Hobart CYBER FLEX 652 User's Manual
Contents
1. 278 163 769 June 2000 Processes 29 Multiprocess Welding WELDING PRODUCTS Description 24 Di EJ Arc Welding Power Source Cyber Flex 652 Model OWNER S MANUAL From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit Hobart is registered to the needs repair there s a Troubleshooting section 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 your local to receive th2. Check position of Remote Amperage Voltage Control switch see Section 4 1 Erratic or improper weld output Use proper size and type of weld cable see Section 3 8 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Check position of Process selector switch see Section 4 1 Have Factory Authorized Service Agent check control board PC1 and hall device HD1 No 115 volts ac output at duplex recep tacle Remote 14 receptacle or terminal strip 1T Reset circuit breaker CB1 see Section 3 7 No 24 volts ac output at Remote 14 re ceptacle or terminal strip 1T Reset circuit breaker CB2 see Section 3 7 Fan not operating Note fan only runs when cooling is necessary Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc poor control of arc direction Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten Check for water in torch and repair torch if necessary See torch Owner s Manual Digital meter not working properly Have Factory Authorized Service Agent check control board PC1 and connect
3. 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
4. e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 43 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 Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 K MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipme
5. his dod ikem VIT an 1 Part of Option 042 983 Ground Current Sensor 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 278 Page 29 Item Dia Part Mkgs No 1 07 12 048 420 Bem 191 989 CEDAT 188 691 e 188 839 5 SCH1 6 148 091 iioc Os 166 667 PLG1 158 720 ee ed EPS es 192078 TC E TP6 192674 LF Hardware is common and not available unless listed Description Quantity Figure 7 3 Rectifier Si Diode Fig 7 1 Item 31 CAPACITOR cer disc 01uf 1000VDC 6 BAR MIO C RT cm 2 CLAMP thyristor rectifier 5 500 3 HEAT SINK rectifier snowflake 800 12 THYRISTOR SCR 865A 300V hockey 6 CLAMP spring thyristor rectifier 5 500 3 CONNECTOR amp SOCKETS iret tdo e aiii 1 THERMOSTAT rated e deck ee aa 1 THERMOSTAT recie x t tos cO RU Deka BE BA e aes 1 ST 802 351 Figure 7 3 Rectifier Si Diode To maintain the factory original performance of your equipment use only Manuf
6. KW PHASE 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Plate Label CE Models Only Label located under front access door 5 Rating Label CE Models Only Use rating label to determine input power needs Label located on rear access door see Section 2 5 6 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 Holes Ref ST 153 556 A Dimensions Height 27 1 4 in 692 mm Width 22 1 4 in 565 mm Depth 36 in 914 mm A 35 in 889 mm B 1 1 4 in 32 mm C 21 in 533 mm D 1 3 16 in 30 mm E 7 16 in 11 mm Dia Weight 650 Amp Net 545 Ib 247 kg Ship 561 Ib 254 kg OM 278 Page 14 3 6 Tipping Be careful when placing or moving unit over uneven surfaces 3 7 115 VAC Receptacle And Circuit Breakers A Turn Off power before connecting to receptacle 1 115V15AAC Receptacle RC9 Power is shared between RC9 and Remote 14 receptacle RC8 or terminal strip 1T See Section 3 10 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts a
7. e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr 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 e Sisoler de la piece et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et
8. lt lt RC11 9 AMP VOLT RCS PLGS ad RC4 9 gt 22 RC10 2 METER Tags wo nx Vee RM 80998 6 8 8 4 RC10 PLG10 c c c c E 5 5 5 D RC11 PLG11 V_V_V_V V_V_V 568 amp ttu sum 55 73 74 75 77 67 a Vala N Nl IB CR2 CR2 43 79 12 S47 u OUTPU 5 77 43 11 13 12 4 27 28 43 2 3 NFC la Ta O tow poy E P J A BNP K ML RC7 2Y RC7 had Nut M REMOTE 24NAC REMOTE 43 OUTPUT REMOTE GND POWER CONTROL CONTACTOR ON OFF 115VAC REMOTE REMOTE VOLTAGE GROUND CURRENT O CONTACTOR SENSE SENSE OPTION 46 76 77 47 48 C6 C13 C14 ircuit Di Figure 6 1 C OM 278 Page 25 SECTION 7 PARTS LIST LF Hardware is common not available unless listed 79 US S Ur y XX Al SAT TE nenn 28 Fig 7 2 ST 800 703 D LZ ade VS Mana Figure 7 1 Main Assembly 652 Model Illustrated OM 278 Page 26 Mkgs No Description Quantity Figure 7 1 Main Assembly 652 Model Illustrated Ur Ee ne 717949252 PANEL 8106 ga RE m EUR 2 Lr Um 179431 lt COVER TO D nass da med ORC Ao eod as gs 1 T A 164 700 2 BAFFLE Al vaio edd eibi di mi bed wad ee 2 ME ERNEUT TEE 162 816 CHANNEL OOM QIN a atm i tare Dec aO de rm Put ane en 4 TIR Drm 162 820 BARS MMO EVE
9. tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy gene provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 278 Page 5 LES RAYONS DE peuvent voquer des brulures 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 sou
10. 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 Y a A 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes S 0007 E 3 9 Remote 14 Receptacle And Terminal Strip 1T Information Socket Terminal Information Vanesa OUTPUT A A 24 volts ac Protected by circuit breaker CB2 24 VOLTS CONTACTOR B B Contact closure to A completes 24 volts ac contactor control circuit C C Command reference 0 to 10 volts dc CC 10 volts dc CV REMOTE OUTPUT CONTROL D D Remote control circuit common E E 0 to 10 volts dc input command signal from remote control F f k 1 1 vol 1 A V AMPERAGE Current feedback 0 to 10 volts dc 1 volt per 100 amperes VOLTAGE H Voltage feedback 0 to 10 volts dc 1 volt per 10 arc volts OUTPUT 115 volts 15 amperes 60 Hz ac Protected by circuit breaker CB1 115 VOLTS AC CONTACTOR J J Contact closure to completes 115 volts ac contactor control circuit GND K K Chassis common G i Circuit common for 24 and 115 volts ac circuits L REMOTE POWER ON OFF P To remote On Off switch N Voltage sensing signal from Negative weld output terminal REMOTE VOLTAGE SENSING Voltage sensing signal from Positive weld output
11. 80 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 year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 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 Models Field Options NOTE Field options are covered u
12. OM 278 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and 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 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Regles 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
13. and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som _nd_5 97 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work 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
14. basse fr quence L extrait suivant est tir des conclusions g n rales du document intitul Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publi par le Office of Technology Assessment du Congr s am ricain il existe maintenant d abon dantes donn es scientifiques compil es la suite d exp riences sur la cellule ou d tudes sur des animaux et des humains qui montrent clai rement que les champs lectromagn tiques basse fr quence peuvent avoir des effets sur l organisme et m me y produire des transforma tions M me s il s agit de travaux de tr s grande qualit les r sultats sont complexes Cette d marche scientifique ne nous permet pas d tablirun tableau d ensemble coh rent Pire encore elle ne nous per met pas de tirer des conclusions finales concernant les risques ventuels ni d offrir des conseils sur les mesures prendre pour redui re sinon liminer les risques ventuels Traduction libre OM 278 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les cables 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 vous 4 Garder le poste de soudage et les
15. cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 2 5 Manufacturer s Rating Label For CE Products LF For label location E see Section 3 4 EN 60974 1 50A 12V 815A 34V eff ow 50A 20V 815A 44V 100A 10V 650A 44V X 77A 73A 66A 63kVA 50 6 5 174 343 278 11 2 6 Symbols Definitions NOTE gt Some symbols are found only on CE products A Amperage bltage Gas Tungsten Arc 7 Shielded Metal Arc Mee Control Panel Welding GTAW oe Welding SMAW Temperature Wire Feeder Arc Force DIG won Positive High In Positive Low In ductance Weld ductance Weld 2 Input Output Terminal Output Terminal 1 0 Uns 2 1 Primary Voltage A 2 Load 1 Three Phase Rated Welding A Current Duty Cycle CO HDI Transformer Rectifier Degree Of Suitable For Areas Protective Eanh Of Increased Ground Shock Hazard SECTION 3 INSTALLATION 1 Primary Current 3 1 Specifications Amperes Input at Rated Load Output IP Rated Amperage Max 50 or 60 Hz Three Phase Model Rating Welding Voltage OCV DC V V V V V V V KVA KW 50 815 A 2 VD VDE 650 44 In CC Mode cc Mode 126 77 73 66 63 54 50 4 50 34 8 650 21M Vol
16. cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les consignes mentionn es pr c demment font partie de celles desti n es aux personnes ayant recours un stimulateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails SECTION 2 DEFINITIONS 2 1 General Precautionary Label 1 96 Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arcrays can burn eyes and injure skin Wear hat and safety glasses Use ear protection and button shirt collar Use welding
17. fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 278 Page 18 3 12 Placing Jumper Links And Connecting Input Power 230 VOLTS 460 VOLTS 575 VOLTS GARR Mo coool o o o oo of Ref S 174 973 A 380 VOLTS 400 VOLTS 440 VOLTS AloAAooo ooMoo ooMoo oARooo oo Ref 5 174 975 380 VOLTS 520 VOLTS A o o GND PE Earth Ground Do not overtighten jumper link nuts Connect GND PE Conductor First 6 N 8 Tools Needed gt 3 8 in Connect GND PE C 3 8 in Conductor First E TY ST 800 103 B Ref ST 801 116 Check input voltage available at site 3 Input And Grounding Conductors 6 Grounding Conductor 1 Jumper Link Label See Section 3 11 If unit is equipped with optional ground current B 4 Line Disconnect Device sensor route grounding conductor through my See Section 3 11 reed switch two times and connect to ground 2 5 Reed Switch Ground Current Sensor terminal Move jumper links to match input voltage Optional Close access door OM 278 Page 19 4 1 SECTION 4 OPERATION 1 2 DIG Alam AD nera START ON TAW gt 9 1 0
18. 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 ELECTRIC SHOCK kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual
19. terminal Not Used OM 278 Page 16 3 10 Connecting Remote Control D J A N K L Ld tu REMOTE 115 VAC 24VAC REMOTE GND REMOTE OUTPUT REMOTE REMOTE VOLTAGE POWER ON OFF 5 162 895 B CONTROL CONTACTOR CONTACTOR SENSE 1 Remote 14 Receptacle RC8 Connect remote control to RC8 If plug does not fit wire cord to terminal strip 1T Turn Off power before open ing terminal strip cover 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain Relief Customer Supplied Secure cord in strain relief Reinstall and secure access panel Close door Ref ST 800 170 E Ref 5 0004 5 0750 OM 278 Page 17 3 11 Electrical Service Guide 60 Hz Models 50 Hz Models Input Voltage 230 460 575 380 400 440 520 Input Amperes At Rated Output 126 63 50 4 77 73 66 54 Max Recommended Standard Fuse Rating Amperes 1 Time Delay 2 150 70 60 90 90 80 60 Normal Operating 3 200 90 80 125 110 100 80 Min Input Conductor Size In AWG Kcmil 1 6 6 4 4 4 6 Max Recommended Input Conductor Length In Feet Me 208 328 513 335 371 449 419 ters 64 100 156 102 113 137 128 Min Grounding Conductor Size In AWG Kcmil 6 8 8 6 6 8 8 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class 5 3 Normal Operating general purpose no intentional delay
20. w Components Fig 7 1 Item 30 ere re 159969 22 ELECTRONICS BOX x24 5 50 anne 1 TUR C NEP POL eu 187 834 CIRCUIT CARD control 60HZ 1 TR No POT ness 187 835 CIRCUIT CARD control 50HZ 1 m PLG1 158720 CONNECTOR amp SOCKETS see Fig 7 3 EHRE PLG3 169240 CONNECTOR amp SOCKETS 1 PLG4 148439 CONNECTOR 8 SOCKETS 1 Pe PLG5 152249 CONNECTOR 8 SOCKETS 1 FEE CR erer 052 964 RELAY 24VDC DPDT 1 E ORD uia 006 393 RELAY 24 DPDT 1 T eon eg CB1 2 093 995 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 PA aot asc RC9 604 176 RECEPTACLE str dx 2P3W 15A 125V 1 163 855 CONNECTOR CAPACITOR w leads consisting of 1 didici and RC8 143976 CONNECTOR amp SOCKETS 1 Tm 163863 LEAD ASSEMBLY elect 1 Lad n C6 163861 LEAD ASSEMBLY elect d SDN O13 aus 099 LEAD ASSEMBLY emer dace anc ae EA 125 168 857 a2 LEAD ASSEMBLY el
