Hobart CYBERTIG 180 SD User Manual

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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. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit

Hobart is registered to the ISO 9001 Quality System Standard.

needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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.)

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISA TION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Included with Your Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Selecting A Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dimensions And Weights 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Duty Cycle Chart 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Weld Output Terminals And Selecting Cable Sizes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Remote 14 Receptacle 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Shielding Gas Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Electrical Service Guide 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11. Connecting Input Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Example of Front Panel Amperage Control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Example of Remote Amperage Control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Typical TIG Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Typical Stick Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Process and Material Thickness Guide Label 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Adjusting Spark Gaps 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – HIGH FREQUENCY (HF) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Welding Processes Using HF 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Sources Of HF Radiation From Incorrect Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Correct Installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – SELECTING AND PREPARING

TUNGSTEN ELECTRODE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Selecting Tungsten Electrode 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Safety Information About Tungsten 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding 23. . . . . . . . . . . . . . . . . . . . .

SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Positioning The Torch 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Torch Movement During Welding 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Positioning Torch Tungsten For Various Weld Joints 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – STICK WELDING (SMAW) GUIDELINES 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – PARTS LIST 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

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Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body.

power circuit and machine internal circuits are also

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.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

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 exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-355 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed. D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder – explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

OM-355 Page 2

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 UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-355 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-355 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

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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.

1-2. Dangers relatifs au soudage à l’arc

Y Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Au cours de l’utilisation, tenir toute personne à l’écart et plus par-

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les

tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

D Ne jamais toucher les pièces électriques sous tension. D Porter des gants et des vêtements de protection secs ne comportant

pas de trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

D Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

D Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installer et mettre à la terre correctement cet appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours v érifier la terre du cordon d’alimentation – Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée fixer d’abord le conducteur

de mise à la terre approprié et contre-vérifier les connexions.

D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas

endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de l a soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’alimenta- tion électrique.

D Arrêter les convertisseurs, débrancher le courant électrique, et dé-

charger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

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. Ne pas respirer

D A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau

de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à alimenta-

tion d’air homologué.

D Lire les spécifications de sécurité des matériaux (MSDSs) et les

instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations de

dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l ’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

les fumées.

OM-355 Page 5

LES RAYONS DE L’ARC peuvent pro- voquer 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

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 énuméré dans les normes de sécurité).

D Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair

et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

D Porter des vêtements de protection constitué dans une matière dura-

ble, résistant au feu (cuir ou laine) et une protection des pieds.

(ultraviolets et infrarouges) susceptibles de provoquer

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D Ne pas toucher des parties chaudes à mains nues D Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être

les, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement o u u n incendie. A vant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Se protéger et d’autres personnes de la projection d’étincelles et de

métal chaud.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur

des substances inflammables.

D Déplacer toutes les substances inflammables à une distance de 10,7

m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Des étincelles et des matériaux chauds du soudage peuvent facile-

ment passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que des

réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’élec- trocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans re- vers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos poches

telles qu’un allumeur au butane ou des allumettes.

projetées de l’arc de soudure. La projection d’étincel-

DES PARTICULES VOLANTES peuvent blesser les yeux.

D Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs d e stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, du laitier, des flammes ouvertes, des étin- celles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnai-

re ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits d e soudage ou autres cir-

cuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une

bouteille.

D Ne jamais souder une bouteille pressurisée – risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

D Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-

lisation ou de branchement de la bouteille.

D Lire et suivre les instructions concernant les bouteilles de gaz com-

primé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

font normalement partie du procédé de soudage, les

OM-355 Page 6

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou à proxi-

mité de surfaces infllammables.

D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D Utiliser l’anneau de levage uniquement pour sou-

lever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin d’une capacité appropriée pour

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

soulever l’appareil.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

D Ne pas obstruer les passages d’air du poste.

recommancer le soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

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.

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute frequence peut provoquer

des interférences avec les équipements de radio–navigation e t d e communication, les services

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa- tion.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appa-

reil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interfé- rences éventuelles.

de sécurité et les ordinateurs.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

D L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

patible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires tel- les que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points.

OM-355 Page 7

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding 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 A WS

F4.1, de l ’American Welding Society , 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFP A 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur , il est alors recommandé de respecter les consignes ci–dessus.

