Hobart CYBERTIG 250 User guide

OM-359 196 831A
March 2001
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
CYBERTIG 250
Visit our website at
www.HobartWelders.com
And Non-CE Models
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.)
The following terms are used interchangeably throughout this manual: TIG = GTA W Stick = SMAW
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 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions And Weights 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Volt-Ampere Curves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Weld Output Terminals And Selecting Cable Sizes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 14 Receptacle Information 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Automation 10-Pin Connection (Optional) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle 17. . . . . . . . . . . . . . . . . . . . .
3-10. TIG Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) 18. . . . .
3-12. Front Panel Display For TIG AC 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Stick Connections 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 24. . . . . . . . . . . . . . .
3-15. Front Panel Display For Stick AC 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Electrical Service Guide 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Placing Jumper Links And Connecting Input Power 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Selector Switch 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Process Control 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Amperage Control 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Output Control 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional
Sequence Controls) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control 38. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting TIG Starting Characteristics 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Start Mode 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Meters 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Amperage Adjustment Control 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Balance/DIG Control 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Preflow Time Control 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Postflow Time Control 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Pulse Controls (Optional) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. High Frequency Control 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Sequence Controls (Optional) 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Initial Time Control And Initial Amperage Control 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Final Slope Control And Final Amperage Control 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Continued)
TABLE OF CONTENTS
4-20. Spot T ime Control 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Timer/Cycle Counter 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22. Resetting Unit To Factory Default Settings (All Models) 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Circuit Breaker CB1 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Adjusting Spark Gaps 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Voltmeter/Ammeter Help Displays 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Troubleshooting 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – HIGH FREQUENCY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Welding Processes Requiring High Frequency 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR
AC WELDING 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 64
8-2. Preparing Tungsten Electrode For Welding 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Positioning The Torch 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – STICK WELDING (SMAW) GUIDELINES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – PARTS LIST 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
som _nd_4/98
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
Owners 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-359 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-359 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-359 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-359 Page 4
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 ; nest 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 linformation contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.
Y Linstallation, lutilisation, lentretien 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 lappareil est sur ON. Le circuit dentrée 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 Sisoler de la pièce et de la terre au moyen de tapis ou dautres
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 dune source électrique àcourant électrique savère néces-
saire, se servir de la fonction de télécommande si lappareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à linstal-
lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller lalimentation 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 dutilisation et aux codes nationaux, provinciaux et municipaux.
D Toujours v érifier la terre du cordon dalimentation Vérifier et sassu-
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 dabord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D Vérifier fréquemment le cordon dalimentation pour voir sil nest pas
endommagé ou dénudé – remplacer le cordon immédiatement sil est endommagé – un câble dénudé peut provoquer une électrocution.
D Mettre lappareil hors tension quand on ne lutilise 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 dune autre machine.
circuits internes de lappareil 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 Nutiliser quun matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir lappareil 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 dalimentation 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 lintérieur, 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 dair 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 lair et abaisser le niveau doxy­gène provoquant des blessures ou des accidents mortels. Sassu­rer que lair de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité dopérations 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 dun revêtement, tels que lacier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que lendroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation dair. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
les fumées.
OM-359 Page 5
LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.
Le rayonnement de larc 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
dutiliser 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 dautres 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 larc de soudage. En cas dimpossibilité 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 dincendie 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 quils naient 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 dincendie.
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 dhuile 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 quun allumeur au butane ou des allumettes.
projetées de larc 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 dun stimulateur cardiaque doivent
dabord consulter leur médecin avant de sapprocher 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 louïe.
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 dune 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 dexplosion. 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-359 Page 6
1-3. Dangers supplémentaires en relation avec linstallation, le fonctionnement
et la maintenance
Risque DINCENDIE OU DEXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou à proxi-
mité de surfaces infllammables.
D Ne pas installer lappareil à proximité de produits inflammables D Ne pas surcharger linstallation électrique sassurer que lalimen-
tation est correctement dimensionné et protégé avant de mettre lappareil en service.
LA CHUTE DE LAPPAREIL peut blesser.
D Utiliser l’anneau de levage uniquement pour sou-
lever lappareil, NON PAS les chariot, les bouteil­les de gaz ou tout autre accessoire.
D Utiliser un engin dune capacité appropriée pour
D En utilisant des fourches de levage pour déplacer lunité, sassurer
que les fourches sont suffisamment longues pour dépasser du côté opposé de lappareil.
soulever lappareil.
LEMPLOI 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 dair 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 Lutilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de linstallation.
D Si le FCC signale des interférences, arrêter immédiatement lappa-
reil.
D Effectuer régulièrement le contrôle et lentretien de linstallation. 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 sapprocher des organes mobiles. D Ne pas sapprocher 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 linstruction.
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 dinterférence, 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 demploi.
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, lutilisation de câbles blindés, luti­lisation 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
dabord consulter leur médecin avant de sappro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points.
OM-359 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican 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 lAmerican 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, na pas démontré que lexposition 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 lenvironnement 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 lopérateur. 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-359 Page 8
SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
1 1.1 1.2
2
3 3.1 3.2 3.3
4 4.1
2.1
+
2.2
2.3
+
+
1.3
Warning! Watch Out! There are possible hazards as shown by the symbols.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating yourself from work and ground.
1.3 Disconnect input plug or power before working on machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from welding. Dont weld near flammables.
3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it.
3.3 Do not weld on drums or any closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.
5 Become trained and read the
instructions before working on the machine or welding.
6 Do not remove or paint over
(cover) the label.
5 6
+
S-176 254-A
OM-359 Page 9
2-2. Symbols And Definitions
NOTE
A V
Some symbols are found only on CE products.
Amperes Panel–Local
Volts
Output Circuit Breaker Remote Temperature
Protective Earth
(Ground)
Postflow Timer Preflow Timer
Gas (Supply) Gas Input Gas Output
On Off Percent Direct Current
Do Not Switch While Welding
Alternating Current
Gas Tungsten Arc
Welding (GT AW)
Arc Force (DIG) Background Amps
High Frequency -
Start
High Frequency -
Continuous
Shielded Metal Arc
Welding (SMAW)
High Frequency
Increase/Decrease
Of Quantity
Input
U
I
1
IP
S
Balance Control Maximum Cleaning
Electrode
Negative
Voltage (A verage)
0
Rated No Load
Primary Current
Degree Of Protection
Electrode Work Thickness Gauge Spark Gap
Seconds Final Amperage Initial Time Initial Amperage
U
I
I
1eff
1
2
Maximum
Penetration
Final Slope Meter Single-Phase
Primary Voltage
Rated Welding
Current
Maximum Effective
Supply Current
U
X
I
1max
Conventional Load
2
Rated Maximum
Supply Current
Voltage
Duty Cycle
1
Hz
Electrode Positive
Line Connection
Single-Phase
1
Combined AC/DC
Power Source
Hertz
OM-359 Page 10
Pulse Percent On
Time
Trigger Hold Pulser On-Off Pulse Frequency
Spot Time Lift-Arct
4T
4 Step Trigger Op-
eration Sequence
SECTION 3 – INSTALLATION
3-1. Selecting A Location
Movement
1
OR
Y Falling Unit Can Cause
Injury.
S Use lifting eye to lift unit only,
NOT running gear, gas cylinders, or any other accessories.
S Use equipment of adequate
capacity to lift and support unit.
S If using lift forks to move unit,
be sure forks are long enough to extend beyond opposite
2
side of unit. 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.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 2 0 . Y Be careful when placing or
moving unit over uneven
surfaces.
