OM-259 177 743K September 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Cyber Pro 302, And 252TS Models
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.
TABLE OF CONTENTS 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 & Safety Code Section 25249.5 et seq.) The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW SECTION 1 – SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . .
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. 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. 1-2.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
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 electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding 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 Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Output OpenCircuit Voltage Range DC 250 Amp 250 A @ 35 Volts DC, 100% Duty Cycle 300 Amp 300 A @ 32 Volts DC, 100% Duty Cycle Model Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase 200 V 220 V 230 V 380 V 400 V 440 V 460 V 520 V 575 V KVA KW 14–44 34.5 1.7* –– 30 1.4* –– –– –– 15 0.7* –– –– 11.9 0.57* 11.2 0.42* 14–44 38 3* 34.5 2.8* 33 2.7* 20 1.9* 19 1.6* 17.3 1.5* 16.5 1.4* 14.6 1.1* 13.0 0.
2-3. Volt-Ampere Curves A. 250 Ampere Models Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. B.
2-4. Dimensions And Weights C Dimensions D E 4 Holes Height 27-1/4 in (692 mm) 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 A Weight B 320 lb (145 kg) ST-801 530 2-5. Selecting A Location 1 Tipping Movement Rating Label Use rating label to determine input power needs. Label located under front access door. 2 Y Do not move or operate unit where it could tip.
2-6. Typical MIG Process Connections Using A Constant Speed Wire Feeder Y 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. 14-Pin Interconnecting Cord Regulator/ Flowmeter Constant Speed Wire Feeder Constant Voltage (CV) Welding Power Source Constant speed wire feeders are used with constant voltage (CV) power sources having a 14-pin receptacle. .
2-8. Slope Selection (250 Ampere Model) 1 2 Slope Connection Label Tapped Reactor AC-Z And Slope Coils Tapped reactor AC-Z is factory connected to slope tap 8 which is suitable 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 number.
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 increase inductance and wet out the weld puddle, connect to stabilizer Z ending. To change inductance proceed as follows: 2 3 4 5 Lead 25 Stabilizer Z Tap Stabilizer Z Ending Lead 26 To increase inductance, connect lead 26 to stabilizer ending and secure. Reinstall side panel.
2-10. Weld Output Terminals And Selecting Cable Sizes Y 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.
2-12. Connecting To 115 Volts AC Duplex Receptacle 1 3 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and remote 14 receptacle RC8. 2 2 3 Circuit Breaker CB1 Circuit Breaker CB2 CB1 protects 115 volts ac portion of RC8 and RC9 from overload. 1 CB2 protects 24 volts ac portion of RC8 from overload. Press button to reset breaker. Ref. ST-801 380-B 2-13.
2-14. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Link Move jumper links to match input voltage, and label on unit. 2 3 200 VOLTS 230 VOLTS 460 VOLTS Input And Grounding Conductors See Section 2-13. L1 L2 L3 L1 L2 L3 L1 L2 L3 S-072 135-B 4 Line Disconnect Device See Section 2-13. 220 VOLTS L1 L2 L3 400 VOLTS 440 VOLTS L1 L2 L3 L1 L2 L3 Close access door.
SECTION 3 – OPERATION 3-1. Controls 1 2 Power Switch Pilot Light Light is on when power is On. 3 5 Preset Indicator Light When light is on, the voltmeter displays preset welding voltage as selected by the Voltage Adjustment control. 6 1 2 When light is off, the voltmeter displays actual welding voltage while welding. 3 Y Weld output terminals are energized only when the preset indicator light is Off. 4 4 5 6 Voltage Adjustment Control Voltmeter Ammeter Ref.
4-2. Troubleshooting Trouble Completely inoperative; fan does not run. Remedy 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).
SECTION 5 – ELECTRICAL DIAGRAMS SB-183 958-A Figure 5-1. Circuit Diagram For 250 Ampere Model For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside the wrapper of the welding power source. Figure 5-2.
Notes OM-259 Page 21
OM-259 Page 22 12 3 13 14 15 11 2 10 4 9 6 Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly . . . 1 . . . . . . . . . . . . . 134 464 . . LABEL, warning general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 179 430 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 179 429 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly (Continued) . . . 36 . . . . . . . . . . . . . ................... . . . 37 . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . 180 666 162 891 190 104 201 065 .. .. .. .. BRACKET, mtg PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLUMN, brush rigging . . . . . . . . .
12 11 10 9 8 7 5 14 6 13 15 4 16 3 17 5 18 2 19 20 21 1 2 22 Ref. 802 497 Figure 6-2.
5 6 4 3 7 2 1 8 10 9 Figure 6-3. Rectifier Assembly Item No. Dia. Mkgs. Part No. Ref. 802 497 Description Figure 6-3. Panel, Front w/Components (Figure 6-1 Item 17) ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 ............. ............. . . . TP1 . . . . . ............. . . PLG1 . . . . . SCR1-3 . . . ............. . R1, VR1 . . . . . . D1-4 . . . . . . . C1-6 . . . . OM-259 Page 26 022 285 087 461 165 670 024 241 158 720 180 456 195 790 083 420 037 956 031 689 .... ....
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. 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.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Contact your Distributor for: Welding Supplies and Consumables Call 1-877-Hobart1 or visit our website at www.HobartWelders.