OM-355 Page 8

SECTION 2 – INSTALLATION

2-1. Included with Your Unit

1 12 ft (3.7 m) Work Cable

With Clamp And Quick-Connect

2 150 Amp TIG Torch with

12-1/2 ft (3.8 m) Cable

3 Electrode Holder and

Quick-Connect

4 Gas Hose 5 Gas Regulator 6 RFCS-14 Foot Control with

20 ft (6 m) Cable

7 8 ft (2.4 m) Primary Cord

. Some assembly is required.

For options and accessories see back of book or contact your distributor.

2-2. Selecting A Location

Movement

Location And Airflow

18 in

(460 mm)

18 in (460

mm)

1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to

move unit. If using lifting forks, extend forks

beyond opposite side of unit. 3 Rating Label Use rating label to determine input

power needs.

4 Line Disconnect Device Locate unit near correct input pow-

er supply. Position unit so air can circulate. For information about sources of

high-frequency see Section 6. For carts and caster kits see back

of book or contact your distributor.

Y Special installation may be

required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .

18 in (460

mm)

18 in (460

mm)

ST-802 238

OM-355 Page 9

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)

4 HolesE

Front

ST-802 259

E 1/2 (13 mm)

Weight

210 lbs (95 kg)

2-4. Specifications

Rated Output at 40%

Mode

DC TIG 150 Amps at 16 Volts 230 V–38 A - (2)* 8.7 - (0.50)* 4.0 - (0.3)* 10–180 80 DC Stick 150 Amps at 26 Volts 230 V–42 A - (2)* 9.7 - (0.50)* 5.7 - (0.3)* 10–180 80 AC TIG 150 Amps at 16 Volts 230 V–67 A - (2)* 15.5 - (0.50)* 4.9 - (0.3)* 15–180 80 AC Stick 150 Amps at 26 Volts 230 V–53 A - (2)* 12.2 - (0.50)* 6.2 - (0.3)* 15–180 80 * () While idling.

Duty Cycle

Rated Input,

60 HZ, Single-Phase

KVA KW

Welding Amperage

Range

Max. Open-Circuit

Voltage

2-5. Duty Cycle Chart

Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

Y Exceeding duty cycle can

damage unit and void warranty.

OM-355 Page 10

40% Duty Cycle at 150 A AC/DC

4 Minutes Welding 6 Minutes Resting

ST-188 276-A

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.

AC MODE

80 70 60 50 40

VOLTS

30 20 10

0 50 100 150 200 250 300 350

Stick MIN Stick MAX

AMPERES

80 70 60 50 40

VOLTS

30 20 10

TIG–MIN STICK–MIN

0 50 100 150 200 250

2-7. Weld Output Terminals 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. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

DC MODE

AMPERES

TIG–MAX

ssb1.1 10/91 – ST-188 277 / ST-188 278

STICK–MAX

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

Weld Output

Terminals

Electrode

Work

Ref. ST-802 238

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 – 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

OM-355 Page 11

400 ft

(120 m)

2-8. Remote 14 Receptacle

NOTE

*The remaining sockets are not used.

ST-802 238

Remote control device has complete control of amperage at all times when connected to Remote 14 receptacle.

Socket* 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.

2-9. Shielding Gas Connections

Tools Needed:

5/8, 1-1/8 in

Y Turn Off power before con-

necting t o receptacle.

1 Gas Valve In Fitting Fitting has 5/8-18 right-hand

threads. Located o n rear of unit. 2 Gas Valve Out Fitting Gas connection is integrated into

the Electrode weld output terminal by means of a flow-through type connector.

3 Cylinder Valve Open valve slightly so gas flow

blows dirt from valve. Close valve. 4 Regulator/Flow Gauge Connect regulator/flow gauge to

gas cylinder. Connect gas hose to gas in fitting. 5 Flow Adjust Typical flow rate is 20 cfh (cubic feet

per hour).

OM-355 Page 12

Ref. ST-802 238 / Ref. ST-802 258 / Ref. ST-157 858

2-10. Electrical Service Guide

NOTE

Input Voltage 230 Input Amperes at Rated Output 67

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1996 National Electrical Code (NEC) S-0092-J

All values calculated at 40% duty cycle.