Location A n d A i r f l o w
3
4
1
18 in (460 mm)
18 in (460 mm)
Ref. ST-117 264-C / ST-802 455-B
OM-359 Page 11
3-2. Dimensions And Weights
G
Front
Front
C
H 8 Holes
A
D
C
B
G
E
F
Ref. ST-196 584-B
Height 34 in (864 mm)
Width 22-1/2 in (572 mm)
Length 25 in (635 mm)
A 25 in (635 mm)
B 1-25/64 in (35 mm)
C 1-5/8 in (41 mm)
D 20-5/8 in (524 mm)
E 19-15/16 (506 mm)
F 22-1/4 (565 mm)
G 1-5/32 in (30 mm)
H 1/2 in (13 mm) Dia
Dimensions
Weight
389 lbs (176 kg)
3-3. Specifications
Rated
Welding Output
NEMA Class I (40) –
200 Amperes, 28
Volts AC, 60% Duty
Cycle
NEMA Class I (40) –
200 Amperes, 28
Volts AC, 60% Duty
Cycle
NEMA Class II (40) –
250 Amperes, 30
Volts AC, 40% Duty
Cycle
NEMA Class II (40) –
250 Amperes, 30
Volts AC, 40% Duty
Cycle
*While idling **Power Factor Correction
PFC**
No
PFC
With PFC
No
PFC
With PFC
Amperes Input at AC Balanced Rated
Load Output, 60 Hz, Single-Phase
200V 230V 460V 575V
88
*3.3
60
*55.3
110
*3.3
82
*55.3
77
*2.8
52
*49.5
96
*2.8
71
*49.5
38
*1.5
26
*24.5
48
*1.5
35
*24.5
31
*1.1
21
*19.6
38
*1.1
28
*19.6
KVA KW
17.6
*.59
12.06 *11.2
21.98 *.59
16.32
*11.2
8.6
*.29
8.11 *.39
11.76 *.29
11.81
*1.93
Amperage
Range
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
Max
OCV
OM-359 Page 12
3-5. Specifications(continued)
Amperes Input at AC Balanced Rated
Load Output, 50/60 Hz, Single-Phase
Rated
Welding Output
NEMA Class I (40) –
200 Amperes, 28
Volts AC, 60% Duty
Cycle
NEMA Class I (40) –
200 Amperes, 28
Volts AC, 60% Duty
Cycle
NEMA Class II (40) –
250 Amperes, 30
Volts AC, 40% Duty
Cycle
NEMA Class II (40) –
250 Amperes, 30
Volts AC, 40% Duty
Cycle
*While idling **Power Factor Correction
Rated
Welding Output
NEMA Class I (40) –
175 Amperes, 27
Volts AC, 60% Duty
Cycle
NEMA Class I (40) –
175 Amperes, 27
Volts AC, 60% Duty
Cycle
NEMA Class II (40) –
225 Amperes, 29
Volts AC, 40% Duty
Cycle
NEMA Class II (40) –
225 Amperes, 29
Volts AC, 40% Duty
Cycle
*While idling **Power Factor Correction
PFC**
No
PFC
With PFC
No
PFC
With PFC
PFC**
No
PFC
With PFC
No
PFC
With PFC
220V 400V 440V 520V
82
*3.0
61
*45.9
100 *3.0
81
*45.9
45
*1.6
34
*25.1
55
*1.6
44
*25.1
41
*1.4
31
*22.8
50
*1.4
40
*22.8
35
*1.2
26
*23.2
42
*1.2
34
*23.2
Amperes Input at AC Balanced Rated
Load Output, 50 Hz, Single-Phase
200V 230V 460V 575V
80
*3.3
52
*55.3
101 *3.3
74
*55.3
69
*2.8
45
*49.5
88
*2.8
64
*49.5
35
*1.5
22
*24.5
44
*1.5
32
*24.5
28
*1.1
18
*19.6
35
*1.1
26
*19.6
KVA KW
17.6
*.59
12.06 *11.2
21.98 *.59
16.32
*11.2
8.6
*.29
8.11 *.39
11.76 *.29
11.81
*1.93
KVA KW
15.9
*.59
10.3
*11.2
20.2
*.59
14.7
*11.2
7.4
*.29
7.3
*.39
10.2 *.29
10.1
*1.93
Amperage
Range
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
Amperage
Range
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
5 – 310A 80V
Max
OCV
Max
OCV
OM-359 Page 13
3-4. Duty Cycle And Overheating
Duty Cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating.
If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see Section 5-4), and cooling fans run. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle be­fore welding.
Y Exceeding duty cycle can
damage unit and void war­ranty.
40% Duty Cycle At 250 Amperes
4 Minutes Welding 6 Minutes Resting
Overheating
3-5. Volt-Ampere Curves
0
Minutes
60% Duty Cycle At 200 Amperes
6 Minutes Welding 4 Minutes Resting
A
15
OR
Reduce Duty Cycle
duty1 4/95 / SB-116 198
The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.
OM-359 Page 14
ssb1.1 10/91 – 194 385-A / 194 384-A
3-6. 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.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
Work
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 *Select weld cable size for pulsing application at peak amperage value.. S-0007-D
Electrode
Ref. ST-801 972
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
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
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)
400 ft
(120 m)
3-7. Remote 14 Receptacle Information
AJ
K
B
C
D
*The remaining sockets are not used.
L
I
NH
M
G
F
F
E
E
ST-801 972
24 VOLTS DC
24 VOLTS DC
REMOTE
OUTPUT
CONTROL
AMPERAGE
VOLTAGE
OUTPUT CONTACTOR
A
A/V
GND
Socket* Socket Information
A Contactor control 24 volts dc.
B Contact closure to A completes 24 volts dc
contactor control circuit and enables output.
C Output to remote control; 0 to +10 volts dc output
to remote control.
D Remote control/feedback circuit common. E 0 to +10 volts dc input command signal from
remote control.
F Current feedback; +1 volt dc per 100 amperes.
H Voltage feedback; +1 volt dc per 10 volts output.
K Chassis common.
OM-359 Page 15
3-8. Automation 10-Pin Connection (Optional)
Socket Socket Information For 10-Pin Receptacle RC2
A Start/Stop
F
E
D
G
H
A
D
J
C
I
B
B Gas
C Output disabled
D Chassis ground
E Final slope – collector
F Final slope – emitter
G Pulse lockout – collector
Ref. ST-801 972
A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, but less than 3/4 seconds) starts and stops weld output.
B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initia­tion.
C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to time out, and HELP 13 will be displayed on the meters.
Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30 VDC.
Final Slope - output is on when in Final Slope.
Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10 Hz.
Arc On - output is on when the contactor is on and there is less than 50 load volts.
H Pulse lockout – emitter
I Valid arc – collector
J Valid arc – emitter
Definitions Of Inputs And Outputs
Inputs
Outputs
OM-359 Page 16
3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle
Y Turn Off power before con-
necting t o receptacle.
1 Gas Valve In Fitting Located on rear of unit. 2 Gas Valve Out Fitting Fittings have 5/8-18 right-hand
threads. 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 customer supplied gas
hose between regulator/flow gauge and gas in fitting.
5 Flow Adjust Typical flow rate is 20 cfh (cubic feet
per hour). 6 115 V 15 Amp AC Receptacle Receptacle is protected from over-
load by circuit breaker CB1 (see Section 5-2).
Tools Needed:
5/8, 3/4, 1-1/8 in
6
4
5
2
1
3
Front View Rear View
3-10. TIG Connections
3
4
Ref. ST-801 972 / Ref. ST-801 973 / Ref. ST-157 858
1 Gas In Connection Connect gas hose from gas supply
to gas in fitting. 2 Output Selector Switch (See
Section 4-2)
Switch is shown in DCEN (direct current electrode negative) position for TIG HF Impulse DCEN welding. For front panel control dispay, see Section 3-11. For TIG AC welding, place switch in AC position (see Section 4-2). For TIG AC front pan­el control dispay, see Section 3-12.
