User manual

ManualsBrandsHobart Welding Products ManualsWelding SystemWelding System 302

Cyber Flex

Processes

302 and 452 Models

Multiprocess Welding

Description

Arc Welding Power Source

OM-277 163 768V

June 2000

Summary of content (40 pages)

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OM-277 163 768V June 2000 Processes Multiprocess Welding Description Arc Welding Power Source Cyber Flex 302 and 452 Models
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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.
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TABLE OF CONTENTS The following terms are 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 & Safety Code Section 25249.5 et seq.) SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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.
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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.
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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.
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 1. Keep cables close together by twisting or taping them. Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_Fre 4/97 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.
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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.
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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.
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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.
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SECTION 2 – DEFINITIONS 2-1. General Precautionary Label 1/96 Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1.3 1 1.1 1.3 1.2 2 2.1 2.2 2 2.1 2.2 2.3 2.3 3 3.1 3.2 3 3.1 3.2 3.3 3.3 4 4 4.1 4.1 + + + 5 5 6 6 + 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.
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2-2. Input Connection Label 1 1/96 2 3 4 1 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.
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2-5. Manufacturer’s Rating Labels For CE Products Match label to one on unit. See Section 3-4. 2-6. Symbols And Definitions NOTE A U0 I1 IP S Some symbols are found only on CE products.
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SECTION 3 – INSTALLATION 3-1. Specifications Model 300 Amp 450 Amp IP Rating Rated Welding Output 21M 300 A @ 32 (29) Volts DC, 100% Duty Cycle 21M 450 A @ 38 (36.5) Volts DC, 100% Duty Cycle Amperage/ Voltage Range Max OCV–DC 15 – 375A In CC Mode Amperes Input at Rated Load Output 50 or 60 Hz, Three-Phase 200 V 230 V 380 V 400 V 440 V 460 V 520 V 575 V KVA KW 60 VDC In CC Mode 57.5 4.0* 50 3.5* 30 1.5* 28 1.4* 26 1.3* 25 1.8* -- 20 1.4* 20 1.4* 12.9 0.
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3-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. 300 Amp 450 Amp A. CC Mode A. CC Mode B. CV Mode B.
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3-4. Selecting A Location 1 2 Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. 1 3 Rating Label (Non CE Models Only) Use rating label to determine input power needs. Label located under front access door. OR 2 4 Plate Label (CE Models Only) Label located under front access door. 5 6 Location Rating Label (CE Models Only) Use rating label to determine input power needs.
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3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 115 VAC Receptacle And Circuit Breakers Y Turn Off power before connecting to receptacle. 1 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and Remote 14 receptacle RC8 or terminal strip 1T (see Section 3-10). 2 3 Circuit Breaker CB1 Circuit Breaker CB2 3 CB1 protects 115 volts ac portion of RC8, 1T, and RC9 from overload. 2 CB2 protects 24 volts ac portion of RC8 and 1T from overload.
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3-8. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less Turn Off power before connecting to weld output terminals.
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3-10. Connecting Remote Control 1 Remote 14 Receptacle RC8 Connect remote control to RC8. If plug does not fit, wire cord to terminal strip 1T. Y Turn Off power before opening terminal strip cover. OR 2 3 4 OR Terminal Strip 1T Remote Control Cord Strain Relief (Customer Supplied) Secure cord in strain relief. Reinstall and secure access panel. Close door.
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3-11.
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3-12. Placing Jumper Links Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input voltage. Close access door, or go on to Section 3-13. 200 VOLTS 230 VOLTS 460 VOLTS Ref. S-174 976-A 230 VOLTS 460 VOLTS 575 VOLTS Ref. S-174 973-A 1 220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS (FACTORY OPTION) 380 VOLTS Ref. S-174 975-A 520 VOLTS 2 Ref. S-177 159 Tools Needed: 3/8 in Do not overtighten jumper link nuts.
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3-13. Connecting Input Power 1 Tools Needed: Input And Grounding Conductors See Section 3-11. 3/8 in 3/8 in 2 Line Disconnect Device See Section 3-11. 3 4 Reed Switch (Ground Current Sensor) (Optional) Grounding Conductor If unit is equipped with optional ground current sensor, route grounding conductor through reed switch two times and connect to ground terminal. 2 Close access door. L1 (U) L2 (V) L3 (W) 1 Connect GND/PE Conductor First.
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SECTION 4 – OPERATION 4-1. Controls (Non CE Models) 450 Amp Model Shown 1 2 9 3 4 5 8 7 6 Ref. ST-184 940 1 2 Process Selector Switch 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 amperage. Turn clockwise to increase short-circuit amperage. 3 Hot Start Switch Turn switch On for SMAW, SAW, and CAC-A. Turn Off for GTAW welding.
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4-2. Controls (CE Models) 300 Amp Model Shown 1 2 9 3 4 5 8 7 6 Ref. ST-184 938 1 2 Process Selector Switch 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 amperage. Turn clockwise to increase short-circuit amperage. 3 Hot Start Switch Turn switch On for SMAW, SAW, and CAC-A. Turn Off for GTAW welding.
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SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair or replace cracked weld cable. Replace unreadable labels. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. OR 5-2. Fuse F1 Y Turn Off power before opening rear access door. 1 Fuse F1 (See Parts List For Rating) Fuse F1 protects control transformer from overload. If F1 opens, weld output and fan motor stops. Replace F1.
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5-3. Troubleshooting Trouble No weld output; unit completely inoperative; pilot light PL1 off. Remedy Place line disconnect device in On position (see Section 3-13). Check for open line fuse(s), and replace if open (see Section 3-13). Check for proper input power connections (see Section 3-13). 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.
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SECTION 6 – ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. SC-196 109-A Figure 6-1.
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SECTION 7 – PARTS LIST 22 . Hardware is common and 21 20 13 15 29 (Fig. 7-3 & 4) 22 28 (Fig. 7-2) 1 27 3 2 4 24 26 25 5 23 6 7 11 8 4 12 10 9 14 16 17 3 19 18 (Fig.7–5) not available unless listed. Figure 7-1.
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Quantity Item No. Dia. Mkgs. Part No. Model Description 302 452 Figure 7-1. Main Assembly . . . 1 . . . . . . . . . . . . . . +179 430 . . . 1 . . . . . . . . . . . . . . +179 432 . . . 2 . . . . . . . . . . . . . . . 179 429 . . . 2 . . . . . . . . . . . . . . . 179 431 . . . 3 . . . . . . . . . . . . . . . 164 699 . . . 4 . . . . . . . . . . . . . . . 162 816 . . . 5 . . . . . . . . . . . . . . . 162 820 . . . 6 . . . . . . . . . . . . . . . 162 830 . . . . . . . . . . . . . . . . . . . . .
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Quantity Item No. Dia. Mkgs. Part No. Model Description 302 452 Figure 7-1. Main Assembly (Continued) . . . 26 . . . . . . . . . . . . . . . 179 213 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . T1 . . . . . . 189 846 . . TRANSFORMER, pwr main 380/520 (consisting of) . . . . . . . . . . . . . . . . . 1 . . . 25 . . . . . . . . . . . . . . . 179 210 . . . . COIL, pri/sec LH . . . . . . . . . . . . . . . . . . .
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Quantity Item No. Dia. Mkgs. Part No. Model Description 302 452 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 30) . . . 1 . . . . . . S1 . . . . . . 163 557 . . . SWITCH, mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . S1 . . . . . . 163 556 . . . SWITCH, mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . PC1 . . . . . 187 831 . . .
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Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-3. Rectifier, Si Diode (302 Model) (Fig 7-1 Item 31) . . . 1 . . . . C7-12 . . . . ... 2 ............... ... 3 ............... ... 4 ............... . . . 5 . . . . . TP3 . . . . . . . . 6 . . . . . TP6 . . . . . . . . 7 . . . SCR1-6 . . . . . . . . . . . . . PLG1 . . . . ... 8 ............... 048 420 177 316 177 317 166 667 185 679 185 680 161 668 158 720 188 692 .. .. .. .. .. .. .. .. .. CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . .
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Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-4. Rectifier, Si Diode (452 Model) (Fig 7-1 Item 31) . . . 1 . . . . C7-12 . . . . ... 2 ............... ... 3 ............... ... 4 ............... . . . 5 . . . SCR1-6 . . . ... 6 ............... . . . . . . . . . . PLG1 . . . . . . . . . . . . . . . TP3 . . . . . . . . . . . . . . . . TP6 . . . . . 048 420 191 989 188 691 188 839 161 668 166 667 158 720 192 673 192 674 .. .. .. .. .. .. .. .. .. CAPACITOR, cer disc .01uf 1000VDC . . . . .
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Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-5. Panel, Rear w/Components (Fig 7-1 Item 18) . . . 1 . . . . . . . . . . . . . . . 173 283 . . . 2 . . . . . . . . . . . . . . . 180 165 . . . 3 . . . . . . . . . . . . . . . 162 807 . . . 4 . . . . . . . . . . . . . . . 168 343 . . . 5 . . . . . . . . . . . . . . +162 818 . . . 6 . . . . . . . . . . . . . . . 168 384 . . . 7 . . . . . . . . . . . . . . . 602 177 . . . 8 . . . . . . . . . . . . . . . 124 274 . . . 9 . . . . . R3 . . . . . .
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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.
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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.