Contact closure to completes 24 volts DC contactor control circuit ST 802 238 Command reference 0 to 10 volts DC output to remote control Remote control circuit common 0 to 10 volts DC input command signal from remote control Chassis common remaining sockets not used 2 9 Shielding Gas Connections n2 Tools Needed I 5 8 1 1 8in Turn Off power before con necting to receptacle 1 Gas Valve In Fitting Fitting has 5 8 18 right hand threads Located on rear of unit 2 Gas Valve Out Fitting Gas connection is integrated into the Electrode weld output terminal by means of a flow through type connector 3 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 4 Regulator Flow Gauge Connect regulator flow gauge to gas oylinder 1 Connect gas hose to gas in fitting Q4 5 Flow Adjust o rate is 20 cfh cubic feet Ref ST 802 238 Ref ST 802 258 Ref ST 157 858 OM 355 Page 12 2 10 Electrical Service Guide NOTE t All values calculated at 40 duty cycle Input Voltage 230 Input Amperes at Rate
7. 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 c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l 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 d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran faci
8. 0 4 Wrong Tungsten Preparation Wandering Arc Ref S 0161 Ref S 0162 OM 355 Page 23 SECTION 8 GUIDELINES FOR TIG WELDING GTAW 8 1 Positioning The Torch 1 16 in Bottom View Of Gas Cup Grinding the tungsten elec trode produces dust and fly ing sparks which can cause injury and start fires Use lo cal exhaust forced ventila tion at the grinder or wear an approved respirator Read MSDS for safety information Consider using cerium or lanthanum based tungsten instead of thoriated Tho rium dust contains low level radioactive material Proper ly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Sections 7 1 and 7 2 or 7 3 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade quate shielding gas coverage For example if tungsten is 1 16 in diameter gas cup should be a minimum of 3 16 in diameter Tungsten extension is the distance the tungsten extends out gas cup of torch The tungsten extension should be no greater than the inside diameter of the gas cup Arc length is the distance from
9. Hobart s option 1 repair or 2 replacement or where authorized in writing by Hobart in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart authorized service facility as determined by Hobart Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART Some states in the U S A do not allow limitations of how long an implie
10. IS REQUIRED USE REMOTE 90 OUTPUT CONTROL 70 110 20 130 Am O AN ELECTRODE ELECTRODE 30 NEGATIVE POSITIVE 150 DO NOT SWITCH 180 UNDER LOAD Select polarity Select In Example For remote amperage control front panel amperage control setting is the maximum amperage available Full range is 10 180 amps DOC but if front panel amperage control is set at 130 amps the range of remote amperage control is 10 to 130 amps DC NOTE Remote amperage control is active whenever a remote control is connected If the remote device does not include a means of controlling amperage through OM 355 Page 15 3 4 Typical TIG Connections gt p Tools Needed 5 8 1 1 8 1 Remote Foot Control A customer supplied remote finger tip control may also be used 2 Torch 3 Work Clamp Connect remote control torch and work clamp to receptacles as shown 4 Cylinder Chain or secure cylinder to running gear wall or other stationary support 5 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 6 Regulator Flow Gauge Install so face is vertical 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour 9 4 L min NOTE After activating remote con trol 0 3 seconds of gas preflow will begin Application Preflow is used to purge the imme diate weld area of atmosphere Preflo
11. break 2103 b 61 76 mm c 1 4 in _4 2 6 4 mm E d UR 1 S 0057 B 9 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 9 15 Troubleshooting 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 OM 355 Page 33 9 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead AN 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 weavi
12. burn eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion 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 Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can c
