OM-278400B 2017−04 Processes Stick (SMAW) Welding Description Arc Welding Power Source Stickmate 160i Stickmate 210i R R File: Stick (SMAW) www.HobartWelders.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 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. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. 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. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
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_2015−09 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.
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. D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. D Eloigner votre tête des fumées.
LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. LES BOUTEILLES peuvent exploser si elles sont endommagées. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LE SOUDAGE À L’ARC risque de provoquer des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. 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.
. A complete Parts List is available at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1. Miscellaneous Symbols And Definitions . Some symbols are found only on CE products.
. A complete Parts List is available at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Unit Specifications . Do not use information in unit specifications table to determine electrical service requirements.
. A complete Parts List is available at www.HobartWelders.com B. Temperature Specifications Operating Temperature Range* Storage/Transportation Temperature Range 14 to 104°F (−10 to 40°C) −4 to 131°F (−20 to 55°C) *Output is derated at temperatures above 104°F (40°C). Temp_2016- 07 4-4. Duty Cycle Charts A. Stickmate 160i Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 140 If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.
. A complete Parts List is available at www.HobartWelders.com B. Stickmate 210i Duty Cycle is percentage of 10 minutes 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 voltage, or duty cycle before welding.
. A complete Parts List is available at www.HobartWelders.com 4-5. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall between the curves shown. A. Stickmate 160i (120 Volt Input) 80 70 60 MAXIMUM VOLTS 50 40 MINIMUM 30 20 10 0 0 10 20 30 40 50 60 AMPERES 70 80 90 100 B.
. A complete Parts List is available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Selecting a Location ! Movement 1 Location And Airflow Do not move or operate unit where it could tip. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 1 Lifting Handle 2 18 in. (460 mm) Use handle to lift unit. 2 Line Disconnect Device Locate unit near correct input power supply. 18 in.
. A complete Parts List is available at www.HobartWelders.com 5-2. Installing Electrode Holder And Work Clamp Removing Barrel From Electrode Holder 3 1 2 3 1 Barrel Barrel Set Screw Electrode Holder Loosen barrel set screw. Slide barrel away from electrode holder. 2 Installing Electrode Cable and Barrel onto Electrode Holder 4 5 6 Electrode Cable From Unit (Has Bare Conductors on End) Shim Cable Set Screws Remove precut insulation from end of electrode cable.
. A complete Parts List is available at www.HobartWelders.com 5-4. Connecting To Weld Output Terminals ! Turn off power before connecting to weld output terminals. ! Do not use worn, damaged, undersized, or repaired cables. 1 2 3 Negative (−) Weld Output Terminal Positive (+) Weld Output Terminal Dinse Weld Connector Insert Dinse connector fully into terminal. Rotate connector clockwise to lock in position. 1 2 3 Connect dinse 2017−03 − 279282-A / 802554 5-5.
. A complete Parts List is available at www.HobartWelders.com 5-6. Multi−Voltage Plug Adapter (MVP) Connection (Stickmate 160i Only) Selecting Plug Adapter 1 2 3 4 5 ! 6 Do not cut off power cord connector and rewire. The power cord connector and plugs adapters will work with standard NEMA receptacles. Modifying power cord, connector, and plug adapter will void product warranty.
. A complete Parts List is available at www.HobartWelders.com 5-7. Weld Output Cables . For weld output cable replacements or extensions, contact your Factory Authorized Service Agent. 5-8. Electrical Service Guide Elec Serv 2017-01 A. Stickmate 160i Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
. A complete Parts List is available at www.HobartWelders.com 5-9. Connecting 120 Volt Input Power (Stickmate 160i Only) ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. . The circuitry in this unit automatically links the power source to the primary voltage being applied, either 120 or 240 VAC.
. A complete Parts List is available at www.HobartWelders.com 5-10. Connecting 240 Volt Input Power 1 3 =GND/PE Earth Ground ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before installing receptacle. Follow established procedures regarding the installation and removal of lockout/tagout devices.
. A complete Parts List is available at www.HobartWelders.com SECTION 6 − OPERATION 6-1. Controls A. Stickmate 160i 1 Amperage Adjustment Control Use control to select desired weld amperage. 2 Power Indicator Light Lamp goes on when unit is on. 3 Over Temperature Light Light goes on when unit has stopped due to overheating (see Section 4-4). Light goes off and weld output returns when unit has cooled. 4 1 Power Switch Use switch to turn unit on and off.
. A complete Parts List is available at www.HobartWelders.com B. Stickmate 210i 1 Amperage Adjustment Control Use control to select desired weld amperage. 2 Power Indicator Light Light goes on when unit is on. 3 Over Temperature Light Light goes on when unit has stopped due to overheating (see Section 4-4). Light goes off and weld output returns when unit has cooled. 4 Power Switch Use switch to turn unit on and off.
. A complete Parts List is available at www.HobartWelders.com SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions. l = Replace Reference Every 3 Months l Unreadable Labels Every 6 Months ~ Weld Terminals nl Weld Cables OR ~ Inside Unit 7-2.
. A complete Parts List is available at www.HobartWelders.com SECTION 8 − PARTS LIST 8-1. Recommended Spare Parts Dia. Mkgs. Part No. . . . 1 . . . . . . . . . . 254330 . . . 2 . . . . . . . . . ♦254331 . . . 3 . . . . . . . . . . 254328 . . . 4 . . . . . . . . . . *770026 . . . . . . . . . . . . . . . . **PA532 . . . 5 . . . . . . . . . . *770770 . . . . . . . . . . . . . . . **240697 . . . 6 . . . . . . . . . . 208548 ♦OPTIONAL Description .. .. .. .. .. .. .. ..
SECTION 9 − ELECTRICAL DIAGRAMS 279190-A Figure 9-1.
SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure ! Weld current starts when electrode touches workpiece. ! 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. Equipment Needed: Tools Needed: . Always wear appropriate per1 sonal protective clothing. Workpiece Make sure workpiece is clean before welding.
7014 7018 7024 Ni-Cl 308L 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DEEP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL MED SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN FLAT HORIZ* LOW SMOOTH, EASY, FASTER NI-CL EP ALL LOW CAST IRON 308L EP ALL LOW STAINLESS USAGE ALL EP AC EP 6011 DC* 6010 ELECTRO
10-4. Positioning Electrode Holder 1 2 After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode. 1 10°-30° 90° End View Of Work Angle Side View Of Electrode Angle Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the direction of travel) will be helpful. 2 90° . To produce the best results, hold a short arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it melts.
10-7. Conditions That Affect Weld Bead Shape . Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Electrode Angle Drag Spatter Arc Length Too Short Normal Too Long Slow Normal Fast Travel Speed S-0061 10-8. Electrode Movement During Welding .
10-10. Welding Groove (Butt) Joints 1 Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will “curl” up toward the weld. Distortion will also cause the edges of a butt joint to pull together ahead of the electrode as the weld cools. 1 2 1/16 in. (1.6 mm) Square Groove Weld 3 Single V-Groove Weld 4 Double V-Groove Weld Materials up to 3/16 in.
10-12. Weld Test 1 2 3 Strike the weld joint in the direction shown. A good weld bends over but does not break. 3 If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long. 3 If the weld contains bits of slag, the arc may have been too long or the electrode was moved incorrectly which allowed molten slag to be trapped in the weld.
Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed.
Effective January 1, 2017 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MH 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.
