OM-245 020F 2012−04 Processes TIG (GTAW) Welding Description 230 Volt Arc Welding Power Source Hobart EZ-TIG 165I 230 Volt 60 Hz TIG Only File: TIG (GTAW) www.HobartWelders.
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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. 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 Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
1-4. California Proposition 65 Warnings Welding or cutting equipment 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.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. LES FILS DE SOUDAGE peuvent provoquer des blessures.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
OM-245 020 Page 10
. A complete Parts List is available at www.MillerWelds.com SECTION 3 − SPECIFICATIONS 3-1. Included with Your Unit 2 1 1 2 3 4 5 7 6 7 Welding Power Source 5 ft (1.5 m) Primary Cord With Plug Gas Hose Gas Regulator 12 ft (3.7 m) Work Cable With Clamp Air-Cooled 150 Amp TIG Torch with 12-1/2 ft (3.8 m) Cable RFCS−RJ45 Foot Control . Some assembly is required. For options and accessories see back of book or contact your distributor. 6 3 4 5 Ref. 805 467 -B / 805 158-A 3-2.
. A complete Parts List is available at www.MillerWelds.com 3-4. Dimensions And Weights Dimensions 23-15/16 in. (608 mm) 17 in. (432 mm) 9-7/8 in. (251 mm) Height 17 in. (433 mm) Width 9-7/8 in. (251 mm) Length 23-15/16 in. (608 mm) w/handles 19-1/4 in. (489 mm) w/o handles Ref. 805 467-B Weight 50 lbs (23 kg) 3-5. Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Selecting A Location 1 1 Handles Use Handles to lift welder; get help if necessary. 2 Movement 2 Cart Place welder on cart to move unit. 3 Line Disconnect Device Locate unit near correct input power supply. Position unit so air can circulate. For information about sources of high-frequency see Section 8. ! For carts and caster kits see back of book or contact your distributor.
. A complete Parts List is available at www.MillerWelds.com 4-3. Shielding Gas Connections . Use argon shielding gas for best performance. 1 2 Tools Needed: 5/8, 1-1/8 in. Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 1 3 2 Regulator/Flow Gauge Connect regulator/flow gauge to gas cylinder. Do not over tighten. Connect gas hose to gas in fitting. 3 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Ref. 805 467-B 4-4. Electrical Service Guide .
. A complete Parts List is available at www.MillerWelds.com 4-5. Connecting Input Power 1 18 in. (457 mm) of space for airflow 6 =GND/PE Earth Ground 8 ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 4 2 1 Material Switch ! Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control. ! Do not change position of switch while welding or while under load. Use switch to select DC for steel, stainless steel, and chrome-moly, or AC for aluminum applications.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent = Repair l = Replace Every 3 Months nl Labels n l Gas Hoses Every 3 Months n lCables And Cords Every 6 Months ~:Durning heavy service, clean monthly. 6-2.
. A complete Parts List is available at www.MillerWelds.com 6-3. Troubleshooting . The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit. Trouble No weld output; unit completely inoperative. Remedy Place machine power switch in On position (see Section 5-1). Place line disconnect switch in On position (see Section 4-5).
. A complete Parts List is available at www.MillerWelds.
. A complete Parts List is available at www.MillerWelds.com SECTION 7 − ELECTRICAL DIAGRAM 245 018-A Figure 7-1.
SECTION 8 − HIGH FREQUENCY 8-1. Welding Processes Requiring High Frequency 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 Work TIG high_freq 5/10 − S-0693 8-2.
8-3. Recommended Installation To Reduce HF Interference 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Best Practices Followed Metal Building 8 8 11 10 Ref. S-0695 / Ref.
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2011-06 Whenever possible and practical, use DC weld output instead of AC weld output. 9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten ) . Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using.
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) 10-1. Positioning The Torch ! Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using cerium or lanthanum based tungsten instead of thoriated. Thorium dust contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way.
10-2. Torch Movement During Welding Tungsten Without Filler Rod 75 Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75 Welding direction Form pool 15 Tilt torch Remove rod Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B 10-3.
Notes
Effective January 1, 2012 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MC or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281.
Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, operation, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy For Technical Assistance: Call 1-800-332-3281 7 AM to 5 PM EST − Monday through Friday Owner’s Record Please complete and retain with your personal records.
