Hobart Welding Products 252TS Welder User Manual
Contents
1. Voltage Adjustment Control Voltmeter Ammeter Ref ST 801 380 B SECTION 4 MAINTENANCE amp TROUBLESHOOTING 4 1 Routine Maintenance A Disconnect power EF Maintain more often before maintaining during severe conditions 3 Months Replace Repair Or Clean And Damaged Or Replace Tighten Unreadable Cracked Weld Labels Cables And Terminals Cords Blow Out Or Vacuum Inside OM 259 Page 18 4 2 Troubleshooting Trouble Remedy Completely inoperative fan does not run Place line disconnect switch in the On position Check and replace open line fuse s see Section 2 13 Check for proper jumper link positions See Section 2 14 Check for proper input connections see Section 2 14 No weld output fan motor FM running Reset circuit breakers CB1 and or CB2 if necessary see Section 2 12 Unit overheated Allow unit to cool with fan on see Section 2 2 Have Factory Authorized Service Agent check control relay CR1 Excessive line current line fuse s and or circuit Check for proper input connections see Section 2 14 breaker s open repeatedly Check for proper jumper link positions see Section 2 14 Weld output available fan does not run Check for and remove anything blocking fan blades Have Factory Authorized Service Agent check fan motor FM Fan runs slowly Check for proper jumper lin2. K G A l J B 4T lt RC4 Le m CR2 2 lt RC2 4 RC2 3 SS o SB 183 958 A Figure 5 1 Circuit Diagram For 250 Ampere Model 230 460 230 200V au 7 RCE IA LT re 4 E E CET Laa ul J ti AE a 000 000 000 000 Mi Es E lt RC1 3 eu RC2 4 gt X RC1 4 lt RC1 5 NE lt RC1 6 RC2 3 gt 33 lt RC1 8 C4 life lt RC1 7 RC2 2 gt CR1 2 v Ci lt RC2 1 Di BEER e las 34 TPI CR2 CR2 fi 01 9 10 06 9 9 m a en cm gt For Primary Circuit Diagram Portion refer to Circuit Diagram located inside the wrapper of the welding power source Poste NEGATIVE SB 183 959 Figure 5 2 Circuit Diagram For 300 Ampere Models OM 259 Page 20 Notes OM 259 Page 21 SECTION 6 PARTS LIST Fig 6 2 28 801 383 F Figure 6 1 Complete Assembly OM 259 Page 22 Item Dia Par No Mkgs No Description Quantity Figure 6 1 Complete Assembly E wn 134 464 LABEL warning general 2 Eo quM TET 179 43045 PANEL SIOO ido A enr Rt tae EHE dr ori RE eu c ees 2 M MD 173429 COVER TOD eid nho tica ate aia sede a ads ti ERE Rot a acts dc ee 1 To nm Ir ike OIE IBS Br cau tetuer dutdodtisd re auk Sod eee eae 1 bu uui c atis 1020930 DIERON A ato arb a ERU 1 ME eique 19282045 BAR MIG MI GV are aub ede iicet XC Gene ab aen rica da av ita 2 T ac T 038 138 TERMINAL ASSEMBLY pri consisting of 1 VIV
3. 2 Jumper Link Move jumper links to match input voltage and label on unit gt Nar 3 Input And Grounding 460 VOLTS Conductors See Section 2 13 4 Line Disconnect Device 2 o office o o ofA o 2 14 Placing Jumper Links And Connecting Input Power See Section 2 13 Close access door 230 VOLTS EMA A L1 L2 L3 S 072 135 B ARA 200 VOLTS fe AR A o gt A A o AR f Y A L1 L2 9 L3 L1 L2 L3 220 VOLTS 400 VOLTS 440 VOLTS A o gt AR fe AR A o gt AA o o Ao o oo A o o oo A o o offic o o oo o o o Ido oo Lie L26 L3 6 Lie L26 L3 Lie L20 L3 S 177 581 520 VOLTS ooo Ao o o offo o oo Alo LI LZ L3 S 177 582 380 VOLTS o o lo o o o AA o o oo A o o Lio L20 L3 575 VOLTS 000000 000000 000000 THIS MACHINE DOES NOT REQUIRE coco SUPPLIED JUMPER LINKS 1 AIR QC LEN ll Lu V E RUE y L3 i A Always connect grounding conductor first 2 GND PE CLEO 3 8 1 2 in ST 801 382 OM 259 Page 17 SECTION 3 OPERATION 3 1 Controls 1 Power Switch 2 Pilot Light Light is on when power is On 3 Preset Indicator Light When light is on the voltmeter displays preset welding voltage as selected by the Voltage Adjustment control When light is off the voltmeter displays actual welding voltage while welding A Weld output terminals are energized only when the preset indicator light is Off
4. Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Hobart but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s option 1 repair or 2 replacement or where authorized in writing by Hobart in appropriate cases 3 the reasonable cost of repair or replacement at 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 b
5. ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine som nd fre 4 98 Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures prendre pour viter tout danger e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de fa on obtenir un 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 isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU
6. 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 A 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 tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv
7. Operating 3 50 45 20 60 50 25 20 Min Input Conductor Size In AWG Kcmil 8 10 14 8 8 12 14 eo Input Conductor Length In Feet 446 35 100 31 157 48 105 32 139 42 221 67 223 68 Min Grounding Conductor Size In AWG Kcmil 10 10 14 10 10 12 14 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 50 Hertz Models 300 Amp Model Input Voltage 220 380 400 440 520 Input Amperes At Rated Output 34 5 20 19 17 3 14 6 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 40 25 20 20 15 Normal Operating 3 50 30 30 25 20 Min Input Conductor Size In AWG Kcmil 8 12 12 12 14 Max Recommended Input Conductor Length In Feet Meters A D n es Min Grounding Conductor Size In AWG Kcmil 10 12 12 12 14 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 259 Page 16 Check input voltage available at site 1 Jumper Link Label Check label only one is on unit
8. Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e 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 equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically c
9. Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART WARRANTY Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart must be notified in writing within thirty 30 days of such defect or failure at which time Hobart will provide instructions on the 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 th
10. approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 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
11. 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 If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING INN e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit Le STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 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
12. isoler 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 acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d 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
13. properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy Shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding a FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 259 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear
14. 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 259 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 cleared 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
15. 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 259 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l 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 c
16. your local to receive the latest full line catalog or er 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 Hobartl GMAW and GMAW P WELDING PRODUCTS 44 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 The following terms are used interchangeably throughout this manual TIG GTAW Stick SMAW TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS 1 1 1 Symbol USAGES isn at dd md Ps ni d sce ao pant eeu dai d 1 122 ALO Welding Hazards i id iS o Ride e aod vas eid lan 1 1 3 Additional Symbols for Installation Operation and Maintenance 3 1 4 Principal Safety Standards 2 3 1 9 lt EMP IHIORNAllON u sr ae Sie eat ad ee had Geeta ee 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 15 Sighilication des Symboles sa E rie ue ROS EH Ae REIR MESS Meee ME ae 5 1 2 Dangers relatifs au soudage l arc lille eh 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement eka Man