21. 0 OFF ARC FORCE PROCESS gt A V on O mi L 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use very short arc length without sticking the electrode Set control at 0 for normal welding amper age Turn clockwise to increase short circuit amperage 2 Process Selector Switch 3 Amperage Voltage Adjustment Control When Process Selector switch is in the SMAW GTAW position turn control clock wise to increase amperage Read amperage from outer scale of control When Process Selector switch is in the GMAW position turn control clockwise to increase voltage Volt OM 278 Page 20 Controls Non CE Models A V ADJUST meter value changes as control knob is turned Control can be adjusted while welding 4 Digital Meters With Process Selector switch in the SMAW GTAW position digital meters will read O zero with contactor off Digital meters will display actual output voltage and amperage with contactor on With Process Selector switch in the GMAW position voltmeter displays preset voltage with contactor off Voltmeter and ammeter display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light V voLrs amps High Temp Shutdown ON _POWER Ss orr 6 5 Ref 5 184 939 7 Remote Amperage Voltage Control Switch For fr
22. ES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 278 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront explos
23. Remote Control 17 Electrical Service G de Ev et 17 3 12 Placing Jumper Links And Connecting Input Power 18 SECTION 4 OPEBATION os CER a EAE 19 4 1 Controls Non CE 5 19 422 Controls OE MOdSIS as ad een ao ed eren O 20 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 21 5 T Maintenance omiso theme cres san 21 Ore FUSE a A 21 537 Trouble soo ceu ad SS AS Oe SAM MEM 22 SECTION 6 ELECTRICAL DIAGRAM 23 SECTION 7 PARTS LIST au u en Ha 24 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ds A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols LF Means Note not safety related 1 2 Arc Welding Hazards Thesymbols 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
24. York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 278 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 magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 278 Page 4 1 Keepcables 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 cleare
25. a ee 2 A AE N 010913 WASHER flat 218 ID brs 1 ua DZ cq ecd 038 887 STUD pri bd brs 10 32 x 1 375 1 ELO eg d il Abu ce 011 610 SWITCH tgl SPDT 15A 125VAC 1 m PE S3 4 011 609 SWITCH tgl SPDT 15A 125VAC 2 Ti m au qm 035 897 POTENTIOMETER CP std slot 1 T 2W 1K ohm 1 LL 20 2 5426 178 134 CIRCUIT CARD digital meter 1 OPEM PLG10 153 501 CONNECTOR 8 SOCKETS 1 aa PLG11 148 439 CONNECTOR SOCKETS 1 ENT NOME CR2 116 592 RELAY 24VDC 1 192 174 STANDOFF 225 55 bardas arenas raudales 4 TELA PER Beno EA NAMEPLATE order by model and serial number 1 id des S MM 159 039 SWITCH rocker SPDT 15A 125VAC 1 A ad PLG2 185 626 CONNECTOR body 56 series 1 role Peer 199922 2 LED VOlOW ne varies 1 EU en En diet 159 096 LENS EED Cleat Harn ea 1 T C VN NRI 097 924 KNOB pointer 1 erc 097922 25 KNOB DOME armee m wesc dak E es 1 ave SN1 197868 ASSY
26. acturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 278 Page 30 Mkgs No Description Quantity Figure 7 4 Panel Rear w Components Fig 7 1 Item 18 TD ME 124 275 CHAMBER plenum 14 in 1 E 180 165 BLADE fan 14 in 3wg 23deg 375 bore 1 E are eer eer a 162 807 X PANEL TOA ae i bd eyes bad 1 TL TT 168343 lt x HINGE door primary 22 23 hk ERE ERR a eed 2 TE Ro vu 162 818 DOOR access primary 1 5 uec e EN iuda 168 384 LABEL warning electric 1 E 602 177 SCREW set 250 20 x 250knrlpt sch stl 2 TEE MIU 124 274 BRACKET mtg fan motor 1 eee Re 097 459 RESISTOR WW fxd 375W 20 ohm 1 sn NO Brink FM 116 190 MOTOR 1 12HP 230V 1550RPM 50 60Hz 1 5A 1 C 72 PRC EE Y RE 010467 CONNECTOR clamp cable 1 250 1 LF Hardware is common and not available unless listed ST 800 707 A Figure 7 4 Panel Rear w Components When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufact
27. ances inflammables a une distance de 10 7 m de de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur a proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites a moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le cable sur la piece le plus pres possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil a la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes D
28. c portion of RC8 1T and RC9 from overload CB2 protects 24 volts ac portion of RC8 and 1T from overload Press button to reset breaker Ref ST 800 166 C OM 278 Page 15 3 8 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 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft D 100 ft 30 Or Less 45m 60m 70m 90m 105m 120 A 10 60 Weldin 60 100 connecting to weld output Cycle terminals 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 o9 9 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 pou Negative 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 mE Inductance positive 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Low T Inductance 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 a f T 600