2
1
5
6
3 Work Weld Output Terminal Connect work lead to work weld
output terminal. 4 Remote 14 Receptacle Connect desired remote control to
Remote 14 receptacle. 5 Electrode Weld Output
Terminal
Connect TIG torch to electrode weld outout terminal.
6 Gas Out Connection Connect torch gas hose to gas out
fitting.
Tools Needed:
11/16, (21 mm), 3/4 in
802 734-B
OM-359 Page 17
3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1 Front Panel Correct front panel display for basic
TIG HF Impulse DCEN welding.
. For all front panel switch pad
controls: press switch pad to turn on light and enable function.
NOTE: Green on nameplate indi­cates a TIG function (see Section 4-1 for description of controls).
1
OM-359 Page 18
CE Models
1
OM-359 Page 19
3-12. Front Panel Display For TIG AC
1 Front Panel Correct front panel display for basic
TIG AC welding.
. For all front panel switch pad
controls: press switch pad to turn on light and enable function.
NOTE: Green on nameplate indi­cates a TIG function (see Section 4-1 for description of controls).
1
OM-359 Page 20
CE Models
1
OM-359 Page 21
Notes
OM-359 Page 22
3-13. Stick Connections
1 Work Weld Output Terminal Connect work lead to work weld
output terminal. 2 Electrode Weld Output
Terminal
Connect electrode holder to elec­trode weld outout terminal.
3 Remote 14 Receptacle If desired, connect remote control
to Remote 14 receptacle.
4
1
3
2
4 Output Selector Switch (See
Section 4-2)
Switch is shown in DCEP (direct current electrode positive) position for Stick DCEP welding. For front panel control dispay, see Section 3-14. For Stick AC welding, place switch in AC position (see Section 4-2). For Stick AC front panel con­trol dispay, see Section 3-15.
Tools Needed:
11/16, (21 mm), 3/4 in
802 733-B
OM-359 Page 23
3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1 Front Panel Correct front panel display for basic
Stick DCEN welding.
. For all front panel switch pad
controls: press switch pad to turn on light and enable function.
NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).
1
OM-359 Page 24
CE Models
1
OM-359 Page 25
3-15. Front Panel Display For Stick AC
1 Front Panel Correct front panel display for basic
Stick AC welding.
. For all front panel switch pad
controls: press switch pad to turn on light and enable function.
NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).
1
OM-359 Page 26
CE Models
1
OM-359 Page 27
3-16. Electrical Service Guide
NOTE
All values in both tables were calculated at 60% duty cycle.
50/60 Hertz Models Without Power Factor Correction Input Voltage Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker
Time-Delay Fuse
Normal Operating (Fast) Fuse Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In
Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse. 2 Time-Delay fuses are UL class RK5 .
3 “Normal Operating (fast) fuses are UL class K5 (up to and including 60 amp), and UL class “H” ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
200 220 230 400 440 460 520 575
88 82 77 45 41 38 35 31
1
2
125 125 125 70 60 60 50 45
3
125 125 125 70 60 60 50 45
4 6 6 8 8 10 10 10
167
(51)
6 6 6 8 10 10 10 10
137 (42)
153 (47)
305
(93)
369
(112)
281
(86)
50/60 Hertz Models With Power Factor Correction
352
(107)
439
(134)
Input Voltage Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker
Time-Delay Fuse
Normal Operating (Fast) Fuse Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In
Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse. 2 Time-Delay fuses are UL class RK5 .
3 “Normal Operating (fast) fuses are UL class K5 (up to and including 60 amp), and UL class “H” ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
200 220 230 400 440 460 520 575
60 61 52 34 31 26 26 21
1
2
90 90 80 50 45 40 40 30
3
90 90 80 50 45 40 40 30
8 8 8 10 10 10 10 12
87 (26)
8 8 8 10 10 10 10 12
102 (31)
115 (35)
226 (69)
274
(84)
308
(94)
383
(117)
295 (90)
OM-359 Page 28
3-17. Placing Jumper Links And Connecting Input Power
230 VOLTS 460 VOLTS200 VOLTS
LL LL LL
2
230 VOLTS
LL
460 VOLTS
LL
S-083 566-C
575 VOLTS
LL
S-010 587-B
Check input voltage available at site.
1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input
voltage. 3 Input And Grounding
Conductors
Select size and length using Sec­tion 3-16.
4 Line Disconnect Device Select type and size of overcurrent
protection using Section 3-16. Close and secure primary door.
Y Special installation may be
required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .
Connect GND/PE Conductor First
GND/PE Earth Ground
4
L1 (U)
L2 (V)
3
1
3/8 in
Connect GND/PE Conductor First
Tools Needed:
Ref. ST-801 973-B
OM-359 Page 29
SECTION 4 – OPERATION
4-1. Controls
A. For 200/230/460 Volts And Non CE Units
12
1234
11
10
5
6
7
13
9
. Top row of lights in upper left corner are On
for SMAW. Bottom row are On for GTAW.
Green on nameplate indicates a TIG function, Gray indicates a Stick function.
1 Process Control See Section 4-3. 2 Amperage Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Control See Section 4-9.
OM-359 Page 30
8
14
5 Voltmeter See Section 4-10 6 Ammeter See Section 4-10 7 Amperage Adjustment
Control See Section 4-11. 8 Output Selector Switch See Section 4-2. 9 Power Switch Use switch to turn unit Off and On.
10 Postflow Time Control See Section 4-14. 11 Balance/DIG Control See Section 4-12. 12 Pulser Controls (Optional) See Section 4-15. 13 Sequence Controls (Optional) See Section 4-17. 14 High Frequency Control See Section 4-16.
Ref. ST-196 616 / Ref. ST-194 388-B / Ref. ST-801 972
B. For CE Units
12
1234
11
10
5
6
7
13
9
. Top row of lights in upper left corner are On
for SMAW. Bottom row are On for GTAW.
Green on nameplate indicates a TIG function, Gray indicates a Stick function.
1 Process Control See Section 4-3. 2 Amperage Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Control See Section 4-9.
8
14
5 Voltmeter See Section 4-10 6 Ammeter See Section 4-10 7 Amperage Adjustment
Control See Section 4-11. 8 Output Selector Switch See Section 4-2. 9 Power Switch Use switch to turn unit Off and On.
10 Postflow Time Control See Section 4-14. 11 Balance/DIG Control See Section 4-12. 12 Pulser Controls (Optional) See Section 4-15. 13 Sequence Controls (Optional) See Section 4-17. 14 High Frequency Control See Section 4-16.
Ref. ST-196 764 / Ref. ST-196 766 / Ref. ST-801 972
OM-359 Page 31
4-2. Output Selector Switch
4-3. Process Control
1 Output Selector Switch
Y Do not use AC output in
(CE Nameplate)
11
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 (DCEN) Direct Current Electrode Negative, AC, or (DCEP) Direct Current Electrode Positive output.
NOTE: Changing position of Out­put Selector switch may also change Process control, Current control, Output control, and Start Mode control settings to properly function with latest Output Selector switch setting.
1
4-4. Amperage Control
1 1
(CE Nameplate)
(CE Nameplate)
1 Process Control Use control to select Shielded Met-
al Arc Welding (SMAW) or Gas Tungsten Arc Welding (GTAW) pro­cess.
For SMAW, press button to toggle LED to Stick position.
For GTAW, press button to toggle LED to TIG position.
NOTE: Lit LED indicates selected
1
mode. When Output Selector switch posi-
tion changes, LED may change position, based upon last selection.
Ref. ST-196 616 / Ref. ST-196 764
1 Amperage Control Use control to select front panel or
remote amperage control. For front panel amperage control,
press button to toggle LED to Panel position.
For remote amperage control, press button to toggle LED to Re­mote position (see Section 3-7).
NOTE: Lit LED indicates selected mode.