17. 0 357 A 2 7 Typical MIG Process Connections Using A Voltage Sensing Wire Feeder Work Clamp Voltage Sensing Clamp OM 259 Page 12 Constant Current CC Or Constant Voltage CV Power Source Voltage Sensing Wire Feeder Electrode Lead Work Lead A 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 Voltage sensing wire feeders are used with constant current CC or constant voltage CV power sources 14 pin receptacle not re quired If using a CC welding power source without a weld output contactor use optional secondary contactor For GMAW use optional gas valve 802 488 2 8 Slope Selection 250 Ampere Model 1 Slope Connection Label 2 Tapped Reactor AC Z And Slope Coils Tapped reactor AC Z is factory con nected to slope tap 8 which is suit able for most GMAW applications AC Z controls the inductance applied to the weld current To increase inductance and wet out the weld puddle connect to a higher tap number To stiffen the weld puddle connect to a lower tap num ber 3 Leads 70 71 and 72 With Pressure Connectors Slide pressure connectors onto the same tap of each coil and secure them An unbalanced secondary current can damage the main transformer and cause errat ic weld conditions Be sure leads 70 71 and 72 are con nected to the same numbered slo
18. 4 0 3 3 0 3 3 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 2 11 Remote 14 Receptacle Information S 0007 E LA remore 14 Socket Socket Information A 24 volts ac Protected by circuit breaker CB2 B Contact closure to A completes 24 volts ac contactor control circuit OUTPUT 115 volts 15 amperes 60 Hz ac Protected by circuit breaker CB1 CONTACTOR ojo FEEDER J Contact closure to I completes 115 volts ac contactor control circuit G Circuit common for 24 and 115 volts ac circuits K Chassis common The remaining sockets are not used OM 259 Page 15 2 12 Connecting To 115 Volts AC Duplex Receptacle 2 13 Electrical Service Guide y remote 14 receptacle RC8 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts ac portion of RC8 and RC9 from overload CB2 protects 24 volts ac portion of RC8 from overload Press button to reset breaker Ref ST 801 380 B 60 Hertz Models 250 Amp Model 300 Amp Model Input Voltage 200 230 460 200 230 460 575 Input Amperes At Rated Output 34 5 30 15 38 33 16 5 13 Max Recommended Standard Fuse Rating In Am peres Time Delay 40 35 15 45 40 20 15 Normal
19. 50 Amp Volts DC 100 14 44 Zo xs flrs ee Ps E em A Dc E 17 14 0 7 0 57 0 42 300 A 32 38 345 33 20 19 173 165 146 130 13 1 123 SOON MOMS DE OO rede 3 28 27 49 16 1 5 14 14 0 7 0 97 0 68 Duty Cycle While idling 2 2 Duty Cycle And Overheating 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 can damage unit and void warranty 100 Duty Cycle YN Lu Y Li Q lt O m 25 30 40 50 60 A DUTY CYCLE Overheatin g VIL TENE S Minutes Reduce Duty Cycle Continuous Welding duty1 4 95 Ref SA 177 714 B OM 259 Page 9 2 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 250 Ampere Models 50 p MAX VOLTAGE DFC VOLIS 50 100 150 200 250 300 D C AMPERES B 300 Ampere Models 50 40 SE 20 DE VOLTS 10 O sg A00 deg 200 2230 04 SOU 00 4256 DC AMPERES va_curvei 4 95 SA 180 902 SA 180 901 B OM 259 Page 10 2 4 Dimensions And Weights Dimensions E Height 27 1 4
20. AS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir fe
21. DoHnzotntal 42 uet ce o tem RO ee saad RU eh 2 D SM E EUM M 190 100 HOLDER brush assembly consisting of 3 R PEE ETE DO 190 108822 HOLDER DEUS sr ee nie aa ee ee ARS al 190 107 BRUSH SET contact elect 1 sic PA S LEA A Aa decent 190 106 RETAINER brush holder eoa oe eed aaa I WU CERT 019 606 os OP RING CDESDC ser rene borer diu oc teure Rs iO TOES 190105 ess SPACER brusn holder ria 2 ois CO Gh bane E acto diat FRONT PANEL ASSEMBLY Figure 6 2 1 es El assu 187 664 TRANSFORMER main power 200 230 460 consisting of 1 ESS PAR eh 176 602 COIL pri sec 200 230 460 No 3 bottom 1 Ec e See ee ee 176 601 COIL pri sec 200 230 460 No 2 center 1 ipd ir a ie 176 600 COIL pri sec 200 230 460 No 1 top 1 29 Tite 187 667 TRANSFORMER main power 220 400 440 302 models CONSISUNO O out dco hh a BBE ane tie ses terne aw s 1 za d Mii te toda RO 176 770 COIL pri sec 220 380 415 No 3 bottom 1 UM de sue 176 769 COIL pri sec 220 380 415 No 2 center 1 pe tue ee a 176 767 COIL pri sec 220 380 415 No 1 top 1 29 Ti us 187 666 TRANSFORMER main power 380 520 302 models CORSISUNO OT it Dn eie dedo orae dodo Diesen 1 PRE
22. OM 259 177 743K September 2000 Processes MIG GMAW Welding Flux Cored FCAW Welding WELDING PRODUCTS Description 2i E3 22 Arc Welding Power Source Cyber Pro 302 And 252TS Models 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 W 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 a bd 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 REGISTEHED 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