29. d by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles ds ldentifie un message de s curit particulier 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 sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ne font que r sumer l information contenue dans les normes de s curit enumerees la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants TM e 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
30. dage Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds 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 AA Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit la ou des tincelles peuvent tomber sur des substances inflammables D placer toutes les subst
31. e latest full line catalog or distributor Your distributor TP can also supply you with individual catalog sheets To locate your nearest Welding Process Manuals such as SMAW GTAW distributor or service agency call 1 877 1 GMAW and GMAW P WELDING PRODUCTS The following terms used interchangeably throughout this manual MIG GMAW 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 Symbol Usage a Pee maid op 1 152 ALO Welding Hazards 3c mode tram S 2 rers de tas he UE es 1 1 3 Additional Symbols for Installation Operation and Maintenance 3 1 4 Principal Safety Standards 3 1 9 EMP JDIO OF ute do tetto dare tror ad mes ee rode e m ME 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 Signhification des Symboles ES P WE ee xS ae we 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dange
32. ect use near 1 x cc 162 902 PANEL ug ace uice te nae are 1 TRE E IEE EET 161 303 SPRING cprsn 600 OD x 072 wire x 1 500 lg 3 10 POS CC CV 039 047 TERMINAL pwr output red 2 os i eo SEE 02 45 128 750 CAPACITOR cer disc 1uf 500VDC 3 roe VL scie R4 5 136 076 RESISTOR WW fxd 30W 200 2 uoc NEG 039 046 TERMINAL pwr output black 1 LF Hardware is common and not available unless listed ST 800 705 D Figure 7 2 Panel Front w Components Fig 7 1 Item 30 OM 278 Page 28 Mkgs No Description Quantity Figure 7 2 Panel Front w Components Fig 7 1 Item 30 Continued ade eke PER d te 174 937 PLATE control lower 60Hz 1 DAR ETT M 179 389 PLATE control lower 50HZ 1 PERO dT sectas 159040 BLOCK term 20 1 TM PET 162 828 PANEL mtg rcpt terminal strip 1 ul A 070 371 BLANK snap in nyl 1 093 1 125mtg hole 1 TES m 162 891 LABEL warning electric shock 1 oL PEL 160530 4 COVER SUA QUIPUE sis ende 1 ER beeen ee ees 100 989 OLIP Re 3 VELIE THERE 601 890 c NUT 10 92 DIS s 21 11 e
33. er Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentair
34. es en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU DES ORGANES MOBILES peuvent PL D EXPLOSION provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements dispositifs de protection e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LE RAYONNEMENT HAUTE FRE QUENCE risque de provoquer LA CHUTE DE L APPAREIL peut des interf rences blesser e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil dio navigation et de communication les services les de gaz ou tout autre accessoire de s curit et les ordinateurs e Utiliser un engin d une capacit appropri e pour e Demander seulement des personnes qualifi es familiarisees soulever l appareil avec des quipements lectroniques de faire fonctionner l installa e En utilisant des fourches de levage pour d placer l unit s assurer tion que les fourches sont suffisamment longu
35. es pour d passer du c t e Lutilisateur est tenu de faire corriger rapidement par un lectricien oppos de l appareil qualifi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement lappa reil L EMPLOI EXCESSIF peut e Effectuer r guli rement le contr le et l entretien de l installation SURCHAUFFER L EQUIPEMENT 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 interfe e Pr voir une p riode de refroidissement respec rences ventuelles ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e pas obstruer les passages d air du poste LE SOUDAGE L ARC risque de provoquer des interf rences LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s 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 NT A e Veiller ce que tout l quipement de la zone de soudage soit com e Etablir la connexion avec la barrette de terre patible lectromagn tiquement avant de manipuler des cartes ou des pi ces y e Pour r duire la possibilit d interf rence maintenir le
36. helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label 1 2 4 OM 278 Page 9 2 2 Input Connection Label OM 278 Page 10 S 179 290 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring and exposed weld terminals can kill Close door before turning on unit 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect
37. ions and replace if necessary OM 278 Page 23 Notes OM 278 Page 24 SECTION 6 ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion refer to the Circuit Dia gram located inside the wrapper of the welding power source s RC8 BR GR SIL 77 T Jl as T2 BLK YEL YEL GRN 0 Y 000 0 Y Qu BLU WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD 90999 la SRI C10 eu C12 2 CR2 SCR SCR SCR 21 26 13 06000901 N d 3 CONNECTS TO W WHEN GROUND CURRENT SENSE OPTION IS NOT USED 13 gt IN iagram gt SC 196 108 A O POSITIVE HIGH T INDUCTANCE 27 P 22 O POSITIVE LOW INDUCTANCE O NEGATIVE 27 C5 d RC6 MAMA ANN A 37 4 N gt nl PLG N N 7 r 4 1 y lt RC10 1 m F lt 5552 555 L 32V T E Qo amp CE 4 4 gt gt 3 lt lt RC10 5 9 B ALK 43 62 5 RC3 16 PC1 RC4 7 gt gt 35 K lt RC11 5 1 1 gt pm UA RC4 5 gt gt lt lt RC11 2 RC3 PLG3 4 82 gt lt lt 11 8 2 RC4 PLG4 4 6 gt gt
38. irect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province WELDERS hobart 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 Equipment Service and Repair Replacement Parts Training Schools Videos Books
39. mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de facon obtenir bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e soler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev
40. municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine som nd Fre 4 97 Ce groupe de symboles signifie Mise en garde Soyez vigilant a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger e N utiliser qu un
41. n 601995 s NUT 10 92 DIS ne ee de ie io ed A NET NS 159034 HOLDER fus e MINT E sek 1 A Fig 7 4 PANEL rear w components 1 TAS ES EM datos 156 065 FUSE crtg 5A 600V time delay 1 bh Latine ts M ossis 160 794 CONTACTOR def prp 75A 24VAC 1 To CR4 9140750 SWITCH reed 1 VERE ES E E 134 464 LABEL warning general precautionary 2 unb do eee o E BA E ee ee ou e tie 1 189 847 TRANSFORMER pwr main 230 460 575 consisting of 1 TEC Ons bine E eee 169 154 pri sec 230 460 575 center amp RH 2 O ON end 169 153 COIL pri sec 230 460 575 LH 1 vus eas es ethos 189 848 TRANSFORMER pwr main 380 400 440 consisting of 1 A 172 358 pri sec center amp RH 2 172 357 es COIL PSEC EH mead tr waked hae newer aes 1 ae ee T bts 189 849 TRANSFORMER pwr main 380 500 consisting of 1 170313 uidet IUD PI deese 1 ETE SOME PISO NO Z ne oies decent dre cos 2 T TP1 2 175405 THERMOSTAT NC I
42. ncluded w T1 2 m TP4 5 168891 THERMOSTAT NC Included w T1 2 E SE PEGO 168847 CONNECTOR amp SOCKETS 1 TE RCO 168845 CONNECTOR amp PINS 1 uteri gene PLG13 189873 CONNECTOR PINS 1 1 189 874 CONNECTOR amp SOCKETS 1 orc rrr 161 294 BRACKET mtg rectifier 2 Fig 7 2 PANEL front w components 1 PD PE SRI 2s 192671 RECTIFIER si diode Fig 7 3 1 o PLG7 152249 CONNECTOR amp PINS 1 168846 CONNECTOR amp SOCKETS 1 DE ENTRE 010 467 CONNECTOR clamp cable 1 250 1 Part of Option 042983 Ground Current Sensor When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts 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 278 Page 27 Dia Par No Mkgs No Description Quantity Figure 7 2 Panel Front
43. nder True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater A 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Hobart but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s option 1 repair or 2 replacement or where a
44. ntat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases Cylinders CGA Pamphlet 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 1HR3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New