13. galvanis plaqu en plomb ou au cadmium moins que le rev te e Ne pas utiliser des c bles us s endommag s de grosseur insuffi ment n ait t enlev dans la zone de soudure que l endroit soit bien sante ou mal piss s ventil et si n cessaire en portant un respirateur alimentation e Ne pas enrouler les c bles autour du corps d air tous dd m taux nin M l ments e Sila pi ce soud e doit tre mise la terre le faire directement avec un peuvenudegager des TumEees toxiques cn eas eg soudage c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine OM 355 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement deman
14. grands pour emp cher le contact phy tre d sique ventuel avec la pi ce ou la terre etre dangereux Ne pas se servir de source lectrique courant lectrique dans les zones Le soudage g n re des fum es et des gaz Leur humides dans les endroits confin s ou l o on risque de tomber inhalation peut tre dangereux pour votre sant e servir d une source lectrique acourant lectrique UNIQUEMENT si le e Eloigner votre t te des fum es Ne pas respirer proc d de soudage le demande les fum es e Sil utilisation d une source lectrique acourant lectrique s av re n ces e A l int rieur ventiler la zone et ou utiliser un chappement au niveau saire se servir de la fonction de t l commande si l appareil en est quip de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal e Sila ventilation est insuffisante utiliser un respirateur alimenta lation la r paration ou l entretien de l appareil D verrouiller tion d air homologu l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de Se xe s curit e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma e Installer et mettre la terre correctement cet appareil conform ment bles les rev tements les nettoyants et les d graisseurs son manuel d utilis
15. rore nied 188 859 ACCESSORY KIT consisting of 1 iu aula etd aaa how i 043 554 RFCS 14 foot control 1 N DB1712RDI TORCH TIG 150A 12 5 ft cable 1 188 860 WORK CABLE w clamp 1 NEUE 193 094 KIT regulator hose 1 PR 176 840 HOLDER electorde w cable amp dinse connector 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 355 Page 38 Hardware is common and not available unless listed 13 11 ST 802 254 A Figure 10 2 Panel Front w Components Item Dia Par No Mkgs No Description Quantity Figure 10 2 Panel Front w Components Figure 10 1 Item 39 TON PLE 174 991 KNOB pointer occ ore oii eu hale UEM XI ERU RR 1 bari NAMEPLATE order by model and serial number 1 143 976 RECEPTACLE W SOCKETS 1 186 092 RECPT KIT Din style
16. the tungsten to the workpiece Ref ST 161 892 OM 355 Page 24 8 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction 75 gt gt lt U gt 1 Z A Z ZZZ 4 7 Z 4 Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod Welding direction 7 wy e 1 i 7 ZZ 4 lt y amp 2122222 amp Tilt torch Add filler metal Remove rod Move torch to front of pool Repeat process ST 162 002 B OM 355 Page 25 8 3 Positioning Torch Tungsten For Various Weld Joints 90 Butt Weld And Stringer Bead ce 70 qp 2 20 20 Joint 70 a 20 10 40 Lap Joint 7 2 20 30 90 Corner Joint ST 162 003 5 0792 355 26 Notes OM 355 Page 27 SECTION 9 STICK WELDING SMAW GUIDELINES uf ES 9 1 Stick Welding Procedure Tools Needed Lm A Weld current starts when electrode touches work piece Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece
17. 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 355 Page 39 Warranty Questions Call 1 877 HOBART1 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART WARRANTY Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart will repair or replace any warranted parts or components that fail due to such defects in material or w