23. ORDERING REPLACEMENT PARTS Item Dia Part No Mkgs No Description Figure 6 2 Panel Front w Components Figure 6 1 Item 28 CE A 184 112 2 PRONISPABNEL sti a 1 a i 181 246 TERMINAL power output black 1 RC ee 161 303 SPRING CEPSA 000 ODK 072 an a ia ed ox IEEE eed 3 pP ied Lie 128 756 SWITCH tgl 3PST 40A 600V 1 born 2 bata tp REINER 181 245 TERMINAL power output red 1 Tm Emm NAMEPLATE order by model and serial number 1 7 CR1 110 386 RELAY enel 24VAC DEDO Tiida tet ica acacia ed Stace dettes 1 8 ORZ aii 186 162 RELAY enel 120VAC DPDT 1 9 H2 visis 114 050 RESISTOR WW fxd 10W 1K ohm 1 10 RC8 143 976 2 RECEPTACLE amp SOCKETS du kui pheux ee ees 1 Wese ROY rores 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 12 CB1 2 093 995 CIRCUIT BREAKER man reset IP 15A 250VAC 2 Aa 176692 avec DAR PENA sto en AA 1 119 005 METER amp DC 50MV 0 400 1 uu ECC ce 118 902 METER volt DG 0 50 ser ea 16 PEL 163 562 LIGHT ind wht lens 115VAC d ese dE eus 074 188 LIGHT ind red lens 115VAC n PCM PE 172 587 OOVER SUO QUIE
24. UPPER 099 619 x ce JUMPERB INK aeos e acre Madey ead added ios eoe nasci a T PM dc 116 190 MOTOR fan 1 12HP 230V 1550R 1 ER ee REN 124 274 BRACKET mtg fan motor 1 bs lO esd Ses buts 173 293 5 CHAMBER Denim mirra the and dunce RA Gat ea ee ew E 1 lacs cu 180 165 BLADE fan 14 000 3wg 28D 1 E AA 162 807 r PANEL TER nessa eat lad neat heen nea demie eh am c maine 1 Ed anaes cama se 168948 MINGE v Sate dia ES ia Stone dau 2 o ad 162 818 DOOR access primary 1 AS 168 384 LABEL warning electric shock 1 MS 201 403 BRACKET mtg rectifier 2 17 2 ORT enes 180 198 RECTIFIER assembly Figure 6 3 1 Otal 1957992 ASSEMBLY SUN ERES ad 1 el teten 1029 10 CHANNEL UPON a en ni 4 A tite TOO SR BAS Eoi nn de dot a ee an ee rere ee ut 1 po 190 101 RIGGING ASSEMBLY brush consisting of 1 DL Se EE RE 176 635 BRACKET mtg vertical 2 mE 187 677 BRACKET mtg horizontal 4 vods iiia mou 20140066 SCREW lead W ClOS nn ae 1 mo En 190 102 MOUNTING bd brush holder 1 OU PRI le ton ware EE 187 0678 BARS Tame
25. a nn 176 666 COIL pri sec 380 520 No 3 bottom 1 c E 176 665 COIL pri sec 380 520 No 2 center 1 Ns ge dieu 176 664 COIL pri sec 380 520 No 1 top 1 I Pl 187 665 TRANSFORMER power main 575V 302 model consisting of 1 Lud sot ston sede 183 188 COIL pri sec 575 No 3 bottom 1 D A 183 187 COIL pri sec 575 No 2 center 1 BER HEP 183 186 COIL pri sec 575 No 1 top 1 cod 187 682 BAR mtg transformer 1 345 POT 180 264 CIRCUIT CARD MING scr dd 1 m 134 201 STAND OFF SUPPORT pc card 4 35 A 177 336 REACTOR 252 model 1 Reco PR RE 036 585 STABILIZER 302 models 1 OM 259 Page 23 Item Dia Part No Mkgs No Description Quantity Figure 6 1 Complete Assembly Continued ICh A 180 666 ic BRACKET mto PO board san ee 1 T 162 891 LABEL warning electric shock 7 E 190 104 COLUMN brush rigging 1 MEC DM EAA 201 065 RING rtng ext 500 shaft x 042 thk E style 2 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN
26. an E due 18 Delo GONO vig ats a ete tre eae A MET DIE dr 18 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 18 4 1 Routine Maintenance 424220 18 4 22 JTROUDIGSHOOHDG susce DR MR ie sd UR eua e ER EDS ee hd is Ree te 19 SECTION 5 EEECTRICAL DIAGRAMS 5 5 kr 2 EE ne tier eee NE e 20 SECHONS PARIS LIST zei eive rudi a EE FER EIU T die 22 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 C7 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 A During operation keep everybody especially children away TEN ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the outp
27. ard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re 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 quenc
28. aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 259 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 Stand
29. e F O B Factory at Appleton Wisconsin or F O B at a Hobart authorized service facility as determined by Hobart Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This 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 ex
30. e original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Hobart Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a 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
31. e 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 259 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INSTALLATION 2 1 Specifications Open Amperes Input at Rated Load Output 50 or 60 Hz Three Phase Rated Circuit Weldin Model utut Hands 200 220 230 380 400 440 460 520 575 kva kw DC V V V V V V V V V 250 35 34 5 30 15 119 112 2