When Output Selector switch posi­tion changes, LED may change position, based upon last selection.
OM-359 Page 32
Notes
OM-359 Page 33
4-5. Output Control
Remote (Standard)Torch Trigger Operation
Current (A)
Preflow
2
1
Initial Amps
2
1
(CE Nameplate)
Remote (Standard)Torch Trigger Operation
Weld Amps
Final Slope
Final Amps
Postflow
Push & Hold Foot Or Finger Remote Control
1 Output Control
Y Weld output terminals are ener-
gized when power is On, and Out­put On LED is lit.
Use control to select front panel, trigger hold, or remote output control.
NOTE: Lit LED indicates selected mode. For weld output, press button to toggle LED
to On position.
OM-359 Page 34
Release For Maintained Switch
2 Remote Trigger (Standard) Operation For remote output control, press button to
toggle LED to Remote position (see Sec­tion 3-7).
Torch trigger operation is as shown.
NOTE: Initial weld amperage and final am­perage is controlled by the remote device, not by the welding power source.
Release Foot Or Finger Remote Control
NOTE: If On/Off only type trigger is used, it must be a maintained switch. All func­tions become active.
Application: Use Remote Trigger when the operator desires to use a foot pedal or finger amperage control.
When Output Selector switch (see Section 4-2) position changes, Output control LED will always switch to Remote.
When Output On is selected, HF and gas control are disabled.
Trigger Hold (2T)
Current (A)
Preflow
3
Initial Amps
3
(CE Nameplate)
2T Torch Trigger Operation
Weld Amps
Final Slope
Final Amps
Postflow
Push & Release Trigger In Less Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page). If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-4).
3 Trigger Hold For trigger hold operation, press button to
toggle LED to Trigger Hold position. Torch trigger operation is as shown.
NOTE: When a foot or finger remote con­trol is connected to the welding power source, only trigger input is functional.
NOTE: Amperage is controlled by the
Push & Release Trigger In Less Than 3/4 Sec.
welding power source. Application: Use Trigger Hold (2T)
when long extended welds are made. Trigger Hold (2T) can help to reduce op­erator fatigue.
OM-359 Page 35
4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional Sequence
Controls)
4T Torch Trigger Operation
If unit is equipped with optional Sequence Controls (see Section 4-17), 4T trigger method is available.
4T torch trigger operation is as shown. While in 4T mode, there is a feature avail-
able during the main weld sequence that al-
Current (A)
Initial Amps
Preflow
Push & Hold Trigger
Release Trigger
lows the operator to toggle between weld current and final current without breaking the arc.
NOTE: When a remote switch is connected to the welding power source, only trigger in­put is functional. Amperage is controlled by the welding power source.
Weld Amps
Push & Release Trigger In Less Than 3/4 Sec.
Push & Release Trigger In Less Than 3/4 Sec.
Application:
Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.
Select 4T trigger method according to Sec­tion 4-7.
Final Slope
Final Amps
Postflow
Push & Hold Trigger
Release Trigger
If unit is equipped with optional Sequence Controls (see Section 4-17), 4T Momen­tary trigger method is available.
4T Momentary torch trigger operation is as shown.
While i n 4 T Momentary mode, once the op­erator toggles out of weld current and be­gins final slope, toggling again will break the arc and go to postflow.
Current (A)
Initial Amps
Preflow
Push & Release Trigger
Push & Release Trigger
4T Momentary Torch Trigger Operation
NOTE: When a remote switch is connected to the welding power source, only trigger in­put is functional. Amperage is controlled by the welding power source.
Weld Amps
Push & Release Trigger
Application:
Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.
Select 4T Momentary trigger method ac­cording to Section 4-7.
Final Slope
Final Amps
Postflow
Push & Release Trigger
OM-359 Page 36
Mini Logic Operation
If unit is equipped with optional Sequence Controls (see Section 4-17), Mini Logic op­eration is available.
Torch trigger operation is as shown. During Mini Logic welding operation, the
weld amperage can be manually changed
Initial Amps
Preflow
Push & Hold Trigger
Push & Hold Trigger For More Than 3/4 Sec.
Final Slope Rate
from the initial amps level to the main weld amps level by pressing and releasing the torch trigger in less than 3/4 seconds.
NOTE: When a remote switch is connected to the welding power source, only trigger in­put is functional. Amperage is controlled by
Weld Amps
Initial Amps
Push & Release Trigger In Less Than 3/4 Sec.
the welding power source. Application: This ability to change amper-
age levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.
Select Mini Logic according to Section 4-7.
Final Slope
Postflow
Push & Hold Trigger For More Than 3/4 Sec.
Release Trigger
Push & Release Trigger In Less Than 3/4 Sec.
Push & Release Trigger In Less Than 3/4 Sec.
OM-359 Page 37
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control
1 Output Control 2 Power Switch To reconfigure Trigger Hold, turn Off
power, push and hold Output control button and turn On power switch. Hold button for approximately 7 sec­onds (or until software version num­ber _ _ _ _ _ _-_clears, and meters display [SEL] [H–2].
Press Output control button to change functions. Active function will be displayed on amperage (bottom) meter.
3 Meter Displays Meter displays for the different func-
tions will be as shown. Press torch trigger or turn power Off
to save setting. Proceed t o Section 4-6 for 4T Opera-
tion. Proceed to Section 4-6 for Mini Logic
operation. Proceed to Section 4-6 for 4T Mo-
mentary operation. NOTE: These features are only
available when optional Sequencer is installed.
2
Front Panel
1
SEL
H-2
SEL
HĆ4E
4T Momentary
=
(See Section 4-6)
SEL
H-4
=
4T (See Section 4-6)
SEL
H4L
Mini Logic (See Section 4-6)
=
3
OM-359 Page 38
(CE Nameplate)
2
1
Front Panel
SEL
H-2
SEL
HĆ4E
4T Momentary
=
(See Section 4-6)
SEL
H-4
=
4T (See Section 4-6)
SEL
H4L
Mini Logic (See Section 4-6)
=
3
OM-359 Page 39
4-8. Selecting TIG Starting Characteristics
1
4
SEL
-2-
2
Use this function to select desired TIG start­ing characteristics.
1 Start Mode 2 Power Switch 3 Output Selector Switch 4 Meters To select or change TIG starting characteris-
tics, proceed as follows: turn Off power. Place Output Selector switch in desired posi­tion (each position, DCEN, AC, or DCEP has three applicable start characteristics op-
OM-359 Page 40
3
tions). Push and hold Start Mode button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).
The TIG LED and all four Start LEDs will light, and the meters will display [SEL] [-2-].
Press Start Mode button again to step through the three start characteristics choices. Amperage (bottom) meter displays active choice 1= light start, 2=medium/normal start, 3=high/hot start.
Press torch trigger or turn Off power to save setting.
Application:
Select 1 (light/soft start) – when welding at low amperages on thin gauge material.
Select 2 (medium/normal start) – factory de­fault setting used for most welding applica­tions.
Select 3 (high/hot start) – when welding at high amperages on thick materials with a large diameter tungsten.
(CE Nameplate)
1
4
SEL
-2-
2
3
OM-359 Page 41
4-9. Start Mode
(CE Nameplate)
1
Lift-Arct Start Method
2
Touch
Do NOT Strike Like A Match!
1 – 2
Seconds
1
3
1 Start Mode For SMAW welding, press button to toggle
LED to Off position. For GTAW welding, use control to select
Off for no HF, Lift-Arct, HF for arc starting only , or continuous HF. See Section 4-16 for adjusting high frequency intensity.
Application:
When Off is selected, use the scratch method t o s t a r t a n arc for both the SMA W and GTAW processes.
When Lift-Arc is selected, start arc as follows:
2 TIG Electrode 3 Workpiece Touch tungsten electrode to workpiece at
weld start point, enable output with torch trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 sec-
OM-359 Page 42
onds, and slowly lift electrode. An arc will form when electrode is lifted.
Shielding gas begins to flow when elec­trode touc h e s w o r k p i e c e .
Normal open-circuit voltage is not present before tungsten electrode touches work­piece; only a low sensing voltage is pres­ent between electrode and workpiece. The solid state output contactor does not energize until after electrode is touching workpiece. Th i s a l l o w s electrode to touch workpiece without overheating, sticking, or getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW pro­cess when HF Start method is not per­mitted, or to replace the scratch method.
When HF Start is selected, start arc as follows:
High frequency turns on to help start arc when output is enabled. High frequency
turns off when arc is started, and turns on whenever arc is broken to help restart arc.
Application:
HF Start is used when the DCEN GTAW process is required.
When HF Continuous is selected, start arc as follows:
High frequency turns on when output is energized and remains on for duration of weld.
Application:
HF Continuous is used when the AC GTA W process is required.
NOTE: Lit LED indicates selected mode. When Output Selector switch position
changes, LED may change position, based upon last selection.
NOTE: Some start methods may not be available for all processes.
4-10. Meters
1
2
4-11. Amperage Adjustment Control
1
(CE Nameplate)
1 Voltmeter Voltmeter displays average voltage
(to the nearest 0.1 V) at the weld output terminals.
2 Ammeter Use meter to preset amperage. Me-
ter displays average weld amper­age output of unit to nearest am­pere when welding.
NOTE: Meters are self-calibrating. No adjustment available.
1 Amperage Adjustment Control Use control to adjust amperage,
and preset amperage on ammeter (see Section 4-10). This control
1
may be adjusted while welding. For remote amperage control,
front panel control setting is the maximum amperage available. For example: I f front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.
For pulse welding, use Amperage Adjust control to select from 5–300 amps of peak amperage (see Sec­tion 4-15).
For spot welding, use Amperage Adjust control to select from 5–300 amps of peak amperage (see Sec­tion 4-20).
OM-359 Page 43
4-12. Balance/DIG Control
Balanced
3
More Penetration
10
More Cleaning
0
1 1
Balance Control Examples
Output Waveforms
50% Electrode
Positive
50% Electrode
Negative
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
(CE Nameplate)
1 Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output square wave. Rotating the control towards 10 prov i d e s d e e p e r p e n e ­tration. Rotating the control towards 0 provides more cleaning action of the workpiece.
When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.
Application:
When welding on oxide forming ma­terials such as aluminum or magne­sium, excess cleaning is not neces­sary. To produce a good weld, only a minimal amount, approximately a
ArcSetting
0.10 in (2.5mm) of etched zone along the weld toes is required.
Set control to 7 and adjust as nec­essary. Joint configuration, set-up, process variables, and oxide thick­ness may affect setting.
NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, in­creasing the Balance control to­wards maximum penetration, may help to restabilize the arc.
DIG Control (AC And DC SMAW):
When set at 0, short-circuit amper­age at low arc voltage is the same as normal welding amperage.
When setting is increased, short­circuit amperage at low arc voltage increases.
Application:
Control helps arc starting or making vertical or overhead welds by in­creasing amperage at low arc volt­age, and reduces electrode sticking while welding.
OM-359 Page 44
Ref. S-0795-A
Notes
OM-359 Page 45
4-13. Preflow Time Control
1
3
00.2
SEL
2
Use control to set length of time (0.2, 0.4, 0.6,
0.8, 1.0, 2.0 or 4.0 seconds) gas flows before welding starts.
1 Process Control 2 Power Switch 3 Meters To change preflow time, proceed as follows:
OM-359 Page 46
Turn power off. Push and hold Process Con­trol button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).
The TIG LED will light and the meters will dis­play [o.2] [SEL]. The factory preflow default setting is 0.2 seconds. To change preflow
time, p r e s s and release Process Control but­ton until desired time is displayed on meters.
Application:
Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in con­sistent arc starting.
1
(CE Nameplate)
3
00.2
SEL
2
OM-359 Page 47
4-14. Postflow Time Control
1
(CE Nameplate)
1 Postflow Time Control Use control to set length of time
(0–50 seconds) gas flows after welding stops. It is important to s e t enough time to allow gas to flow un-
1
til after the tungsten and weld puddle has cooled down.
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 (approximately 1 second per 10 ampere of welding current).
OM-359 Page 48
4-15. Pulse Controls (Optional)
1
(CE Nameplate)
1
Percent (%) Peak
Time Control Setting
(50%)
Balanced
Peak Amp
More Time
At Peak
Amperage
More Time At
Background
Amperage
(20%)
(80%)
2
2
5
Pulsed Output Waveforms
PPS
Bkg Amp
1 On/Off Control
3
3
4
4
Use control to turn pulse function On and Off.
2 Background Amps Use Background Amps control to
set the low pulse of the weld am­perage, which cools the weld puddle and affects overall heat in­put. Background Amps is set as a percentage of peak amperage.
3 Pulse Frequency Ranges from 0.25–10.0 pps
(pulses per second). Control is used to determine appearance o f weld bead.
4 Peak Time A range of 5–95% of each pulse
cycle can be spent at the peak amperage level.
Peak amperage (5–310 amps), is set with the Amperage Adjust­ment control (see Section 4-1). Peak amperage is the highest welding amperage allowed to oc­cur in the pulse cycle. Weld pene­tration varies directly with peak amperage.
5 Pulsed Output Waveforms Example shows affect changing
the Peak Time control has on the pulsed output waveform.
Application:
Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised por t io n s o f t h e w e l d o u t p u t are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level be­tween them (called the back­ground amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.
Pulsing can also be used for filler material addition technique training.
NOTE: Function is enabled, when LED is lit.
OM-359 Page 49
4-16. High Frequency Control
1
Y Do not use high frequency while Shielded Metal Arc Weld-
ing (SMAW).
1 High Frequency Control For GTA W, use control to set HF intensity. Set as low as possible.
Application:
If HF is present at the tungsten, the control is set high enough.
4-17. Sequence Controls (Optional)
1
Ref. ST-801 972
NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, in­creasing the HF Intensity control towards maximum, may help to re­stabilize the arc.
. As high frequency intensity is increased, the possibility of inter-
fering with local electronic devices, especially communication equipment, also increases. Set control as low as possible to avoid such interference.
1 Initial Time Control See Section 4-18. 2 Initial Amperage Control
5
3
See Section 4-18. 3 Final Slope Control See Section 4-19. 4 Final Amperage Control See Section 4-19. 5 Spot Time Control See Section 4-20.
2
4
(CE Nameplate)
5
1
2
3
4
OM-359 Page 50
Ref. ST-196 616 / Ref. ST-196 764
4-18. Initial Time Control And Initial Amperage Control
(CE Nameplate)
1
2
1
2
1 Initial Time Control Indicator light is on when Initial
Time control function is active. NOTE: Initial Sequence control
function i s inactive when Spot Time function is active.
Use control to select 0–15 seconds of start time.
2 Initial Amperage Control Indicator Light is on when Initial Se-
quence control function is active. NOTE: Initial Amperage control
function i s inactive when Spot Time function is active.
Use control to select a starting am­perage (5–310 amps) that is differ­ent from the weld amperage. Note: Initial Amperage can be used with or without a remote control (Initial Amperage and Initial Time control settings will override a remote con­trol device).
Application:
Initial Amperage can be used while GTAW welding to assist in preheat­ing cold material prior to depositing filler material, or to ensure a soft start. Initial Amperage can also be used for SMAW to ensure a more consistent arc strike.
NOTE: Function is enabled, when LED is lit.
OM-359 Page 51
4-19. Final Slope Control And Final Amperage Control
(CE Nameplate)
1
2
1
2
1 Final Slope Control Indicator light is on when Final
Slope control function is active. Note: Final Slope control function
is inactive when Spot Time func­tion is active.