18. 21 in 533 mm Width 13 5 8 in 346 mm Length 22 1 8 in 562 mm A 21 5 16 in 541 mm A B 13 16 in 21 mm C 12 7 16 in 316 mm D 1 1 16 in 27 mm P d 10 88 1 2 13 Front Weight 212 87 802 259 210 lbs 95 kg 2 4 Specifications Rated Output at 40 Rated Input Welding Amperage Max Open Circuit Mode Duty Cycle 60 HZ Single Phase KVA KW Range Voltage DC TIG 150 Amps at 16 Volts 230 V 38 A 2 8 7 0 50 4 0 0 3 10 180 80 DC Stick 150 Amps at 26 Volts 230 V 42 2 9 7 0 50 5 7 0 3 10 180 80 AC TIG 150 Amps at 16 Volts 230 V 67 A 2 15 5 0 50 4 9 0 3 15 180 80 AC Stick 150 Amps at 26 Volts 230 V 53 A 2 12 2 0 50 6 2 0 3 15 180 80 While idling 2 5 Duty Cycle Chart Duty cycle is percentage of 10 200 minutes that unit can weld at rated load without overheating Exceeding duty cycle 150 damage unit and void warranty o W 100 gt lt Q 50 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE 40 Duty Cycle at 150 A AC DC ag 4 Minutes Welding 6 Minutes Resting ST 188 276 A OM 355 Page 10 2 6 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of welding power source Curves of other set tings fall between curves shown AC MODE DC MODE 80 80 70 70 eor 60 o 90r 50 d 40 40 S 9 STICK MAX TIG MAX
19. OD2 4 2 TRO TO A J E G2VWK2_ 7 1 61 1 LUS x C9 7 12 PLGS yy ea 54 PLG4Y 4 2 000 ELECTRODE PLG1 PLG11 RED 9 B lt 115 ce 4 x 5 N N 2 182 619 x el 9 N qd PIGIA A ARAL RAA A AAAA A A 5 11532 221 17137 9999 583 3 3 8 2 2 BB 55 illl 5 5259 tt cac c coc ge e e ca c O uc c gy PROB gg gg lt lt lt lt RC1 14 1 MAIN BOARD 7 gt gt 18 RC1 PLG10 1 gt 2 BLK TAP lt lt f lt lt 2 RC3 PLG3 7 ELK TAP 2 4 22 RCA S RC4 PLGG RC1 2 55 Z 18VAC yd 4 4 n 3 58838388 5 oe n n a 4 oe wy YI Yo amp WARNING Do not touch live electrical parts A KR KR KR A A RT7 TP2 Disconnect input power or stop D A XFMR engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD For Welding Power Source it Diagram Ircul Figure 5 1 C OM 355 Page 19 SECTION 6 HIGH FREQUENCY HF 6 1 Welding Processes Using HF Les 1 HF Voltage A GTAW helps arc jump air gap between torch and workpiece and or stabilize the arc SAW helps arc reach workpiece 2 through flux granu
20. OM 355 188 290E August 2001 Processes P4 GTAW Welding WELDING PRODUCTS Stick SMAW Welding Description crga KH Arc Welding Power Source Cybertig 180 SD 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 M 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 Hobart is registered to the needs repair there s a Troubleshooting section er Penn Quality System that will help you figure out what the problem is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTERED QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact y
21. ONTROL VN A ch em O O ELECTRODE ELECTRODE NEGATIVE POSITIVE DO NOT SWITCH UNDER LOAD gt lt 1 Ref 5 188 714 1 Output Selector Switch For remote amperage control used when TIG lize welding arc For AC welding the arc starter Do not use AC output in damp areas if welding front panel Amperage control will turn on and stay on to start and stabilize the movement is confined or if there is Setting is the maximum amperage available at welding arc No adjustments needed for arc danger of falling Use AC output ONLY the remote control device starter if required for the welding process and See Section 3 3 for example of remote amper 4 Output Contactor Light then use a remote control age control Lights when output contactor and unit power Do not change position of switch while Weld Process Switch are on i 2 or pi 2 n Use switch to select weld process 5 Overtemp Light se switcn to select Direct Current Electrode In Stick position up weld output goes On and Negative DCEN AC or Direct Current Elec Off with Power switch Ta Na 43 overheats and shuts down i changing GTAW TIG position down remote control 6 Pilot Light ed gupur Cane 9 Schons device turns on and adjusts weld output of unit 2 Amperage Adjust Control as limited by Amperage control For Direct Cur 7 Power Switch For Stick SMAW use control to adjust rent Electrode Negative DCEN built in arc Use switc
22. R APR eee yee d 196 455 o POINTS 22m takers aiken Weald A ses Ane C3 201 197 CAPACITOR polyp met film 002uf 4400 1 074 398 XFMR high voltage 115 v pri 3600 v sec 1 sy qm R8 188 067 RESISTOR WW fxd 100w 200 ohm 1 8 C18 19 191944 CAPACITOR polyp met film 10 2 188 369 HF etel eee bea eee 1 ue dO i vare be 190 514 HOLDER HF coil slide 1 menie 192 828 LABEL fn anne hae ME AG ee ont dur 1 te 188272 FRAME lifting 55522 nr ae ae ae kee E t Er na 1 lo lly 188283 XFMR power main 208 230 1 1 2 020 520 THERMOSTAT NC open 135C w insulator 2 m PLG1 202 119 Connector W Sockets 1 ena PLG7 202116 Connector W Sockets 11 pare PLG8 202 117 Connector W Sockets d PLG11 202 118 Connector W Sockets 1 190 341 HEAT SINK rectifier 1 186 468 RESIS