32. e wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 4 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gase
33. erature Or Nearest Dealer Call 1 877 Hobart1 WELDING PRODUCTS
34. es ir near oe Sri du E Ap Scu qui aD p Sese AM P 162 891 LABEL electric shock and reduced ari flow A 009 433 HANDLE current control viii ra elles ns 009 926 PIN handle current control PR dede io 160 935 A A ie le seine OM 259 Page 24 Figure 6 2 Panel Front w Components OM 259 Page 25 Item Dia Par No Mkgs No Description Figure 6 3 Panel Front w Components Figure 6 1 Item 17 A 022 285 MOUNTING BOARD rectifier nC acia 057 4261 ass MEAT SINK as rr aid e 539 wu ET 165 670 THERMOSTAT NC open 300F bb sd Ka eee AS dae 024 241 22 25 ANGELE IMG ten sea DR dre le des res 5 PLG1 158 720 CONNECTOR amp SOCKETS 6 SCH1 3 180 456 THYRISTOR SCR 175 A30 Tom 195 790 ASSEMBLY BRACKET rectifier 8 R1 VH1 083 420 SUPPRESSOR rect 9 Dt 4 037 956 DIODE TEC 2 75A GOON suas ir ib dose dace cede CR OM 259 Page 26 031 689 Figure 6 3 Rectifier Assembly CAPACITOR CET ASC ea ER Ao oe CIL ct D CR etd Ref 802 497 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
35. f filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash 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 AIZ WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a 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
36. h Stabilizer Connection Use the end Stabilizer connection to reduce weld bead crowning and spread the weld puddle A A Weld Bead Using The Tap Stabilizer Weld Bead Using The End Stabilizer Connection With 17 Volts 100 Amps Connection With 17 Volts 100 Amps J 3 8 7 16 in C H0 3 8 in ST 801 379 B OM 259 Page 14 2 10 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 Y Total Cable Copper Length In Weld Circuit Not Exceeding NUI OE TESS Ea am an a a Us us 50 m Lo Z O Connecting wold Welding Duy Duy 10 100 Duty Cycle Cycle Cycle 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 0 250 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 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2
37. in 692 mm edles Width 22 1 4 in 565 mm Depth 28 1 4 in 717 mm A 27 1 2 in 698 mm B 3 4 in 19 mm C 21 1 8 in 537 mm D 1 1 8 in 29 mm E 7 16 in 11 mm Dia Weight rentes 320 Ib 145 kg 1 Rating Label Use rating label to determine input power needs Label located under front access door 2 Line Disconnect Device A Do not move or operate unit Locate unit near correct input where it could tip power supply Movement Tipping Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location And Airflow INPUT SERIAL NO STOCK NO VOLTS AMPERES KW Ref ST 801 378 B OM 259 Page 11 2 6 Typical MIG Process Connections Using A Constant Speed Wire Feeder Constant Speed Wire Feeder Workpiece a a Work Clamp 14 Pin Interconnecting Cord Regulator Constant Flowmeter Voltage T CV Welding Power Source O O Shielding Gas When Required Electrode Lead Work Lead A 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 Constant speed wire feeders are used with constant voltage CV power sources having a 14 pin re ceptacle For flux cored welding FCAW contact welding wire manufacture for polarity rec ommendations mig 9 99 Ref ST 80
38. ir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement 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 P
39. k positions see Section 2 14 Limited output and low open circuit voltage Check and replace open line fuse s see Section 2 13 Check for proper input connections see Section 2 14 Check for proper jumper link positions see Section 2 14 Erratic or improper weld output Check for proper jumper link positions See Section 2 14 Check for proper input connections see Section 2 14 Select correct size weld cables See Section 2 10 Clean and tighten weld cable connections see Section 2 10 Have Factory Authorized Service Agent adjust brush contact on slide wire For 250 ampere models check tap slope connections see Section 2 8 For 300 ampere models check inductance connections see Section 2 9 Install wire feeder according to it s Owner s Manual No 115 volts ac output at Remote 14 receptacle RC8 Reset circuit breaker CB1 if necessary see Section 2 12 No 24 volts ac output at Remote 14 receptacle RC8 Reset circuit breaker CB2 if necessary see Section 2 12 OM 259 Page 19 SECTION 5 ELECTRICAL DIAGRAMS GND 230 460 230 m TORORO FREI a ciii m a tte tt a e au LE d deua ITTY 00010 05000 00010 UU MEAE POS E Le 70 aos ee a a y IO O E O PS IN TIR IN TT RR EB AEST DE D TT ale a pp BR pP E as 10T lt K RC7 e 2 gr lt ROS RC2 1 7 A GT L lt lt RCS RC2 2 gt ol rez