45. ont panel control place switch in Panel position For remote control place switch in Remote position and connect remote de vice see Section 3 10 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 3 10 Weld output studs are energized only when Output switch is in On position or while welding Turn Off power before connecting re mote device 4 2 Controls CE Models 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use a very short arc length without sticking the electrode Set control at 0 for normal welding amper age Turn clockwise to increase short circuit amperage 2 Process Selector Switch 3 Amperage Voltage Adjustment Control When Process Selector switch is in the SMAW GTAW position turn control clock wise to increase amperage Read amperage from outer scale of control When Process Selector switch is the GMAW position turn control clockwise to increase voltage Volt meter value changes as control knob is turned Control can be adjusted while welding 4 Digital Meters With Process Selector switch in the SMAW GTAW position digital meters will read O zero with contactor off Digital meters will display actual output voltage and amperage with contactor on With Process Selec
46. otective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols for Installation Operation and Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e lfusing lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit D Nj STATIC ESD can damage PC boards 3 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 2 SN MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury
47. paces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch 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 pr
48. rom 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 278 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays 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 749 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 Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection f WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 f
49. rs suppl mentaires en relation avec l installation le fonctionnement eria maintenance sei eei isses euim is 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 DEFINITIONS ne da do duos Wa a ics 9 2 1 General Precautionary 9 2 2 Input Connection Label ii 10 2 3 Electric Shock And Airflow Label 0 0 0 22022 10 2 4 Nameplate Safety Symbols 10 2 5 Manufacturers Rating Label For CE Products 11 2 6 Symbols And D finitions e a epu re Rx ROS Od 12 SECTION 3 INSTALLATION ae ei eed ed en 12 2 gt SBECHCAIONS RE aur S rider esum deu irt 12 3 2 Duty Cycle And Overhealing iaces pe te ha 28 a 13 95d VONAMpPere VS 13 9 4 Delecting A Localo rd ied dete da R A 14 9 9 Dimensions ANG eds ana ren 14 Sos IO 15 3 7 115 VAC Receptacle And Circuit Breakers 15 3 8 Weld Output Terminals And Selecting Cable Sizes 16 3 9 Remote 14 Receptacle And Terminal Strip 1T Information 16 3 10 Connecting
50. s cables de e Utiliser des pochettes et des boites antistatiques soudage aussi courts que possible les grouper et les poser aussi pour stocker d placer ou exp dier des cartes de bas que possible ex par terre R RRRS Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre DES ORGANES MOBILES peuvent conform ment ce mode d emploi provoquer des blessures e Encasdinterf rences apr s avoir pris les mesures pr c dentes il incombe a l utilisateur de prendre des mesures suppl mentaires tel e Ne pas s approcher des organes mobiles les que le d placement du poste l utilisation de c bles blind s l uti e Ne pas s approcher des points de coincement lisation de filtres de ligne ou la pose de protecteurs dans la zone de tels que des rouleaux de commande travail LES CHAMPS MAGN TIQUES peuvent LES FILS DE SOUDAGE peuvent pro affecter les stimulateurs cardiaques voquer des blessures e Porteurs de stimulateur cardiaque restez dis e Ne pas appuyer sur la gachette avant d en avoir tance recu l instruction e Les porteurs d un stimulateur cardiaque doivent e Ne pas diriger le pistolet vers soi d autres person d abord consulter leur m decin avant de s appro nes ou toute pi ce m canique en engageant le fil cher des op rations de soudage l arc de gou de soudage geage ou de soudage par points
51. t 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding a FLYING METAL can injure eyes 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 278 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined s