100

166 (51)

2-11. Connecting Input Power

Tools Needed:

GND/PE

Y Have only qualified persons

make this installation.

Y Special installation may be

required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .

Units come equipped with input power cord for installation into line disconnect device. Select type and size overcurrent protection using Section 2-10.

GND/PE

Connect first.

L1 L2

ST-802 238

OM-355 Page 13

3-1. Controls

SECTION 3 – OPERATION

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.

Use switch to select Direct Current Electrode Negative (DCEN), AC, or Direct Current Electrode Positive (DCEP) output without changing weld output cable connections.

2 Amperage Adjust Control For Stick (SMAW), use control to adjust

amperage.

OM-355 Page 14

For remote amperage control used when TIG (GTAW) welding, front panel Amperage control setting is the maximum amperage available at the remote control device.

See Section 3-3 for example of remote amperage control.

3 Weld Process Switch Use switch to select weld process. In Stick position (up), weld output goes On and

Off with Power switch. In GT A W (TIG) position (down), remote control

device turns on and adjusts weld output of unit as limited by Amperage control. For Direct Current Electrode Negative (DCEN), built-in arc starter comes on when needed to start or stabi-

Ref. ST-188 714-A

lize welding arc. For AC welding, the arc starter will turn on and stay on to start and stabilize the welding arc. No adjustments needed for arc starter.

4 Output (Contactor) Light Lights when output (contactor) and unit power

are on. 5 Overtemp Light Lights when unit overheats and shuts down

(see Section 4-3). 6 Pilot Light 7 Power Switch Use switch to turn unit, fan, and pilot light On

and Off.

3-2. Example of Front Panel Amperage Control For Stick (SMAW) Welding

Select amperage.Select weld process. Select polarity.

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.

In Example:

3-3. Example of Remote Amperage Control For TIG (GTAW) Welding

Connect remote control (see Section 3-4).

Select max amperageSelect weld process. Select polarity.

In Example:

For remote amperage control, front panel amperage control setting is the

maximum amperage available. Full range is 10–180 amps DC, but if front

panel amperage control is set at 130 amps, the range of remote

amperage control is 10 to 130 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.

OM-355 Page 15

3-4. Typical TIG Connections

Tools Needed:

5/8, 1-1/8 in

1 Remote Foot Control

A customer supplied remote fingertip control may also be used.

2 Torch 3 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 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). NOTE: After activating remote con-

trol, 0.3 seconds of gas preflow will begin.

Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

NOTE: When remote control is released, gas continues to flow for 18 seconds

Application:

Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance. NOTE: Both preflow and postflow are preset and are not adjustable.

NOTE: When AC welding, the balance control is preset at 60% electrode negative (EN), and 40% electrode positive (EP).

ST-802 238

3-5. Typical Stick Connections

OM-355 Page 16

1 Electrode Holder 2 Work Clamp Connect electrode holder and work

clamp to receptacles as shown.

ST-802 238

3-6. Process and Material Thickness Guide Label

Guideline For Welding Process And Output For Material

Material Thickness

Material And Weld Output

Steel Or Stainless Steel

()

ELECTRODE

NEGATIVE

DCEN

Aluminum

22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 11 ga 10 ga 6 ga 2 ga –

0.033 in

0.8 mm

0.036 in

0.9 mm

GTAW

Difficult

0.048 in

1.2 mm

0.06 in

1.5 mm

0.07 in

1.8 mm

0.1 in

2.5 mm

Recommended

0.125 in

3.2 mm

GTAW

0.14 in

3.6 mm

0.186 in

4.8 mm

0.25 in

6.3 mm

Recommended

0.25+ in

6.3+ mm

SMAW

With DCEP

Output

GTAW

Not

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

S-167 338

4-1. 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.

Replace o-ring in Electrode/Gas Output receptacle if cracked.

6 Months

Blow out or vacuum inside.

Repair or replace cracked gas hose.

OM-355 Page 17

4-2. Adjusting Spark Gaps

Tools Needed:

Y Turn Off power before ad-

justing spark gaps.

Remove left side panel. 1 Tungsten End Of Point Replace point if tungsten end dis-

appears; do not clean or dress tungsten.

