OM-2208 175 493V May 2002 Processes Multiprocess Welding Description Arc Welding Power Source Stellar AT CC/CV and CC 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 OM-2208 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 – INTRODUCTION 2-1. Specifications Rated Output at 60% Duty Cycle Voltage Range in CV Mode Amperage Range in CC Mode Max. OpenCircuit Voltage 300 A at 32 VDC, 3-Phase 10–35 V 5–400 A 90 VDC 225 A at 29 VDC, 1-Phase RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load Voltages and Class I Rating 230 V 460 V 575 V KVA KW 30.5 (0.21*) 18.9 (0.10*) 15.2 (0.08*) 12.2 (0.09*) 11.6 (0.04*) 47.4 (0.34*) 24.5 (0.14*) –– 11.3 (0.09*) 7.6 (0.
2-3. Volt-Ampere Curves A. CC Mode Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. ARC CONTROL B.
SECTION 3 – INSTALLATION 3-1. Selecting a Location 24 in (610 mm) Dimensions And Weight 76 lb (34.6 kg) 17 in (432 mm) 12-1/2 in (318 mm) 1 Movement Lifting Handles Use handles to lift unit. 2 Y Do not move or operate unit where it could tip. 1 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 1 2 4 Line Disconnect Device Locate unit near correct input power supply.
3-2. Weld Output Receptacles 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.
3-3. Remote 14 Receptacle Information Socket* A 24 volts ac. Protected by circuit breaker CB2. B Contact closure to A completes 24 volts ac contactor control circuit. I 115 volts ac. Protected by circuit breaker CB1. J Contact closure to I completes 115 volts ac contactor control circuit. C Output to remote control; 0 to +10 volts dc, +10 volts dc in MIG mode. D Remote control circuit common. E 0 to +10 volts dc input command signal from remote control. M CC/CV select (CC/CV models).
3-5. Electrical Service Guide Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow- er source requires a CONTINUOUS supply of 60 Hz (+10%) power at +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source. Actual input voltage should not exceed ± 10% of indicated required input voltage.
3-6. Connecting Input Power Check input voltage available at site. . The Auto-Link circuitry in this 3 unit automatically links the power source to the primary voltage being applied. A 230/460 unit can be connected to either 230 or 460 VAC input power. A 460/575 model can be connected to either 460 or 575 VAC input power. 1 1 2 Input And Grounding Conductors Line Disconnect Device See Section 3-5.
SECTION 4 – OPERATION 4-1. Front Panel Controls For CC/CV Model 1 Power Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 3 4 5 Voltmeter (see Section 4-3) Ammeter (see Section 4-3) V/A (Voltage/Amperage) Adjustment Control Mode Switch The Mode switch setting determines both the process and output On/Off control (see Section 4-4). Source of control (panel or remote) for the amount of output is selected on the V/A Control switch.
4-2. Front Panel Controls For CC Model 1 Power Switch V/A Control switch. For Air Carbon Arc (CAC-A) cutting and gouging, place switch in one of the Stick positions. For best results, place Dig control in the maximum position. 6 V/A (Voltage/Amperage) Control Switch For front panel control, place switch in Panel position and use the V/A Adjust control. For remote control, make connections to Remote 14 receptacle, and place switch in Remote position.
4-3. Meter Functions For CC/CV Model NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle V Scratch Start TIG Lift-Arc TIG Meter Reading While Welding A 80.0 85 Actual Volts Actual Amps V A V A 7.0 85 85 Preset Amps Actual Volts Actual Amps V A V A Blank Preset Amps Actual Volts Actual Amps V A V A 24.5 250 Preset Volts Blank Actual Volts Actual Amps V A V A 10.
4-5. Meter Functions For CC Model NOTE The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle V Scratch Start TIG Lift-Arc TIG Meter Reading While Welding A 80.0 85 10.3 A 85 Actual Volts (OCV) Preset Amps Actual Volts Actual Amps V A V A 7.0 85 10.
4-7. Lift-Arc TIG Procedure With Process Switch in the Lift-Arc TIG position, start an arc as follows: 1 “Touch” 2 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted. 1–2 Seconds Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.
5-2. Voltmeter/Ammeter Help Displays V A 1 V A HE.L P–5 V A HE.L P–6 V A HE.L P–7 V A HE.L P–8 V A HE.L P–9 6 HE.L P–0 V A 2 7 HE.L P–1 V A 3 8 HE.L P–2 V A 4 9 HE.L P–3 V A 5 10 HE.L P–4 . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent.
5-3. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. ST-801 192 5-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 3-6). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-6). Check for proper input power connections (see Section 3-6). No weld output; meter display On.
Notes OM-2208 Page 23
SECTION 6 – ELECTRICAL DIAGRAMS 197 550-A Figure 6-1.
197 553 Figure 6-2.
22 62 61 60 1 59 2 OM–2208 Page 26 58 65 67 63 57 3 56 64 55 54 53 4 52 5 66 6 7 8 9 51 11 10 48 47 49 50 12 14 15 45 46 13 16 17 11 44 43 18 42 41 19 23 20 40 24 39 38 22 Figure 7-1. Parts Assembly 9 30 25 21 12 32 33 31 28 34 27 35 26 . Hardware is common and not available unless listed.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Parts Assembly . . . 1 . . . . . . . . . . . . . . +175 148 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 178 551 . . INSULATOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 175 256 . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Parts Assembly (Continued) . . . 36 . . . . . C3,4 . . . . . 192 935 . . CAPACITOR, elctlt 2700uf 450VDC (230/460) . . . . . . . . . . . . . . . . . . . . . 2 . . . 36 . . . . . C3,4 . . . . . 193 738 . . CAPACITOR, elctlt 1800uf 500VDV (460/575) . . . . . . . . . . . . . . . . . . . . . 2 . . . 37 . . . . . PC2 . . . . +197 585 . . CIRCUIT CARD, interconnect (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 37 . . . . .
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Effective January 1, 2001 (Equipment with a serial number preface of “LB” 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.