52. tor switch in the GMAW position voltmeter displays preset voltage with contactor off Voltmeter and ammeter display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light 6 5 Ref 5 184 936 7 Remote Amperage Voltage Control Switch For front panel control place switch in Panel position For remote control place switch in Remote position and connect remote de vice see Section 3 10 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 3 10 Weld output studs energized only when Output switch is in On position or while welding Turn Off power before connecting re mote device OM 278 Page 21 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance Disconnect power before maintaining 3 Months Replace Repair or Clean and unreadable replace tighten weld labels cracked weld terminals cable 6 Months Blow out or vacuum inside During heavy service clean monthly 5 2 Fuse F1 Turn Off power before open ing rear access door 1 Fuse F1 See Parts List For Rating Fuse F1 protects control transform er from overload If F1 opens weld ou
53. tput and fan motor stops Re place F1 Tools Needed TRE 3 8 in Ref ST 800 101 OM 278 Page 22 5 3 Troubleshooting Trouble Remedy No weld output unit completely inoperative pilot light PL1 off Place line disconnect device in On position see Section 3 12 Check for open line fuse s and replace if open see Section 3 12 Check for proper input power connections see Section 3 12 Check for proper jumper link position see Section 3 12 Check fuse F1 and replace if necessary see Section 5 2 No weld output pilot light PL1 on Unit overheated Allow unit to cool with fan On see Section 3 2 If using remote control place Output Contactor switch in Remote 14 position and connect remote control see Sections 3 9 and 3 10 If remote is not being used place switch in On position see Section 4 1 Check repair or replace remote control Limited weld output and low open circuit voltage Check position of Remote Amperage Voltage Control switch see Section 4 1 Check for open line fuse s and replace if open See Section 3 12 Check for proper input power connections see Section 3 12 Check for proper jumper link position see Section 3 12 Clean and tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1
54. ts DC 3 8 19 1 8 1 6 1 9 1 1 14 1 52 0 76 Amp 100 Duty 70 66 VDC Cycle 10 65 V In In CV Mode CV Mode While idling Indicates specification differences for CE models OM 278 Page 12 3 2 Duty Cycle And Overheating RATED OUTPUT MODEL Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding Exceeding duty cycle damage unit and void warranty 60 70 80 90 100 4 DUTY CYCLE 100 Duty Cycle Continuous Welding gt M1 Minutes Overheating OR Reduce Duty Cycle duty1 4 95 Ref SA 168 918 3 3 Volt Ampere Curves Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown A CC Mode B CV Mode TII T L L T L EN IE Mers DC VOLTS DC VOLTS mlARC FORCE N AY We 0 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES 100 200 300 400 500 600 700 800 900 100 DC AMPERES va_curvei 4 95 ST 168 916 ST 168 917 OM 278 Page 13 3 4 Selecting A Location Movement Location And Airflow INPUT SERIAL NO 5 STOCK NO VOLTS ES
55. urer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 278 Page 31 Notes Warranty Questions Call 1 877 HOBART 1 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART WARRANTY Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart must be notified in writing within thirty
56. usamos GA ws aie OG e oe ma 2 E x 1629 mure 1 TURPE 604 536 SCREW 312 18 x 1 750hexhd gr 5 2 m V77 279 25 GASKET MIEY lt aco wk nance a 1 ux qe 173005 e BRAGIET nig EEM ausser res 1 SUPE HD1 168 829 TRANSDUCER current 1000A module 1 etd PLG14 115094 CONNECTOR 8 SOCKETS 1 cp 164 717 BUS BAR stab jumper 1 Zl ik 1980 068 STABIEIZER zn 1 C21 23 163 906 CAPACITOR 50 and 60Hz 3 os gt mo etii e 159042 TRANSFORMER control 50VA 24V 230 460 575 60Hz 1 PAU NM Ts 159 043 TRANSFORMER control 50VA 24V 380 400 440 50Hz 1 He le noce e EE 177264 TRANSFORMER control 50VA 24V 380 520 2 1 te 159 244 PRIMARY BOX consisting of 1 601 835 2035 NUT 10 32 DIS ee hte He ARA 24 PE m 038 887 STUD pri Dd brs 10 982 x 1 375 gianh bebe eR ERR 24 tao ean 038 618 LINK jumper term bd pri 8 E 010 913 WASHER flat 218 ID brs 24 a e
57. uthorized 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 implied warranty lasts or the exclusion of incidental ind
58. when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing 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 f
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