40. n 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 Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin 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 Ten
41. ompatible 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 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 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 259 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
42. pe turn tap on each coil See slope connection label Firing Board PC1 Receptacle RC2 Lead 36 Receptacles RC3 Through RC6 Connect lead 36 from RC2 to correct receptacle RC4 RC5 RC6 or RC7 to match tap slope connec tions made in Section A as follows RC3 300A Used With 300A Mod els Only RCA for 4 turns RC5 for 6 turns RC6 for 8 turns RC7 for 10 turns Reinstall right side panel NOORA SLOPE TURNS IMPORTANT Be sure connections are clean before reconnecting tap IMPORTANT Move friction lug on PC1 to correct tab to insure proper TAP SLOPE CONNECTIONS operation of voltmeter preset S 177 763 B TTC pin CORO 38 in Ref ST 801 518 A OM 259 Page 13 2 9 Inductance Selection 300 Ampere Models 1 Stabilizer Z Tapped stabilizer Z is factory connected to the stabilizer tap which suits most GMAW applications Stabilizer Z controls the inductance applied to the weld current To in crease inductance and wet out the weld puddle connect to stabilizer Z ending To change inductance proceed as follows 2 Lead25 3 Stabilizer Z Tap 4 Stabilizer Z Ending 5 Lead 26 To increase inductance connect lead 26 to stabilizer ending and secure Reinstall side panel 6 Typical Weld Bead Using The Tap Stabilizer Connection Use the tap Stabilizer connection to obtain arc type and weld bead suit able for some mild steel applica tions 7 Typical Weld Bead Using The End Hig
43. rm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appa reil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage
44. s Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 259 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays mF burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade o
45. symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants RN e UN CHOC LECTRIQUE peut tuer R Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension des que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr 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 S
46. tenan s xeu a me Prep SERE a M ERR EE M RV SI Mit 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 INSTAELATION 54 44 1 Ba a 9 Aske SDCCIICANONS uci ae Rasen ERAS stress Penh eee eee ee 9 2 2 Duty Cycle And Overheating 2 nennen 9 2 3 Moll Ampere CUIVES reas dd me Ses d ac goa dare od de ee eae a 10 ed Dimensions And Wege uid Creer sn Rt ret oderat nidi PEE ride Tas ad 11 2 5 SBlEclIng A Loca lOs raras dass de x Eb E eae ae ae anew ads 11 2 6 Typical MIG Process Connections Using A Constant Speed Wire Feeder 12 2 7 Typical MIG Process Connections Using A Voltage Sensing Wire Feeder 12 2 8 Slope Selection 250 Ampere Model 13 2 9 Inductance Selection 300 Ampere Models 14 2 10 Weld Output Terminals And Selecting Cable Sizes 15 2 11 Remote 14 Receptacle Information 2 15 2 12 Connecting To 115 Volts AC Duplex Receptacle 16 2 19 Electrical Service Guide iss aaa a Ra e m y be ee a E qas 16 2 14 Placing Jumper Links And Connecting Input Power 17 SECTION 3 OPRERATION 4 25 52 ba cae sedate
47. tent 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 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 Lit
48. ue des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment a AWS F4 1 voir les normes de s curit Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 259 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 no
49. uir 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 wu Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur a proxi mite 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 q
50. ut is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bar
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