23. RITY Ref S 087 985 A 9 3 Striking an Arc Scratch Start Technique 1 1 Electrode gt 2 Workpiece 7r 3 Arc X Drag electrode across workpiece Nw 5 like striking match lift electrode 4 slightly after touching work If arc XL goes out electrode was lifted to high If electrode sticks to work brc 3 piece use a quick twist to free it S 0049 9 4 Striking an Arc Tapping Technique 1 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start 2 arc If arc goes out electrode was U lifted too high If electrode sticks to LA workpiece use a quick twist to free it S 0050 OM 355 Page 29 9 5 Positioning Electrode Holder 10 30 Lai V o o 90 90 0 Hr 2 End View of Work Angle Side View of Electrode Angle GROOVE WELDS Vel 10 30 V End View of Work Angle Side View of Electrode Angle FILLET WELDS S 0060 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 2 4 5 S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 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 NoOverl
24. TIG WELDING GTAW 8 1 Positioning The Torch ass 2 5 a us gg neida tauri dadina ee ianea t 8 2 Torch Movement During Welding 8 3 Positioning Torch Tungsten For Various Weld Joints SECTION 9 STICK WELDING SMAW GUIDELINES SECTION 10 PARTS LIST px er x RR REX RU Sh here ee ieee OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away A ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe b
25. TOR WW fxd 100w 50 ohm 1 TED M 188 367 BRACKET rectifier 1 17 MOD1 2 192105 THYRISITOR SCR module 95 400V 150C dual 2 fe ANB Aud cebat 190 343 BUS BAR rectifier 1 NOs IR EE CRE 190 342 BUS BAR rectifier 1 20 HD1 191 941 TRANSDUCER current hall effect 1 21 C7 8 9 10 190 460 CAPACITOR ASSEMBLY 2 PS LS D xui 192 116 MODULE 1 ier usas 191 944 CAPACITOR polyp met film 1Ouf 1 RU AERE 189 132 RESISTOR 1 es 194 363 THERMOSTAT NC open 150F close 125F 1 26 133 873 VALVE 24VDC 2way 1 ea Ti eo iste 188 268 PANEL reat o oe eee dee aH eerie ee re Ere E E PR NE e dan 1 604 102 CONNECTOR clamp cable 690 1 070 1 51092 ME Marie Ve 190 442 CORD SET 250V 8 3 10 ft 1 188 366 PLEENUM
26. Unit 1 12ft 3 7m Work Cable With Clamp And Quick Connect 2 150 Amp TIG Torch with 12 1 2 ft 3 8 m Cable 3 Electrode Holder and Quick Connect 4 Gas Hose 5 Gas Regulator 6 RFCS 14 Foot Control with 20 ft 6 m Cable 7 8 ft 2 4 Primary Cord Some assembly is required For options and accessories see back of book or contact your dis tributor 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit Movement 1 If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Use rating label to determine input power needs OR 4 Line Disconnect Device Locate unit near correct input pow er supply Location And Airflow j ERR 3 Position unit so air can circulate PA For information about sources of VOLTS high frequency see Section 6 AMPERES KW For carts and caster kits see back PHASE HERTZ of book or contact your distributor 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 460 mm ST 802 238 OM 355 Page 9 2 3 Dimensions And Weights Dimensions 1 0 Height
27. V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 9 11 Lap Joint 2 Single Layer Fillet Weld 30 Or Less KA 1 Or Less 3 Multi Layer Fillet Weld 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 9 12 Tee Joint 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 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 9 9 Remove slag before making another weld pass S 0060 5 0058 5 0061 OM 355 Page 32 9 13 Weld Test a 2703 51 76 fan 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not
28. al OM 355 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz Sous haute pression Si une bouteille est endomma elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes de
29. andards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equi
30. ap 5 Good Penetration into Base Metal S 0052 B OM 355 Page 30 9 8 Conditions That Affect Weld Bead Shape NOTE Cr Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 410 30 Angle Too Large 1 ee 0 5 neam d prag ELECTRODE ANGLE L pm Rn pr s Too Short Normal Too Long ARC LENGTH ae lS Slow Normal Fast TRAVEL SPEED S 0061 9 9 Electrode Movement During Welding NOTE Normally single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple 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 electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 355 Page 31 9 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single