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. Tighten screws to 12 in/lbs torque (overtightening will deform plastic base). Adjust other gap.

Reinstall left side panel.

4-3. Troubleshooting

Trouble Remedy

No weld output; fan does not run. Place line disconnect switch in On position (see Section 2-11).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-11). Check for proper input power connections (see Section 2-11).

No weld output; fan on. Be sure Polarity switch is not set between positions.

Tighten remote control connection to Remote 14 receptacle. Check remote control (see remote control Owner’s Manual). Unit overheated. Allow unit to cool (see Section 2-5).

Fan not operating; weld output available.

Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor.

ST-802 745

OM-355 Page 18

SECTION 5 – ELECTRICAL DIAGRAM

Figure 5-1. Circuit Diagram For Welding Power Source

SD-188 274-F

OM-355 Page 19

SECTION 6 – HIGH FREQUENCY (HF)

6-1. Welding Processes Using HF

Work Work

1 HF V oltage GTAW – helps arc jump air gap

between torch and workpiece and/ or stabilize the arc.

SAW – helps arc reach workpiece

2 1

through flux granules. 2 Flux

Gas Tungsten Arc

Welding (GT AW)

Submerged Arc

Welding (SAW)

6-2. Sources Of HF Radiation From Incorrect Installation

Weld Zone

11, 12

50 ft

(15 m)

10 9 8

high_freq1 7/95 – S-0693

Sources Of Direct HF Radiation

1 HF source (welding power source with

built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp

OM-355 Page 20

4 5 6

5 Workpiece 6 Work Table

Sources Of Conduction Of HF

7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring

S-0694

Sources Of Reradiation Of HF

10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes And Fixtures 14 External Phone And Power Lines

6-3. Correct Installation

Weld Zone

50 ft

(15 m)

Wire

Ground Workpiece If Required

By Codes

Ground All Metal Objects And All Wiring

In Welding Zone Using #12 AWG

Nonmetal

Building

50 ft

(15 m)

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.

2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint

between HF source and welding torch in all directions.

3 Weld Output Cables Keep cables short and close together. 4 Conduit Joint Bonding And Grounding

Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m).

5 Water Pipes And Fixtures Ground water pipes every 50 ft (15 m). 6 External Power Or Telephone Lines Locate HF source at least 50 ft (15 m) away

from power and phone lines. 7 Grounding Rod Consult the National Electrical Code for

specifications.

Metal Building

Ref. S-0695 / Ref. S-0695

8 Metal Building Panel Bonding Methods Bolt or weld building panels together, install

copper straps or braided wire across seams, and ground frame.

9 Windows And Doorways Cover all windows and doorways with

grounded copper screen of not more than 1/4 in (6.4 mm) mesh.

10 Overhead Door Track Ground the track.

OM-355 Page 21

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

Electrode Diameter DC – Argon – Electrode Negative/Straight

2% Thorium Alloyed Tungsten (Red

Band)

.010” Up to 25 * .020” 15-40 * .040” 25-85 * 1/16” 50-160 10-20 3/32” 135-235 15-30

1/8” 250-400 25-40 5/32” 400-500 40-55 3/16” 500-750 55-80

1/4” 750-1000 80-125

Amperage Range - Gas Type♦ - Polarity

DC – Argon – Electrode Positive/Reverse

Polarity

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour) – 7 to 16.5 lpm (liters per minute).

*Not Recommended. The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode

manufacturers.

7-2. Safety Information About Tungsten

Y Grinding the tungsten elec-

trode 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 tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

1 Tungsten Electrode With

Balled End

2 Pointed Tungsten Electrode

OM-355 Page 22

Ref. S-0161

7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

1 Tungsten Electrode

Electrode Diameter

Ideal Tungsten Preparation – Stable Arc

2-1/2 Times

2 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.

1 Stable Arc 2 Flat Diameter of this flat determines

amperage capacity. 3 Grinding Wheel 4 Straight Ground

Wrong Tungsten Preparation – Wandering Arc

1 Arc Wander 2 Point 3 Grinding Wheel 4 Radial Ground

Ref. S-0161 / Ref. S-0162

OM-355 Page 23

SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW)

8-1. Positioning The Torch

Y Grinding the tungsten elec-

trode 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. Wear proper face, hand, an d body protection. Keep flammables away.