Use control to reduce amperage over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control.
2 Final Amperage Control Indicator light is on when Final
Amperage control function is ac­tive.
Note: Final Amperage control function is inactive when Spot Time function is active (see Sec­tion 4-20).
Final amperage is the amperage to which weld amperage has sloped down to (0–100% of am­perage set on Amperage Adjust control).
Application:
Final Sl o p e s h ould be used while GTAW welding materials that are crack sensitive, and/or the opera­tor wants to eliminate the crater at the end of the weld.
Note: This applies if the operator is using an on/off only type control to start and stop the welding pro­cess.
Note: Do not use this function with a foot or finger amperage control.
NOTE: Function is enabled, when LED is lit.
4-20. Spot Time Control
OM-359 Page 52
1 Spot Time Control
1
(CE Nameplate)
1
Indicator light is on when Spot Time function is active. When Spot T i m e f u nction is active, Ini­tial Time, Initial Amperage, Final Slope, and Final Amperage functions are inactive (see Sec­tion 4-17).
Used with the (GTAW) TIG Spot process, generally with a direct current electrode negative (DCEN) set-up.
Use control to select 0–15 sec­onds of spot time.
Use Amperage Adjust control (see Section 4-1 1) to set amper­age.
Application:
TIG spot welding is used for join­ing thinner materials that are in close contact with the fusion method. A good example would be joining coil ends.
NOTE: Function is enabled, when LED is lit.
4-21. Timer/Cycle Counter
1 2 3
1
(CE Nameplate)
1
1 Amperage Control 2 Output Control (Contactor) To read timer/cycle counter, hold Amper-
age and Output (contactor) buttons while turning o n power.
2
2
3 Timer Display The hours and minutes are displayed on
the volt and amp meters for the first five seconds, and are read as 1, 234 hours and 56 minutes.
3
4 5 6
1 2 3
4
4 5 6
4 Cycle Display
The cycles are displayed on the volt and amp meters for the next five seconds, and are read as 123, 456 cycles.
OM-359 Page 53
4-22. Resetting Unit To Factory Default Settings (All Models)
1
23
4
1 Process Control 2 Amperage Control 3 Output Control 4 Start Control
OM-359 Page 54
5
5 Power Switch To reset all welding power source functions
to original factory settings, turn power off. Push and hold the Process, Amperage,
Output and Start controls and turn On pow­er. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters).
1
23
4
CE Models
5
OM-359 Page 55
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
Unreadable
Labels
Adjust Spark
Gaps
5-2. Circuit Breaker CB1
14-Pin Cord
OR
6 Months
During Heavy Service,
1
Repair Or
Replace
Cracked
Weld
Cables
Gas Hose
Blow Out Or Vacuum
Inside,
Clean Monthly
Clean An d
Tighten
Weld
Terminals
Replace Cracked
Parts
Torch Cable
1 Circuit Breaker CB1 If CB1 opens, high frequency and
output t o the 115 volts ac duplex re­ceptacle stop. Press button to reset breaker.
OM-359 Page 56
Ref. ST-801 972
5-3. Adjusting Spark Gaps
4
3
2
Y Turn Off power before
adjusting spark gaps.
Open access door. 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
1
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. Adjust other gap.
Reinstall access door.
Tools Needed:
0.012 in (0.305 mm)
5/32 in
Ref. ST-801 972 / Ref. S-0043
OM-359 Page 57
5-4. Voltmeter/Ammeter Help Displays
. All directions are in reference to the front
of the unit. All circuitry referred to is lo­cated inside the unit.
0 Help 0 Display Indicates a short in the thermal protection cir-
cuitry located on the transformer of the unit. If this display is shown, contact a Factory Au­thorized Service Agent.
1 Help1 Display An SCR overcurrent condition has occurred.
Turn power off and back on to correct condi­tion. If problem continues, contact a Factory Authorized Service Agent.
2 Help 2 Display Indicates a malfunction in the thermal
protection circuitry located on the transform­er of the unit. If this display is shown, contact a Factory Authorized Service Agent.
3 Help 3 Display Indicates the transformer of the unit has
overheated. The unit has shut down to allow
0
V
1 4
V
the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled.
4 Help 4 Display Indicates a malfunction in the thermal
protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.
5 Help 5 Display Indicates the rectifier assembly of the unit
has overheated. The unit has shut down to allow the fan to cool it (see Section 3-4). Op­eration will continue when the unit has cooled.
6 Help 6 Display Not used. 7 Help 7 Display Not used.
8 Help 8 Display
2
V
Not used. 9 Help 9 Display Indicates a short in the thermal protection cir-
cuitry located on the rectifier assembly of the unit. If this display is shown, contact a Facto­ry Authorized Service Agent.
10 Help 10 Display Indicates Remote Output control is acti-
vated. Release Remote Output control to clear help message.
11 Help 11 Display Indicates Output Selector switch is not in
correct position (see Section 4-2). 12 Help 12 Display Indicates a non-allowable set-up on the front
panel. 13 Help 13 Display AIC option, output enable signal broken
causing weld output to stop, but gas contin­ues to flow.
3
V
V
5
10
HLP
A
--0
V
HLP
A
--5
V
HLP
6
11
HLP
A
--1
V
HLP
A
--6
V
HLP
7
12
HLP
A
--2
V
HLP
A
--7
V
HLP
8
13
HLP
A
--3
V
HLP
A
--8
V
HLP
HLP
A
--4
9
V
HLP
A
--9
A
-10
OM-359 Page 58
A
-11
A
-12
A
-13
5-5. Troubleshooting
Trouble Remedy
NOTE: The remedies listed below are recommendations only. If these remedies do not fix
the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 5-4 for any Help (HLP) message displayed on voltmeter/ammeter.
No weld output; unit completely inoperative.
No weld output; unit on. If using remote control, place Output control in Remote 14 position, and make sure remote control is
Unit provides only maximum or minimum weld output.
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-6).
No control of weld output. If using remote control, place Output control in Remote 14 position, and make sure remote control is
No output from duplex receptacle RC2 and no high frequency.
Lack of high frequency; difficulty in starting GTA W arc.
Wandering arc – poor control of direction of arc.
Tungsten electrode oxidizing and not remaining bright after conclusion of weld.
Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
Place line disconnect switch in On position (see Section 3-17). Check and replace line fuse(s), if necessary (see Section 3-17). Check for proper input power connections (see Section 3-17). Check for proper jumper link position (see Section 3-17).
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position (see Section 4-1).
Check, repair, or replace remote control. Have Factory Authorized Service Agent check unit. Make sure Amperage control is in proper position (see Section 4-1). Have Factory Authorized Service Agent check unit.
Clean and tighten all weld connections. Check position of Output Selector control (see Section Figure 4-1). If using remote control, check position of Amperage Adjustment control (see Section 4-1).
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position (see Section 4-1).
Make sure Amperage control is in proper position (see Section 4-1). Reset circuit breaker CB1 (see Section 5-2).
Reset circuit breaker CB1 (see Section 5-2). Select proper size tungsten. Check High Frequency Intensity control setting (see Figure 4-1). Be sure torch cable is not close to any grounded metal. Check cables and torch for cracked insulation or bad connections. Repair or replace. Check spark gaps (see Section 5-3). Reduce gas flow rate. Select proper size tungsten. Properly prepare tungsten. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten. Check for water in torch, and repair torch if necessary.
protect against overheating.