31. ation et aux codes nationaux provinciaux et a n x municipaux e Travailler dans un espace ferm seulement S il est bien ventil ou en ee i a portant un respirateur alimentation d air Demander toujours un e Toujours v rifier la terre du cordon d alimentation V rifier et s assu surveillant d ment form de se tenir proximit Des fum es et des rer que le fil de terre du cordon d alimentation est bien raccord la gaz de soudage peuvent d placer l air et abaisser le niveau d oxy borne de terre du sectionneur ou que la fiche du cordon est raccord e g ne provoquant des blessures ou des accidents mortels S assu une prise correctement mise la feng ie rer que l air de respiration ne pr sente aucun danger e En effectuant les raccordements d entr e fixer d abord le conducteur Ne pas souder dans des endroits situ s proximit d op rations de de mise ala terre appropri et contre v rifier les connexions d graissage de nettoyage ou de pulv risation La chaleur et les e V rifier fr quemment le cordon d alimentation pour voir s il n est pas rayons de l arc peuvent r agir en pr sence de vapeurs et former des endommag ou d nud remplacer le cordon imm diatement s il est gaz hautement toxiques et irritants endommag un c ble d nud peut provoquer une lectrocution e Ne pas souder des m taux munis d un rev tement tels que l acier e Mettre l appareil hors tension quand on ne l utilise pas
32. ause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 355 Page 2 a BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging o
33. d Output 67 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 100 Min Input Conductor Size In AWG Kemil 8 Max Recommended Input Conductor Length In Feet Meters 166 51 Min Grounding Conductor Size In AWG Kemil 8 Reference 1996 National Electrical Code NEC S 0092 J 2 11 Connecting Input Power Tools Needed Have only qualified persons make this installation m A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Units come equipped with input TS GND PE power cord for installation into line H disconnect device Select type and di size overcurrent protection using HSE Section 2 10 JL vi FX HoB8 TUNI X A 3 A m GND PE Connect first L1 L2 ST 802 238 OM 355 Page 13 SECTION OPERATION 3 1 Controls aw Y ES 2 3 4 5 90 70 110 A on STICK i 130 O O O 30 150 OFF A 5 180 PROCESS O 7 WARNING ELECTRIC SHOCK m NOT USE OUTPUT IN DAMP AREAS IF MOVEMENT IS CONFINED OR IF THERE 15 A DANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE VERG outers USE REMOTE OUTPUT C
34. d 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 5 WELDERS hobart standard 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equ
35. dels Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Hobart but manufactured by others Such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at
36. der aux autres personnes de ne pas re garder l arc e Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu
37. e Lines Locate HF source at least 50 ft 15 m away from power and phone lines 7 Grounding Rod Consult the National Electrical Code for specifications Metal Building Ref S 0695 Ref S 0695 8 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame 9 Windows And Doorways Cover all windows and doorways with grounded copper screen of not more than 1 4 in 6 4 mm mesh 10 Overhead Door Track Ground the track OM 355 Page 21 SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw2 7 97 NOTE gt For additional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process Wear clean gloves to prevent contamination of tungsten electrode 7 1 Selecting Tungsten Electrode Amperage Range Gas Type Polarity Electrode Diameter DC Argon Electrode Negative Straight DC Argon Electrode Positive Reverse Polarity Polarity 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 020 15 40 i 040 25 85 1 1 16 50 160 10 20 3 32 135 235 15 30 1 8 250 400 25 40 5 32 400 500 40 55 3 16 500 750 55 80 1 4 750 1000 80 125 Typical argon shielding gas flow rates are 15 to 35 cfh cubic feet per hour 7 to 16 5 Ipm liters per minute Not Recommended The figures list
