OM-355 188 290E August 2001 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Cybertig 180 SD
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.) 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 – INSTALLATION 2-1. Included with Your Unit 1 2 3 7 4 5 6 5 6 7 12 ft (3.7 m) Work Cable With Clamp And Quick-Connect 150 Amp TIG Torch with 12-1/2 ft (3.8 m) Cable Electrode Holder and Quick-Connect Gas Hose Gas Regulator RFCS-14 Foot Control with 20 ft (6 m) Cable 8 ft (2.4 m) Primary Cord . Some assembly is required. 4 For options and accessories see back of book or contact your distributor. 2 1 3 2-2.
2-3. Dimensions And Weights Dimensions Height 21 in (533 mm) Width 13-5/8 in (346 mm) Length 22-1/8 in (562 mm) A 21-5/16 in (541 mm) B 13/16 in (21 mm) C 12-7/16 in (316 mm) D 1–1/16 in (27 mm) E 1/2 (13 mm) A E 4 Holes B Weight Front D C ST-802 259 210 lbs (95 kg) 2-4. Specifications Rated Output at 40% Duty Cycle Mode Rated Input, 60 HZ, Single-Phase KVA KW Welding Amperage Range Max. Open-Circuit Voltage DC TIG 150 Amps at 16 Volts 230 V–38 A - (2)* 8.7 - (0.50)* 4.
2-6. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. DC MODE 80 80 70 70 60 60 50 50 VOLTS VOLTS AC MODE 40 40 30 30 20 20 10 Stick MIN 10 Stick MAX STICK–MAX TIG–MAX TIG–MIN STICK–MIN 0 0 0 50 100 150 200 AMPERES 250 300 350 0 50 100 150 AMPERES 200 250 ssb1.1 10/91 – ST-188 277 / ST-188 278 2-7.
2-8. Remote 14 Receptacle NOTE Remote control device has complete control of amperage at all times when connected to Remote 14 receptacle. Socket* A B K Socket Information A 24 volts DC. B Contact closure to A completes 24 volts DC contactor control circuit. C Command reference; 0 to +10 volts DC output to remote control. D Remote control circuit common. E 0 to +10 volts DC input command signal from remote control. K Chassis common.
2-10. Electrical Service Guide NOTE All values calculated at 40% duty cycle. Input Voltage 230 Input Amperes at Rated Output 67 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 100 Min Input Conductor Size In AWG/Kcmil 8 Max Recommended Input Conductor Length In Feet (Meters) 166 (51) Min Grounding Conductor Size In AWG/Kcmil 8 Reference: 1996 National Electrical Code (NEC) S-0092-J 2-11. Connecting Input Power Y Have only qualified persons make this installation.
SECTION 3 – OPERATION 3-1. Controls 2 3 4 5 6 7 1 Ref. ST-188 714-A 1 Output Selector Switch Y 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. Y Do not change position of switch while welding or while under load.
3-2. Example of Front Panel Amperage Control For Stick (SMAW) Welding Select weld process. Select polarity. Select amperage. In Example: Remote weld amperage = 10–180 amps DC NOTE: Remote amperage control is active whenever a remote control is connected. If the remote device does not include a means of controlling amperage through pin E, the Amperage Adjustment control on the front panel remains active. 3-3. Example of Remote Amperage Control For TIG (GTAW) Welding Select weld process.
3-4. Typical TIG Connections 1 6 2 3 5 7 Remote Foot Control A customer supplied remote fingertip control may also be used. Torch Work Clamp Connect remote control, torch, and work clamp to receptacles as shown. 4 Cylinder Chain or secure cylinder to running gear, wall, or other stationary support. 5 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 6 Tools Needed: Regulator/Flow Gauge Install so face is vertical.
3-6. Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And Weld Output 22 ga 20 ga 0.033 in 0.036 in 0.8 mm 0.9 mm 18 ga 0.048 in 1.2 mm 16 ga 0.06 in 1.5 mm 14 ga 0.07 in 1.8 mm 12 ga 0.1 in 2.5 mm 11 ga 0.125 in 3.2 mm 10 ga 0.14 in 3.6 mm Steel Or Stainless Steel ( ) DCEN ELECTRODE NEGATIVE 6 ga 0.186 in 4.8 mm 2 ga 0.25 in 6.3 mm – 0.25+ in 6.