OM-359 Page 59
SECTION 6 – ELECTRICAL DIAGRAM
OM-359 Page 60
202 484-A
Figure 6-1. Circuit Diagram For Non-CE Models
Figure 6-2. Circuit Diagram For CE Models
194 381-F
OM-359 Page 61
SECTION 7 – HIGH FREQUENCY
7-1. Welding Processes Requiring High Frequency
1
Work
TIG
7-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
1 High-Frequency Voltage TIG – helps arc jump air gap
between torch and workpiece and/ or stabilize the arc.
high_freq 12/96 – S-0693
13
10 9 8
7
3
2
1
4 5 6
14
Sources of Direct High-Frequency Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table
OM-359 Page 62
Sources of Conduction of High Frequency
7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring
Sources of Reradiation of High Frequency
10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes and Fixtures 14 External Phone and Power Lines
S-0694
7-3. Correct Installation
6
8
Ground all metal ob­jects and all wiring in welding zone using #12 AWG wire.
Nonmetal
Building
Weld Zone
3
50 ft
(15 m)
1
2
8
4
Ground workpiece if required by codes.
50 ft
(15 m)
5
7
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.
2 Center Point of Welding Zone Midpoint between high-frequency source
and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all
directions. 4 Weld Output Cables Keep cables short and close together.
Metal Building
8
11
10
5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground conduit every 50 ft (15 m).
6 Water Pipes and Fixtures Ground water pipes every 50 ft (15 m). 7 External Power or Telephone Lines Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines. 8 Grounding Rod Consult the National Electrical Code for
specifications.
9
8
Ref. S-0695 / Ref. S-0695
Metal Building Requirements
9 Metal Building Panel Bonding Methods Bolt or weld building panels together, install
copper straps or braided wire across seams, and ground frame.
10 Windows and Doorways Cover all windows and doorways with
grounded copper screen of not more than 1/4 in (6.4 mm) mesh.
11 Overhead Door Track Ground the track.
OM-359 Page 63
SECTION 8 – SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2000
Y Whenever possible and practical, use DC weld output instead of AC weld output.
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)
Amperage Range - Gas Type - Polarity
Electrode Diameter DC – Argon – Electrode
2% Ceria (Orange Band), 1.5% Lan-
thanum (Gray Band), Or 2% Thorium
(Red Band) Alloy Tungstens
.010 Up to 25 * Up to 20 Up to 15 .020 15-40 * 15-35 5-20 .040 25-85 * 20-80 20-60 1/16 50-160 10-20 50-150 60-120 3/32 135-235 15-30 130-250 100-180
1/8 250-400 25-40 225-360 160-250 5/32 400-500 40-55 300-450 200-320 3/16 500-750 55-80 400-500 290-390
1/4 750-1000 80-125 600-800 340-525
Pure Tungsten
(Green Band)
.010 Up to 15 * Up to 15 Up to 10 .020 5-20 * 5-20 10-20 .040 15-80 * 10-60 20-30 1/16 70-150 10-20 50-100 30-80 3/32 125-225 15-30 100-160 60-130
1/8 225-360 25-40 150-210 100-180 5/32 360-450 40-55 200-275 160-240 3/16 450-720 55-80 250-350 190-300
1/4 720-950 80-125 325-450 250-400
Zirconium Alloyed Tungsten (Brown
Band)
.010 * * Up to 20 Up to 15 .020 * * 15-35 5-20 .040 * * 20-80 20-60 1/16 * * 50-150 60-120 3/32 * * 130-250 100-180
1/8 * * 225-360 160-250 5/32 * * 300-450 200-320 3/16 * * 400-550 290-390
1/4 * * 600-800 340-525
Negative/Straight Po-
larity
DC – Argon – Elec-
trode Positive/Rev-
erse Polarity
AC – Argon AC – Argon –
Balanced Wave
Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended.
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. OM-359 Page 64
8-2. Preparing Tungsten Electrode For Welding
Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor­mation. Consider using 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.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
1 Tungsten Electrode
1
Electrode Diameter
2
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
2
3
4
Ideal Tungsten Preparation – Stable Arc
1
2
3
4
Wrong Tungsten Preparation – Wandering Arc
1 Stable Arc 2 Flat Diameter of this flat determines
amperage capacity. 3 Grinding Wheel Grinding wheel should be dedi-
cated to grinding tungsten only. 4 Straight Ground
1 Arc Wander 2 Point 3 Grinding Wheel Grinding wheel should be dedi-
cated to grinding tungsten only. 4 Radial Ground
B. Preparing Tungsten For Conventional AC Welding
1
1 – 1-1/2 Times
Electrode Diameter
2
1 Tungsten Electrode 2 Balled End
Y Understand and follow
safety symbols at start of Section 9-1 before preparing tungsten.
Ball end of tungsten by applying AC amperage recommended for a giv­en electrode diameter (see Section 8-1). Let ball on end of the tungsten take its own shape.
OM-359 Page 65
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)
9-1. Positioning The Torch
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.
. For additional information, see
your distributor for a handbook on the Gas Tungsten Arc Weld­ing (GTAW) process.
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 8-1 and 8-2.
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°
3
2
4
90°
1
10–15°
4
5
6
5
6
1/16 in
OM-359 Page 66
3/16 in
Bottom View Of Gas Cup
Ref. ST-161 892
9-2. 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-359 Page 67
9-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
20°
20°
T Joint
70°
75°
Lap Joint
Corner Joint
10°
15°
20-40°
75°
15°
30°
90°
75°
OM-359 Page 68
15°
ST-162 003 / S-0792
SECTION 10 – STICK WELDING (SMAW) GUIDELINES
10-1. 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-
5
4
2
3
6
1
7
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 10-2).
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:
stick 12/96 – ST-151 593
OM-359 Page 69
10-2. 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
50
100
150
200
250
300
350
400
450
AC
DC*
ELECTRODE
EP
6010
EP
6011
EP,EN
6013
EP,EN
7014
EP
7018
EP,EN
7024
EP
NI-CL
EP
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
10-3. Striking an Arc – Scratch Start Technique
1
3
10-4. Striking an Arc – Tapping Technique
1
3
1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece
2
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
2
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-359 Page 70
10-5. Positioning Electrode Holder
90° 90°
End View of Work Angle Side View of Electrode Angle
10°-30°
GROOVE WELDS
45°
45°
End View of Work Angle Side View of Electrode Angle
10-6. Poor Weld Bead Characteristics
FILLET WELDS
2
3
10°-30°
S-0060
1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration
1
4
10-7. Good Weld Bead Characteristics
5
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.
1
5234
4 No Overlap 5 Good Penetration into Base
Metal
OM-359 Page 71
S-0053-A
S-0052-B
10-8. 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
10-9. Electrode Movement During Welding
NOTE
1
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.
3
1 Stringer Bead – Steady
Movement Along Seam
2
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-359 Page 72
10-10.Butt Joints
1
10-11.Lap Joint
2
Single-Layer Fillet Weld
1 Tack Welds
2
1/16 in
(1.6 mm)
3
30° Or Less
11
30°
4
30° Or Less
3
Multi-Layer Fillet Weld
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
10-12.Tee Joint
2
1
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
2
1
3
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 10-9. Remove slag before making another weld pass.
S-0060 / S-0058-A / S-0061
OM-359 Page 73
10-13.Weld Test
3
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
2 1
2
10-14.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
3
1
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.
10-15.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-359 Page 74
10-16.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.
10-17.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.
10-18.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.
Good Penetration
Increase and/or maintain steady travel speed.
OM-359 Page 75
10-19.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.
10-20.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.
10-21.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-359 Page 76
Notes
OM-359 Page 77
SECTION 11 – PARTS LIST
12
11
10
9
13
14
1516
. Hardware is common and
not available unless listed.