38. e Maintenance Ta TEE Disconnect power before maintaining Maintain more often during severe conditions 3 Months Replace unreadable labels Clean and tighten weld terminals 2 i 62 Repair or replace cracked weld cable Repair or replace cracked gas hose as lt 2 Replace o ring in Electrode Gas Output receptacle if cracked 6 Months Blow out or vacuum inside OM 355 Page 17 4 2 Adjusting Spark Gaps gt Tools Needed A Turn Off power before ad justing spark gaps Remove left side panel 1 Tungsten End Of Point Replace point if tungsten end dis appears do not clean or dress tungsten 2 Spark Gap Normal spark gap is 0 012 in 0 305 mm If adjustment is needed proceed as follows 3 Adjustment Screws Loosen screws Place gauge of proper thickness in spark gap 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap Tighten screws to 12 in lbs torque overtigh tening will deform plastic base Ad just other gap Reinstall left side panel ST 802 745 4 3 Troubleshooting Trouble Remedy No weld output fan does not run Place line disconnect switch in On position see Section 2 11 Check and replace line fuse s if
39. ed are intended as a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 7 2 Safety Information About Tungsten D N Grinding the tungsten elec trode produces dust and fly ing sparks which can cause injury and start fires Use lo cal exhaust forced ventila tion at the grinder or wear an approved respirator Read MSDS for safety information Consider using tungsten containing ceria lanthana or yttria instead of thoria Grinding dust from thoriated electrodes contains low lev el radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Tungsten Electrode With Balled End Pointed Tungsten Electrode Ref S 0161 OM 355 Page 22 7 3 Preparing Tungsten For DC Electrode Negative DCEN Welding 1 Tungsten Electrode 2 1 2 2 Tapered End Grind end of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality 2 1 2 Times Electrode Diameter 1 Stable Arc 2 Flat Diameter of this flat determines amperage capacity 3 Grinding Wheel 4 Straight Ground Ideal Tungsten Preparation Stable Arc Arc Wander Point Grinding Wheel Radial Ground 1 om EL 8 ND
40. emote Amperage Control 3 4 Typical TIG Connections 3 5 Typical Stick Connections 3 6 Process and Material Thickness Guide Label SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance 4 2 Adjusting Spark Gaps 4 4 3 Troubleshooting 5 xot EI ae dite A RR step mans a Eq SECTION 6 ELECTRICAL SECTION 7 HIGH FREQUENCY 1 7 1 Welding Processes Using HF 1 7 2 Sources Of HF Radiation From Incorrect Installation 7 3 Correct Installation eie re nr E REX E HERR ERE E ENS SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE 2 cai se FCR EO ned ewe qe 7 1 Selecting Tungsten Electrode 7 2 Safety Information About 7 8 Preparing Tungsten For DC Electrode Negative DCEN Welding SECTION 8 GUIDELINES FOR
41. ger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage 5 3 DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des Sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible
42. h to turn unit fan and pilot light On amperage starter comes on when needed to start or stabi Off OM 355 Page 14 3 2 Example of Front Panel Amperage Control For Stick SMAW Welding STICK TIG PROCESS Select weld process WARNING ELECTRIC SHOCK CAN KILL 00 NOT USE AC OUTPUT IN DAMP AREAS IF MOVEMENT IS CONFINED OR IF THERE 15 A DANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE WELDING PROCESS 1F AC OUTPUT IS REQUIRED USE REMOTE 90 OUTPUT CONTROL 70 110 50 5 ELECTRODE ELECTRODE 30 NEGATIVE POSITIVE 150 10 DO NOT SWITCH A 180 UNDER LOAD Select polarity Select amperage In Example Remote weld amperage 10 180 amps DC NOTE Remote amperage control is active whenever a remote control is connected If the remote device does not include a means of controlling amperage through pin E the Amperage Adjustment control on the front panel remains active 3 3 Example of Remote Amperage Control For TIG GTAW Welding Select weld process d in E the Amperage Adjustment control on the front panel remains active Connect remote control see Section 3 4 P P WARNING ELECTRIC SHOCK CAN KILL 00 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
43. heck connections 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 som nd 4 98 e i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Sect