4-2. Adjusting Spark Gaps 4 Tools Needed: 4 Y Turn Off power before adjusting spark gaps. Remove left side panel. 1 3 3 2 Tungsten End Of Point Replace point if tungsten end disappears; do not clean or dress tungsten. 1 2 Spark Gap Normal spark gap is 0.012 in (0.305 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screws Loosen screws. Place gauge of proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap.
SECTION 5 – ELECTRICAL DIAGRAM SD-188 274-F Figure 5-1.
SECTION 6 – HIGH FREQUENCY (HF) 6-1. Welding Processes Using HF 1 HF Voltage GTAW – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SAW – helps arc reach workpiece through flux granules. 2 1 2 1 Work Work Gas Tungsten Arc Welding (GTAW) Submerged Arc Welding (SAW) Flux high_freq1 7/95 – S-0693 6-2.
6-3. Correct Installation 6 Weld Zone 50 ft (15 m) 50 ft (15 m) 4 1 5 2 7 3 7 Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire Nonmetal Building Ground Workpiece If Required By Codes 8 7 7 10 Metal Building 9 Ref. S-0695 / Ref. S-0695 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.
SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw2 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. Wear clean gloves to prevent contamination of tungsten electrode. 7-1. Selecting Tungsten Electrode Amperage Range - Gas Type♦ - Polarity Electrode Diameter DC – Argon – Electrode Negative/Straight Polarity DC – Argon – Electrode Positive/Reverse Polarity .010” Up to 25 * .020” 15-40 * .
7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding 1 1 2 2 Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2-1/2 Times Electrode Diameter 1 2 3 1 2 Stable Arc Flat Diameter of this flat determines amperage capacity.
SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. Positioning The Torch 3 2 4 90° 1 Y 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.
8-2. 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 Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process.
8-3.
Notes OM-355 Page 27
SECTION 9 – STICK WELDING (SMAW) GUIDELINES 9-1. Stick Welding Procedure Y Weld current starts when electrode touches workpiece. 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. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 9-2).
7014 7018 7024 Ni-Cl 308L 9-3.
9-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS 9-6. S-0060 Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 9-7.
9-8. Conditions That Affect Weld Bead Shape NOTE 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 Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED 9-9.
9-10. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30° Single V-Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.
9-13. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 9-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty.
9-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique.
9-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 9-20. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands.
14 not available unless listed. OM-355 Page 36 ST-802 252-D Figure 10-1. Main Assembly 43 .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly + 1 . . . . . . . . . . . . . . 188 270 . . 2 . . . . . T4 . . . . . 190 332 . . 3 . . . . . . . . . . . . . . 190 436 . . 4 . . . . . G1 . . . . . 199 854 . . . . . . . . . . . . . . . . . . . 199 855 . . . . . . . . . . . . . . . . . . . 199 856 . . . . . . . . . . . . . . . . . . . 196 455 . . 5 . . . . . C3 . . . . . 201 197 . . 6 . . . . . T3 . . . . . 074 398 . . 7 . . . . . R8 . . . . . 188 067 . . 8 . . C18, 19 . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (continued) . . . . . . . . . . . . . . . . . . . 188 859 . . . . . . . . . . . . . . . . . . . 043 554 . . . . . . . . . . . . . . . . DB1712RDI . . . . . . . . . . . . . . . . . . . 188 860 . . . . . . . . . . . . . . . . . . . 193 094 . . . . . . . . . . . . . . . . . . . 176 840 . . ACCESSORY KIT (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RFCS-14, foot control . . . . . . .
. Hardware is common and 3 not available unless listed. 7 4 6 5 2 1 8 13 9 4 10 14 12 11 ST-802 254-A Figure 10-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-2. Panel, Front w/Components (Figure 10-1 Item 39) . . 1 . . . . . . . . . . . . . . 174 991 . . .. 2 ......................... . . 3 . . . . RC7 . . . . . 143 976 . . . . 4 . . . . . . . . . . . . . . 186 092 . . . . 5 . . . . . . . . . . . . . . 192 451 . . . . 6 . . . . PC1 . . . . .
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.