51
52
17
53
54
24
23
8
7
6–Fig. 1 1-2
4
25
37
36
35
5
27
18 19
20
21
22
32
31
26
30
33
29
28-Fig. 11-4
38
OM-359 Page 78
3
2
1
50
44
45
49
48
47
Figure 11-1. Main Assembly
46
43
42
41
39
34–Fig. 11-3
40
802 609-B
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 11-1. Main Assembly
1 PC1 203 899 Circuit Card Assy, Interface (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186 914 Display, LED Numeric 7 Segment 3 Digit (LEDs 18 – 23) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 PC1 203 899 Circuit Card Assy, Interface (consisting of) (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . .
186 914 Display, LED Numeric 7 Segment 3 Digit (LEDs 18 – 23) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG13, 15 131 054 Connector W/Sockets 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG10 130 203 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG14 115 092 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG4 115 093 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG17 131 052 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG16 115 091 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 195 778 Actuator Push Button Assy 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 190 512 Stand–off, No 6–32 X .6406 Lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 PC2 190 734 Circuit Card, Pulser 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC3 190 738 Circuit Card, Sequencer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 196 762 Hf Control Box Assy, ( Figure 11-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 204 289 Panel, Side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194 590 Label, Miller 12.563 X 5.376 Horizontal Syncrowav 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 204 312 Top, Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 R3 201 133 Resistor, WW Fxd 400 W 35 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 +204 291 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127 363 Label, Warning Electric Shock Can Kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168 384 Label, Warning Electric Shock And Incorrect Input P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 168 343 Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 184 057 Door, Primary Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
189 491 Spacer, Hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 605 227 Nut, 750–14 Knurled1.68dia .41h Nyl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 GS1 133 873 Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 969 Plug, Protective No 6 Plastic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 010 146 Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 176 272 Conn, Clamp Cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 202 485 Baffle, Rear Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
186 162 Relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 184 058 Fan, Plenum 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 1T 199 312 Block, Terminal Fast–on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 150 783 Blade, Fan 9.000 5wg 39deg .312 Bore Cw Plstc 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 FM1, FM2 188 706 Motor, Fan 230v 50/60hz 1550 Rpm .312 Dia Shaft 2. . . . . . . . . . . . . . . . . . . . . . . . . .
22 187 807 Bracket, Mtg Motor Fan 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 192 864 Support, Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 026 627 Gasket, Lifting Eye Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 T1, Z1 194 379 Xfmr/Stabilizer Assy, 200/230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 T1, Z1 196 715 Xfmr/Stabilizer Assy, 230/460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 T1, Z1 196 711 Xfmr/Stabilizer Assy, 220/400/440/520 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TH1 201 443 Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 200 647 Bracket, Support Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 192 862 Bracket, Mtg Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 SR1 196 485 Rectifier Assy, (Figure 11-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 603 Tubing, Gl Acryl 1.000–1.036 Idxspool Nat Fa1 0.875. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 184 052 Baffle, Cap Power Factor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 C5, C6 111 634 Capacitor Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 TE1 034 587 Term Assy, Pri 1ph 3v (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
083 426 Terminal Board, pri 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
038 618 Link, jumper term bd pri 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 835 Nut, brs hex 10-32reg 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 836 Nut, brs hex .250-20 jam hvy 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
038 888 Stud, pri board brs .250-20 x 1.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
038 887 Stud, pri board brs 10-32 x 1.375 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 913 Washer, flat brs .187 ID 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 915 Washer, flat brs .250 ID x .625 OD x .031thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 207 Washer, lock .255 ID x .489 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
175 479 Link, jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-359 Page 79
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (continued)
190 161 Lug, Univ W/Screw 1/O–14 Wire .266std 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 +196 584 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155 436 Label, Ground/Protectiv 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 189 224 End Cap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 197 026 HF Panel Assy, Lower (Figure 11-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 S1 128 757 Switch, Tgl Dpst 60a 600vac Scr Term Wide Tgl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 R5 198 547 Rheostat, Ww 25. W 1.5 Ohm Fric Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 S5 201 121 Switch Assy, Polarity With Leads And Hardware (Dx) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 204 305 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143 397 Blank, Snap–in Nyl .312 Mtg Hole Black 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117 860 Blank, Snap–in Nyl .187 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107 983 Blank, Snap–in Nyl .500 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 097 922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
174 041 Label, Indicator Intensity Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 +196 492 Door, Access Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 327 Label, Warning General Precautionary Static&wire Fe 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127 363 Label, Warning Electric Shock Can Kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 175 952 Plastic, Handle Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 194 388 Nameplate, Miller Syncrowave 250DX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 196 766 Nameplate, Miller Syncrowave 250DX (Wordless) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 184 066 Door Spark Gap Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 196 616 Plate, Indicator Syncrowave 250DX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 196 764 Plate, Indicator Syncrowave 250DX (Wordless) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 183 332 Knob, Pointer .570 Dia X .125 Id W/Spring Clip 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip–.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 204 416 Drawer, Mat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 204 313 Drawer, Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 204 307 Slide, Drawer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 204 314 Drawer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51 204 389 HOLDER, Torch/Cable (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 200 920 Door, Torch/Cable Holder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 200 922 Housing, Torch/Cable Holder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 494 907 SCREW, k50 x 20 pan hd – trx pld pt thread forming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONAL +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 Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-359 Page 80
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
196 762
Figure 11-2. HF Control Box Assembly (Figure 11-1 Item 6)
1 G1 199 854 Spark Gap Assy, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199 855 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199 856 Holder, Points 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196 455 Points, Spark Gap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 184 068 Bracket, Spark Gap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 C3 201 197 Capacitor, Polyp Met Film .002uf 4400vacpnlmtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 R8 188 067 Resistor, ww fxd 100 w 200 ohm w/clips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 C11, C19 195 552 Capacitor, Polyp Met Film 20. Uf 250 Vac 10% 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 R2 189 132 Resistor Assy, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 R1 186 468 Resistor, Ww Fxd 100 W 50 Ohm W/Clips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 010 493 Bushing, Snap–in Nyl .625 Id X .875 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 196 576 Hf, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 T3 074 398 Xfmr, High Voltage 115v Pri 3600v Sec 30 Ma 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
not available unless listed.
7
6
5
4
3
2
1
10
5
Figure 11-2. HF Control Box Assembly
8
9
802 756
OM-359 Page 81
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
197 026
Figure 11-3. HF Panel Assembly, Lower (Figure 11-1 Item 34)
1 197 022 Panel, Lower Hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 193 415 Connector, Faston 1/4 Ring W/75deg Bend 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 RC2/CB1/C12 201 153 Receptacle, W/Leads And Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
156 734 Nut, 010–32 .31hex .13h Stl Pld Sem Cone Wshr.38d 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 RC1 201 127 Harness, Assy 14 Pin Recpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG5 143 976 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 CM1 197 220 Module, Filter .1mf 500vdc 8 Ckt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 089 120 Clamp, Hose .375 – .450 Clp Dia Slfttng Green 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 155 527 Hose, Nprn Brd No 1 X .250 Id X 28.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 120 854 Ftg, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 C13, C14 196 499 Capacitor Assy, 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 157 317 Holder, Hf Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 T4 199 487 Coil, Hf Coupling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 474 Service Kit, DX Coupling Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 157 318 Holder, Hf Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 097 421 Terminal, Pwr Output Red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
not available unless listed.
1
2 3
4
6
5
8
9
13
7
9
10
11
12
802 757
Figure 11-3. HF Panel Assembly, Lower
OM-359 Page 82
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
196 485
Figure 11-4. HF Rectifier Assembly (Figure 11-1 Item 28)
1 Mod 1, 2 196 760 Thyristor, SCR Module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 196 191 Heat Sink, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 HD1 191 941 Transducer, Current Hall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TH2 188 431 Thermister, NTC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 196 171 Insulator, Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 C7, 8, 9, 10 190 460 Capacitor Assy 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
not available unless listed.
5
1
4
2
1
3
6
Figure 11-4. Rectifier Assembly
5
Ref. 802 609-A
OM-359 Page 83
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 manufacturers 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 customers risk and expense. Hobarts 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
Owners 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
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