1 Workpiece Make sure workpiece is clean

before welding. 2 Work Clamp Place as close to the weld as

possible. 3 Torch 4 Filler Rod (If Applicable) 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten

according to Sections 7-1, and 7-2 or 7-3.

Guidelines:

The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter.

Tungsten extension is the distance the tungsten extends out gas cup of torch.

The tungsten extension should be no greater than the inside diameter of the gas cup.

Arc length is the distance from the tungsten to the workpiece.

10–25°

10–15°

3/16 in

Bottom View Of Gas Cup

90°

1/16 in

OM-355 Page 24

Ref. ST-161 892

8-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75°

of pool. Repeat process.

75°

15°

Move torch to front

of pool. Repeat process.

ST-162 002-B

OM-355 Page 25

8-3. Positioning Torch Tungsten For Various Weld Joints

90°

Butt Weld And Stringer Bead

20°

“T” Joint

70°

Lap Joint

Corner Joint

10°

20°

40°

70°

20°

30°

90°

70°

OM-355 Page 26

20°

ST-162 003 / S-0792

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. P lace work clamp as close t o the weld as possible.

1 Workpiece Make sure workpiece is clean be-

fore welding. 2 Work Clamp 3 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).

4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the

electrode t o the workpiece. A short arc with correct amperage will give a sharp, crackling sound.

7 Slag Use a chipping hammer and wire

brush to remove slag. Remove slag and check weld bead before making another weld pass.

Tools Needed:

OM-355 Page 28

stick 12/96 – ST-151 593

9-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

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

100

150

200

250

300

350

400

450

DC*

ELECTRODE

6010

6011

EP,EN

6013

EP,EN

7014

7018

EP,EN

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

POSITION

ALL ALL ALL

ALL ALL

FLAT HORIZ FILLET

ALL ALL

PENETRATION

DEEP DEEP

LOW MED

LOW

LOW LOW

LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON STAINLESS

Ref. S-087 985-A

9-3. Striking an Arc – Scratch Start Technique

9-4. Striking an Arc – Tapping Technique

1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece

like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

S-0049

1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to

workpiece; then lift slightly to start

arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

S-0050

OM-355 Page 29

9-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

End View of Work Angle Side View of Electrode Angle

9-6. Poor Weld Bead Characteristics

FILLET WELDS

10°-30°

S-0060

1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration

9-7. Good Weld Bead Characteristics

OM-355 Page 30

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being w elded.

5234

4 No Overlap 5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

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

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

S-0061

9-9. Electrode Movement During Welding

NOTE

Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.

1 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side to Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.

S-0054-A

OM-355 Page 31

9-10. Butt Joints

9-11. Lap Joint

Single-Layer Fillet Weld

1 Tack Welds

30°

1/16 in

(1.6 mm)

30° Or Less

Multi-Layer Fillet Weld

30° Or Less

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 Single V-Groove W eld 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.

Create 3 0 degree angle of bevel on materials in V -groove welding.

4 Double V-Groove W eld Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavi-

er fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.

S-0063 / S-0064

9-12. Tee Joint

OM-355 Page 32

45°

Or Less

1 Electrode 2 Fillet Weld Keep arc short and move at definite

rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.

For maximum strength weld both

sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavi-

er fillet is needed. Use any of the weaving patterns shown in Section 9-9. Remove slag before making another weld pass.

S-0060 / S-0058-A / S-0061

9-13. Weld Test

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2 1

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.

1 Vise 2 Weld Joint 3 Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

S-0057-B

Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

9-15. Troubleshooting – Excessive Spatter

Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage.

OM-355 Page 33

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. Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

9-17. Troubleshooting – Lack Of Penetration

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.

9-18. Troubleshooting – Excessive Penetration

Excessive Penetration – weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

OM-355 Page 34

Good Penetration

Increase and/or maintain steady travel speed.

9-19. Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

9-20. Troubleshooting – Waviness Of Bead

Waviness O f Bead – weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

9-21. Troubleshooting – Distortion

Distortion – contraction of weld met- al during welding that forces base metal t o move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds.