44. heme k E unn eR unes nn nes 1 M 150 783 BLADE fan 9 5wg 39deg 312 bore cw 1 ELEC 188 706 MOTOR fan 230V 50 60Hz 1550 RPM 1 pets aut 187 807 BRACKET fan motor mtg 1 O94 wo sn etka dus 188 362 PANEL side right 1 CR a take 188269 BASE irate nere tee aed lord cee eRe SAS 1 MO EZ T ases 188284 STABILIZER 1 aed OO durs 187 467 SWITCH polarity changeover 1 88 C13 14 188964 CAPACITOR ASSEMBLY 2 ABO Figure 10 2 PANEL front w components 1 m URN 198271 PANEL Side left este ls horse yh EE 1 Al esi eine 141 162 HOUSING PLUG AND PINS service kit 0 ADS suc E 155 552 CONNECTOR torch service kit 0 E UR ees eer 134 460 CONNECTOR work cable service kit 0 UN ee E 134 327 LABEL warning general precautionary 1 5 cote wesc p dun 185 759 LABEL warning electric shock 1 OM 355 Page 37 No Mkgs No Description Quantity Figure 10 1 Main Assembly continued ded
45. i dessous afin de conna tre les mesures prendre pour viter tout danger som nd fre 4 98 1 1 identifie un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les risques champ les pi ces endommag es Entretenir l appareil conform ment de danger Lorsque vous voyez un symbole soyez vigilant et ce manuel suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer e Porter un harnais de s curit quand on travaille en hauteur l information contenue dans les normes de s curit num r es 4 la section 1 4 Veuillez lire et respecter toutes ces normes de Maintenir solidement en place tous les panneaux et capots s curit e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal EE L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisat
46. ion before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 355 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
47. ion tenir toute personne l cart et plus par ticulierement les enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres LES FUM ES ET LES GAZ peuvent moyens isolants suffisamment
48. ipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment 2000 Hobart Welding Products 1 00 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 WELDING PRODUCTS
49. les 1 0 0 1 2 Flux E E5 Work Work Gas Tungsten Arc Submerged Arc Welding GTAW Welding SAW high freg1 7 95 S 0693 6 2 Sources Of HF Radiation From Incorrect Installation S 0694 Sources Of Direct HF Radiation 5 Workpiece Sources Of Reradiation Of HF 1 source welding power source with 6 Work Table 10 Ungrounded Metal Objects built in HF or separate HF unit Sources Of Conduction Of HF 11 Lighting 2 Weld Cables 7 Input Power Cable 12 Wiring 3 Torch 8 Line Disconnect Device 13 Water Pipes And Fixtures 4 Work Clamp 9 Input Supply Wiring 14 External Phone And Power Lines OM 355 Page 20 6 3 Correct Installation A Ground All Metal Objects And All Wiring In Welding Zone Using 12 AWG Wire Nonmetal Building 1 Source Welder With Built In HF Or Separate HF Unit Ground metal machine case work output terminal line disconnect device input supply and worktable 2 Welding Zone And Centerpoint A circle 50 ft 15 m from centerpoint between HF source and welding torch in all directions 3 Weld Output Cables Keep cables short and close together 4 Conduit Joint Bonding And Grounding Workpiece If Required Ground Electrically join bond all conduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 5 Water Pipes And Fixtures Ground water pipes every 50 ft 15 m 6 External Power Or Telephon
50. necessary or reset circuit breaker see Section 2 11 Check for proper input power connections see Section 2 11 No weld output fan on Be sure Polarity switch is not set between positions Tighten remote control connection to Remote 14 receptacle Check remote control see remote control Owner s Manual Unit overheated Allow unit to cool see Section 2 5 Fan not operating weld output Check for and remove anything blocking fan movement available Have Factory Authorized Service Agent check fan motor OM 355 Page 18 SECTION 5 ELECTRICAL DIAGRAM POWER ELK PLG1 PLG11 RED CAR 1 gt 2 gt 2 gt FED 9 3 gt PLG7 PLGB AK 6 5152 AKO 4 D s 3 gt lt KE as 24 gt 5 gt PLG4 PLG5 2 2 1 lt 2 2e _ I7 IZ lt 5 e 25 5 lt HI 3 1 1413 Ww N 55 gt HD1 ea 17 1 FT PR B a 2 1234 a T AA 162 5 1 D 762 K2 i 7 work 15 1 POL PLG5 A ac gt 822325 927274 M
51. netic 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 355 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION APA Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives c
52. ng 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 9 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration 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 9 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath 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 OM 355 Page 34 9 19 Troubleshooting Burn Through 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 9 20 Troubleshooting Waviness Of Bead
53. nment Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui on
54. orkmanship Hobart must be notified in writing within thirty 30 days of such defect or failure at which time Hobart will provide instructions on the warranty claim procedures to be followed Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Hobart Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Mo
55. our local to receive the latest full line catalog or sul ir 2d e can also su o wit individual catalog sheets To locate your nearest Welding FUA Manuals such as SMAW GTAW distributor or service agency call 1 877 Hobart1 GMAW and GMAW P WELDING PRODUCTS WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 5554 ahve saat etant atteste 1 2 Arc Welding Hazards 2 2 0 4 1 3 Additional Symbols for Installation Operation and Maintenance 1 4 Principal Safety Standards 1 5 EME ilnformation 5 CE ere rere eR c pop SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles 1 2 Dangers relatifs au soudage larc 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement etla maintenance asore segue nee dre tes eee vate ERI
56. pment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 355 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro mag
57. r spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE EXPLOSION hazard e Do not in
58. s tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais placer une torche de soudage 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 cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen ta
59. stall or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders 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 Re LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards 79 e on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 22 N MOVING PARTS can cause injury 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 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health St
60. t t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 355 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INSTALLATION 2 1 Included with Your
61. tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 355 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI 249 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Gover
62. tion est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s gt amp e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diri
63. urns 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 Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double c
64. w also aids in consistent arc starting NOTE When remote control is released gas continues to flow for 18 seconds Application Postflow is required to cool tung sten and weld and to prevent con tamination of tungsten and weld In crease postflow time if tungsten or weld are dark in appearance NOTE Both preflow and postflow are preset and are not adjustable NOTE When AC welding the bal ance control is preset at 60 elec trode negative EN and 40 elec trode positive EP ST 802 238 3 5 Typical Stick Connections gt 1 Electrode Holder 2 Work Clamp Connect electrode holder and work clamp to receptacles as shown ST 802 238 OM 355 Page 16 3 6 Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And 22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 11 ga 10 ga 6 ga 2 ga Weld Output 0 033 in 0 036 0 048 in 0 06 0 07 in 0 1 0 125in 0 14in 0 186 in 0 25in 0 25 in 0 8 0 9 mm 1 2 1 5 mm 1 8mm 2 5 mm 32 3 6 mm 4 8 mm 6 3 mm 6 3 Steel Or Stainless Steel SMAW P 2 DCEN 4470 Et GTAW GTAW With DCEP EGRE i allies Aluminum e 227 GTAW U Difficult Recommended e e Et AC Not Recommended S 167 338 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routin
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