OM-303 155795N January 2002 Description Arc Welding Power Source Gas Tungsten Arc (TIG) Welding Shielded Metal Arc (Stick) Welding Processes TIGMATE
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 SECTION 1 – SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 – DEFINITIONS 2-1.
2-2.
3-2. Specifications A. 60 Hertz Models Max. Open-Circuit Voltage Rated Output KVA Dimensions TIG Welding A Range 50–165 20–50 30–160 78 200 V–60 A (3.6)* 12.0 (0.64)* H: 18 in (457 mm) Stick Welding A Range 35–165 20–50 25–130 78 460 V–33 A (1.5)* Max. Open-Circuit Voltage Rated Output KVA Dimensions 380 V–39 A (2.0)* 14.8 (0.
SECTION 4 – INSTALLATION 4-1. Selecting a Location Position unit so air can circulate. For information about sources of high-frequency see Section 8. 18 in (460 mm) 18 in (460 mm) For carts and caster kits see back of book or contact your distributor. 18 in (460 mm) ST-158 075 4-2. Typical Stick Connections Y Turn Off power before making connections. 1 2 Electrode Holder Work Clamp Connect to receptacle as shown.
4-3. Typical TIG Connections Y Turn Off power before making connections. 1 2 Connect to receptacles as shown. 6 3 4 7 Remote Control Torch 5 Work Clamp 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 Regulator/Flow Gauge Install so face is vertical. 7 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour) (9.4 L/min). 4 1 2 3 Tools Needed: 5/8, 1-1/8 in Ref.
4-4. Electrical Service Guide S-0092J . For 230 V models with wall receptacle, 100% duty cycle used to calculate data below. 20% duty cycle used for all other models. Input Voltage 200 230 380 415 460 Input Amperes at Rated Output 59 52 39 36 33 Standard Fuse or Circuit Breaker Rating (Max. Recommended) 90 Amps 80 Amps 60 Amps 50 Amps 40 Amps Input Conductor Size (Min.
SECTION 5 – OPERATION 5-1. Controls 6 1 2 3 8 5 7 4 Ref. ST-155 790-F 1 Weld Process Switch Use switch to select weld process. In Stick position (down), weld output goes On and Off with Power switch. In GTAW (TIG) position (up), remote control device turns on and adjusts weld output of unit as limited by Amperage control. Built-in arc starter comes on when needed to start or stabilize welding arc. No adjustments needed for arc starter.
5-2. Example of Front Panel Amperage Control Select weld process. Select range and polarity. In Example: Range = DC Percentage of Range = 50% Weld Amperage = 33 A DC Select percentage. 5-3. Example of Remote Amperage Control Select weld process. Select range and polarity. Select percentage. GTAW Welding Amperage Range or Connect remote control.
5-4. 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 2 ga 0.25 in 6.3 mm – 0.25+ in 6.3+ mm SMAW GTAW GTAW Difficult Recommended With DCEP Output GTAW Aluminum AC 6 ga 0.
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Repair or replace cracked gas hose. Replace o-ring in Electrode/Gas Output receptacle if cracked. 6 Months Blow out or vacuum inside. Or 6-2. Troubleshooting Trouble No weld output; fan does not run.
SECTION 7 – ELECTRICAL DIAGRAMS SB-154 141-C Figure 7-1.
SECTION 8 – HIGH FREQUENCY 8-1. Welding Processes Requiring High Frequency 1 1 High-Frequency Voltage Helps arc jump air gap between torch and workpiece and/or stabilize the arc. Work TIG high_freq1 11/96 – S-0693 8-2.
8-3. Correct Installation Weld Zone 3 7 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. Ground workpiece if required by codes. Nonmetal Building 9 Metal Building 8 8 11 10 Ref. S-0695 / Ref. S-0695 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.
21 23 9 31 36 37 38 39 OM–303 Page 22 47 Figure 9-1.Main Assembly 46 48 11 1 40 32 41 43 42 34 2 3 35 45 44 34 33 30 32 29 7 28 27 4 5 26 6 25 24 7 8 10 22 12 11 14 15 13 19 not available unless listed. 20 16 .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly . . . 1 . . . . . . . . . . . . . 154 335 . . BEZEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . 203 990 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . +165 986 . . WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure Figure 9-1. Main Assembly (Continued) . . . 42 . . . . . PL1 . . . . . . 43 . . . . . . . . . . . . . . . . 44 . . . . . S2 . . . . . . . 45 . . . . . S4 . . . . . . . 46 . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . ................... ................... ................... ................... 157 958 155 422 154 896 089 645 177 359 010 368 026 843 128 188 193 094 176 840 134 460 . .
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.