OM-355 Page 35

SECTION 10 – PARTS LIST

. Hardware is common and

not available unless listed.

OM-355 Page 36

ST-802 252-D

Figure 10-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 10-1. Main Assembly

+ 1 188 270 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 T4 190 332 COIL, coupling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 190 436 HOLDER, HF coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 G1 199 854 SPARK GAP ASSEMBLY (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 855 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 856 HOLDER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 455 POINTS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 C3 201 197 CAPACITOR, polyp met film .002uf 4400 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 T3 074 398 XFMR, high voltage 115 v pri 3600 v sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 R8 188 067 RESISTOR, WW fxd 100w 200 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 C18, 19 191 944 CAPACITOR, polyp met film 10uf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 188 369 HF BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 190 514 HOLDER, HF coil slide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ 11 192 828 LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 188 272 FRAME, lifting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 T1 188 283 XFMR, power main 208/230 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP1, 2 020 520 THERMOSTAT, NC open 135C w/insulator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 202 119 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 202 116 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 202 117 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 202 118 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 190 341 HEAT SINK, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 R1 186 468 RESISTOR, WW fxd 100w 50 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 188 367 BRACKET, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 MOD1, 2 192 105 THYRISIT OR, SCR module 95A 400V 150C dual 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 190 343 BUS BAR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 190 342 BUS BAR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 HD1 191 941 TRANSDUCER, current hall effect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 C7, 8, 9, 10 190 460 CAPACITOR ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 D1 192 116 MODULE, diode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 C1 191 944 CAPACITOR, polyp met film 10uf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 189 132 RESISTOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 TP3 194 363 THERMOSTAT, NC open 150F close 125F 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 133 873 VALVE, 24VDC 2way 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 188 268 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 604 102 CONNECTOR, clamp cable .690/1.070 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 190 442 CORD SET, 250V 8/3 10 ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 188 366 PLENUM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 150 783 BLADE, fan 9 in 5wg 39deg .312 bore cw 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 188 706 MOTOR, fan 230V 50/60Hz 1550 RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 187 807 BRACKET, fan motor mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ 34 188 362 PANEL, side right 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 188 269 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 Z1 188 284 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 S5 187 467 SWITCH, polarity/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 C13, 14 188 964 CAPACITOR ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 Figure 10-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 188 271 PANEL, side left 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 141 162 HOUSING PLUG AND PINS (service kit) 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 155 552 CONNECTOR, torch (service kit) 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 134 460 CONNECTOR, work cable (service kit) 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 185 759 LABEL, warning electric shock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-355 Page 37

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 10-1. Main Assembly (continued)

188 859 ACCESSORY KIT (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

043 554 RFCS-14, foot control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DB1712RDI TORCH, TIG 150A 12.5 ft cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 860 WORK CABLE, w/clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 094 KIT, regulator/hose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 840 HOLDER, electorde w/cable & dinse connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-355 Page 38

. Hardware is common and

not available unless listed.

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 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 RC7 143 976 RECEPTACLE W/ SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 186 092 RECPT KIT, Din style 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 192 451 COVER, LED diffuser 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 PC1 190 772 CIRCUIT CARD ASSEMBLY, control w/ hardware 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 115 092 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 115 091 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG20 115 093 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 131 052 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 192 279 ENCLOSURE, circuit card assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 111 634 CAPACITOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 S1 128 755 SWITCH, tgl DPST 40A 600VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C5, 6 188 273 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 175 952 PLASTIC, handle switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 169 136 PIN, handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 174 992 KNOB, pointer .840 DIA x .250 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 185 703 RECEPTACLE, Twistlock assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

OM-355 Page 39

Warranty Questions?

Call 1-877-HOBART1 for your local Hobart distributor.

Service

Y ou 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. The expertise of the distributor and Hobart is there to help you, every step of the way.

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

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original ret a i l p urchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSL Y IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or e i ghteen months after the equipment is sent to an International distributor.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Hobart Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches * Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2. Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation bas e d u p o n actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F .O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

hobart standard 7/00

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:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

An Ill inoi s Tool Works Company 600 West Main Street Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

PRINTED IN USA  2000 Hobart Welding Products. 1/00

Hobart CYBERTIG 180 SD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual