Hobart STICKMATE 160i User guide

OM-278400E 2020−10

Processes

Stick (SMAW) Welding

Description

Arc Welding Power Source

R

Stickmate 160i

www.HobartWelders.com

File: 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 Hazards For Installation, Operation, And Maintenance 3.......................

1-4. California Proposition 65 Warnings 4.................................................

1-5. Principal Safety Standards 4.......................................................

1-6. EMF Information 4................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5..........................

2-1. Symboles utilisés 5...............................................................

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

2-3. Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement

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

2-4. Proposition californienne 65 Avertissements 8.........................................

2-5. Principales normes de sécurité 8....................................................

2-6. Informations relatives aux CEM 8...................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Miscellaneous Symbols And Definitions 9............................................

SECTION 4 − SPECIFICATIONS 10..............................................................

4-1. Serial Number And Rating Label Location 10...........................................

4-2. Software Licensing Agreement 10....................................................

4-3. Information About Default Weld Parameters And Settings 10..............................

4-4. Unit Specifications 10..............................................................

4-5. Environmental Specifications 10.....................................................

4-6. Duty Cycle Chart 11...............................................................

4-7. Volt-Ampere Curves 12.............................................................

SECTION 5 − INSTALLATION 13................................................................

5-1. Selecting a Location 13.............................................................

5-2. Installing Electrode Holder And Work Clamp 14.........................................

5-3. Installing Work Clamp 14...........................................................

5-4. Connecting To Weld Output Terminals 15..............................................

5-5. Adjusting Shoulder Strap 15.........................................................

5-6. Multi−Voltage Plug Adapter (MVP) Connection 16.......................................

5-7. Weld Output Cables 17.............................................................

5-8. Electrical Service Guide 17..........................................................

5-9. Connecting 120 Volt Input Power 18..................................................

5-10. Connecting 240 Volt Input Power 19..................................................

SECTION 6 − OPERATION 20..................................................................

6-1. Controls 20.......................................................................

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 21.........................................

7-1. Routine Maintenance 21............................................................

7-2. T

SECTION 8 − PARTS LIST 22...................................................................

8-1. Recommended Spare Parts 22......................................................

SECTION 9 − ELECTRICAL DIAGRAMS 23......................................................

roubleshooting

21................................................................

TABLE OF CONTENTS

SECTION 10 − GUIDELINES FOR STICK WELDING (SMAW) 24....................................

10-1. Stick Welding Procedure 24............................................................

10-2. Electrode And Amperage Selection Chart 25..............................................

10-3. Striking An Arc 25.....................................................................

10-4. Positioning Electrode Holder 26.........................................................

10-5. Poor Weld Bead Characteristics 26......................................................

10-6. Good Weld Bead Characteristics 26......................................................

10-7. Conditions That Affect Weld Bead Shape 27...............................................

10-8. Electrode Movement During Welding 27..................................................

10-9. Welding Lap Joints 27.................................................................

10-10. Welding Groove (Butt) Joints 28........................................................

10-11. Welding T-Joints 28..................................................................

10-12. Weld Test 29........................................................................

10-13. T

COMPLETE PARTS LIST − Available at www.HobartWelders.com
WARRANTY

roubleshooting

29...................................................................

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2020−02

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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 Principal Safety Standards listed in Section 1-5.
Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train­ing and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety train­ing to recognize and avoid the hazards involved.

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
power circuit and machine internal circuits are also
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 weld output in damp, wet, or confined spaces, 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

Additional
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

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).

safety precautions are required when any of the follow-

DC constant voltage (wire) welder, 2) a DC manual

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid
these hazards.

D Properly install, ground, and operate this equipment according to

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

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

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

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
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 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

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. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn off unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

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

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-278400 Page 1

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 Ventilate the work area and/or use local forced ventilation at the arc

to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the

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

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 the 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks 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,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

D Do not cut or weld on tire rims or wheels. Tires can explode if heat-

ed. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

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, sparks, 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 body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

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

FLYING METAL or DIRT 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.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

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 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 Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
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.

OM-278400 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise lev-

el is high.

CYLINDERS can explode if damaged.

Compressed 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, physical damage, 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 compressed gas cylinders, regulators, hoses,

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

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use correct procedures and equipment of ade-

quate 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.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

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.

FLYING SPARKS can injure.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

MOVING PARTS can injure.

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

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

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.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

OM-278400 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation,
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.

safety services, computers, and

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.

For more information, go to www.P65W

arnings.ca.gov

.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1 from American National Standards Institute.

Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1 from Glob-

al Engineering Documents. Website: www

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0 from Global

Engineering Documents. Website: www.global.ihs.com.
National Electrical Code, NFPA Standard 70 from National Fire Protection

Association. Website: www.nfpa.org and www. sparky.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1

from Compressed Gas Association. Website:www.cganet.com.

.global.ihs.com.

D

Electromagnetic
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 to 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.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association.
Website: www.csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.
OSHA Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement on

the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH).
Website: www.cdc.gov/NIOSH.

energy can interfere with

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

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

OM-278400 Page 4

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

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

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

som_2020−02_fre

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.

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

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les consignes
de sécurité présentées ci−après ne font que résumer les in-
formations contenues dans les principales normes de
sécurité énumérées à la section 2-5. Lire et observer toutes les
normes de sécurité.

L

’installation,
doivent être confiés qu’à des personnes qualifiées. Une per­sonne qualifiée est définie comme celle qui, par la
possession
statut professionnel, ou qui, par une connaissance, une for­mation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

D Ne pas utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

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

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,

l’utilisation, l’entretien et les réparations ne

d’un diplôme reconnu, d’un certificat ou d’un

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

telles que sols, grilles ou échafaudages ; en position

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Reportez−vous aux symboles et aux directives
ci−dessous afin de connaître les mesures à prendre pour éviter tout
danger.

l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée.

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

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation
mes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément
nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

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

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

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

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

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

avec un câble distinct.

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

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

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

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

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

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 la soudure.

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

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Éteignez l’unité, débranchez le courant électrique, et déchargez

les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.

En outre, ne pas travailler seul !

selon la norme OSHA 29 CFR 1910.147 (voir nor-

à son Manuel d’Utilisation et aux réglementations

OM-278400 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

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

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

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

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

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

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

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

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

et tous les métaux renfermant ces éléments peuvent

peut être dangereux pour votre santé.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
peau. Des étincelles sont projetées pendant le soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux 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 lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

des rayons visibles et invisibles intenses (ultraviolets

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

être projetées de l’arc de soudure. La projection d’étincelles, 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 ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

OM-278400 Page 6

provoquer leur éclatement. Des étincelles peuvent

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

D Ne pas couper ou souder des jantes ou des roues. Les pneus

peuvent exploser s’ils sont chauffés. Les jantes et les roues répa­rées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.

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

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

D Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

avec des protections homologués.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

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

facial.

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

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

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

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

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

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

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

endommagée, elle peut exploser. Du fait que

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

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

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

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

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

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

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

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter les
bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance

Risque D’INCENDIE OU D’EXPLOSION.

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

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation
de mettre l’appareil en service.

duits inflammables.

est correctement dimensionnée et protégée avant

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

D Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

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

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

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

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

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

D Affûter l’électrode au tungstène uniquement à

LES CHARGES ÉLECTROSTATI­QUES 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, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation

D Maintenir fermés et verrouillés les portes,

électrique.

OM-278400 Page 7

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes
lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie,

ainsi que les codes municipaux.

et le Mode d’emploi avant l’instal-

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L

’utilisateur

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.

provoquer des interférences avec les équi-

est tenu de faire corriger rapidement par un électricien

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

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

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

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

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

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

2-4. Proposition californienne 65 Avertissements

AVERTISSEMENT : ce produit peut vous exposer à des pro­duits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65W

arnings.ca.gov

.

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences

éventuelles.

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

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

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

électronique

conformément

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation
de travail.

sensible.

à ce mode d’emploi.

de filtres de ligne ou la pose de protecteurs dans la zone

sensible tel que les ordinateurs et

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1 from American National Standards Institute.

Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1 from Glob-

al Engineering Documents. Website: www

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0 from Global

Engineering Documents. Website: www.global.ihs.com.
National Electrical Code, NFPA Standard 70 from National Fire Protection

Association. Website: www.nfpa.org and www. sparky.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1

from Compressed Gas Association. Website:www.cganet.com.

.global.ihs.com.

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

médicaux doivent être prises: Limiter par exemple tout accès

du ruban adhésif ou avec une housse.

(CEM) à certains endroits. Le courant issu d’un

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association.
Website: www.csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.
OSHA Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement on

the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH).
Website: www.cdc.gov/NIOSH.

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précé­dentes.

OM-278400 Page 8

. A complete Parts List is available at www.HobartWelders.com

U

U

SECTION 3 − DEFINITIONS

3-1. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

A
V

U

I

1eff

I

1max

I

2

0

1

2

Maximum Effective

Amperage

Voltage

Rated No-Load

Voltage (OCV)

Primary Voltage

Load Voltage

Supply Current

Rated Maximum

Supply Current

Rated Welding

Current

Positive

X

Hz

Negative

Input Power Or

Input Voltage

On

Off

Line Connection

Duty Cycle

Protective Earth

(Ground)

Hertz

T

emperature

Alternating

Current

IP

Direct Current

Shielded Metal Arc

Welding (SMAW)

Single Phase

Single-Phase Static

Frequency
Converter-

Transformer-

Rectifier

Percent

Suitable For Weld-

ing In An Environ-

ment With An In-

creased Risk Of

Electric Shock

Internal Protection

Rating

Look Under Unit

For Label

OM-278400 Page 9

. A complete Parts List is available at www.HobartWelders.com

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at

https://www

.hobartwelders.com/eula

4-3. Information About Default Weld Parameters And Settings

NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding
parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference
purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters
and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely
responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate
quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness
for a particular purpose.

4-4. Unit Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8 thru 5-10 for information on con-

necting input power.

A. Stickmate 160i

. and are incorporated by reference herein.

Maximum

Input Power

Single-Phase

AC

120 V

240 V

Rated

Welding

Output

65 A At 22.6

Volts DC,

20% Duty Cycle

43 A At 21.7

Volts DC

60% Duty Cycle

34 A At 21.4

Volts DC

100% Duty Cycle

160 A At 26.4

Volts DC,

30% Duty Cycle

113 A At 24.5

Volts DC

60% Duty Cycle

88 A At 23.5

Volts DC

100% Duty Cycle

Output

Amperage

Range

20−80 A 91 VDC 20.7 A

20−160 A 91 VDC 27.8 A

4-5. Environmental Specifications

A. IP Rating

Open-

Circuit
Voltage
DC (U

)

0

Single−Phase

Maximum

Amperage

Input At

Rated Load

Output

50/60 Hz,

(I

max)

1

KVA KW

2.48 1.76

1.76 1.16

1.42 0.91

7.47 4.91

5.14 3.22

3.91 2.36

Overall

Dimensions

(L x W x H)

13.375 x 7.125
x 10.5 in.

340 x 181 x

268 mm

Weight

15 lb (7 kg)

This equipment is designed for indoor use and is not intended to be used or stored outside.

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

14 to 104°F (−10 to 40°C)

*Output is derated at temperatures above 104°F (40°C).

OM-278400 Page 10

IP Rating

IP21S

IP21S 2014−06

−4 to 131°F (−20 to 55°C)

Temp_2016-07

4-6. Duty Cycle Chart

A. Stickmate 160i

160

140

120

100

80

60

DC WELDING AMPERES

40

20

. A complete Parts List is available at www.HobartWelders.com

240 VAC

120 VAC

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

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty

0

Overheating

10

20 30 40 50 60 70 80 90 100

% DUTY CYCLE

120 Volt Models

20% Duty Cycle at 65 A

2 Minutes Welding 8 Minutes Resting

240 Volt Models

30% Duty Cycle at 160 A

3 Minutes Welding 7 Minutes Resting

0

A or V

Minutes

15

OR

Reduce Duty Cycle

sduty1 2013−04 / 279027-B

OM-278400 Page 11

. A complete Parts List is available at www.HobartWelders.com

4-7. Volt-Ampere Curves

A. Stickmate 160i (120 Volt Input)

80

70

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities.
Curves of other settings fall be­tween the curves shown.

60

MAXIMUM

50

40

VOLTS

30

MINIMUM

20

10

0

0 102030405060708090100

AMPERES

B. Stickmate 160i (240 Volt Input)

80

70

60

MAXIMUM

50

40

MINIMUM

30

VOLTS

20

10

0

0 20 40 60 80 100 120 140 160 180

AMPERES

279224-A

OM-278400 Page 12

. A complete Parts List is available at www.HobartWelders.com

SECTION 5 − INSTALLATION

5-1. Selecting a Location

Movement

! Do not move or operate unit

1

where it could tip.

Location And Airflow

18 in.

(460 mm)

Notes

2

18 in.

(460 mm)

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

1 Lifting Handle
Use handle to lift unit.
2 Line Disconnect Device
Locate unit near correct input

power supply.

loc_small 2015-04

OM-278400 Page 13

. A complete Parts List is available at www.HobartWelders.com

5-2. Installing Electrode Holder And Work Clamp

3

2

Note orientation of shim.

1

Removing Barrel From Electrode
Holder

1 Barrel
2 Barrel Set Screw
3 Electrode Holder
Loosen barrel set screw. Slide barrel

away from electrode holder.

Installing Electrode Cable and
Barrel onto Electrode Holder

4 Electrode Cable From Unit

(Has Bare Conductors on End)
5 Shim
6 Cable Set Screws
Remove precut insulation from end

of electrode cable. Insert cable
through barrel into end of electrode
holder. Insert shim into electrode
holder exactly as shown. Install set
screws and tighten securely.

4

Slide barrel over electrode holder.
Tighten set screw to secure barrel.

. Verify shim is installed correctly

if set screws do not secure elec-

trode holder assembly.

Tools Needed:

4 mm

5-3. Installing Work Clamp

Tools Needed:

5

6

Shim Installation

5

4

6
5

2

1

4

3

6

279288-A

. Tighten connection hardware with

proper tools. Do not just hand tight­en hardware. A loose electrical
connection will cause poor weld
performance and excessive heat­ing of the work clamp.

1 Work Clamp
2 Work Cable From Unit
3 Screw
4 Flat Washer
5 Lock Washer
6 Nut
Route work cable through hole in clamp

handle. Secure cable with hardware as
shown.

10 mm

OM-278400 Page 14

Ref. 258 550-B

. A complete Parts List is available at www.HobartWelders.com

5-4. Connecting To Weld Output Terminals

! Turn off power before connecting

to weld output terminals.

! Do not use worn, damaged, un-

dersized, or repaired cables.

1 Negative (−) Weld Output Terminal
2 Positive (+) Weld Output Terminal
3 Dinse Weld Connector
Insert Dinse connector fully into termi-

nal. Rotate connector clockwise to lock
in position.

21

3

5-5. Adjusting Shoulder Strap

2

Connect dinse 2017−03 − 279282-A / 802554

1 Shoulder Strap
2 Adjuster
Use adjuster to change strap length as

desired. Be sure strap is routed through
adjuster as shown.

1

279982-A / 279438-A

OM-278400 Page 15

. A complete Parts List is available at www.HobartWelders.com

5-6. Multi−Voltage Plug Adapter (MVP) Connection

Selecting Plug Adapter

2

3

4

5

6

7

1

1

! Do not cut off power cord

connector and rewire. The
power cord connector and
plugs adapters will work with
standard NEMA receptacles.
Modifying power cord,
connector, and plug adapter
will void product warranty.

8

Selecting Plug Adapter

1 Power Cord Connector From

Welding Power Source − NEMA
Type L6−30P

Select plug adapter for power supply
receptacle available at site. Not all plug
adapters shown are provided as standard
with unit.

2 Plug Adapter − NEMA Type 5−15P
3 Receptacle − NEMA Type 5−15R

(Customer Supplied)

Connecting Plug Adapter To Power Cord

4 Plug Adapter − NEMA Type 5−20P

(Optional)

5 Receptacle − NEMA Type 5−20R

(Customer Supplied)

6 Plug Adapter − NEMA Type 6−50P

7 Receptacle − NEMA Type 6−50R

(Customer Supplied)

8 Receptacle − NEMA Type L6−30R

(Customer Supplied)

! Follow electrical service guide for

240 VAC in Section 5−8. Do not use
plug rating to size branch circuit
protection.

Connecting Plug Adapter To Power
Cord

Align plug adapter and power cord
contacts. Push together.

Turn plug adapter clockwise until
completely tight.

Connect plug to receptacle.

OM-278400 Page 16

MVP Plug2 2011−09 / Ref. 254 665-A

. A complete Parts List is available at www.HobartWelders.com

1

2

3

4

4

5-7. Weld Output Cables

. For weld output cable replacements or extensions, contact your Factory Authorized Service Agent.

5-8. Electrical Service Guide

Elec Serv 2017-01

A. Stickmate 160i

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

50/60 Hz 1-Phase 50/60 Hz 1−Phase

Input Voltage (V) 120 240
Rated Maximum Supply Current I
Maximum Effective Supply Current I
Max Recommended Standard Fuse Rating In Amperes

Normal Operating Fuses

Min Input Conductor Size In AWG (mm2)
Max Recommended Input Conductor Length In Feet (Meters) 66 (20)
Min Grounding Conductor Size In AWG (mm2)

Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than

three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table

400.5(A) for flexible cord and cable requirements.

(A)

1max

(A) 15.2

1eff

A 15 or 20 ampere

individual branch cir-

Time-Delay Fuses

cuit protected by

time-delay fuses or

circuit breaker is

required.

See Section 5-9.

27.8

30
40

14 (2.1)

14 (2.1)

OM-278400 Page 17

. A complete Parts List is available at www.HobartWelders.com

5-9. Connecting 120 Volt Input Power

! Installation must meet all

National and Local Codes − have
only qualified persons make this
installation.

! Special installation may be

required where gasoline or volatile
liquids are present − see NEC Ar­ticle 511 or CEC Section 20.

. The circuitry in this unit automatically

links the power source to the primary
voltage being applied, either 120 or
240 VAC.

For 120 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.

1 Multi-Voltage Plug And Power Cord

Connector (NEMA Type 5−15P Plug

1

Shown)

For additional multi−voltage plug (MVP)
connections, see Section 5-6.

2 Receptacle − NEMA Type 5−15R

(Customer Supplied)

Notes

2

Ref. Input6 2011−03 Ref. 279230

Work like a Pro!

OM-278400 Page 18

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

. A complete Parts List is available at www.HobartWelders.com

5-10. Connecting 240 Volt Input Power

1

3

7

2

4

L1

L2

6

9

1

L2

8

L1

240 VAC,
1−Phase

=GND/PE Earth Ground

5

! Installation must meet all National

and Local Codes − have only
qualified persons make this
installation.

! Disconnect and lockout/tagout in-

put power before installing recep­tacle. Follow established proced­ures regarding the installation and
removal of lockout/tagout devices.

! Always connect green or

green/yellow conductor to supply
grounding terminal first, and never
to a line terminal.

See rating label on unit and check input
voltage available at site.

1 Input Power Cord
2 Disconnect Device (switch shown in

the OFF position)

3 Disconnect Device Grounding

Terminal
4 Disconnect Device Line Terminals
5 Black And White Input Conductor

(L1 And L2)
6 Green Or Green/Yellow Grounding

Conductor
Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

Connect input conductors L1 and L2 to
disconnect device line terminals.

7 Over-Current Protection
Select type and size of over-current

protection using Section 5-8 (fused dis­connect switch shown).

8 Proper Receptacle

(NEMA 6-50R) (Customer Supplied)
Receptacle must comply with applicable

codes.
9 Plug (NEMA 6-50P)

. A molded 240 volt plug is shown. Con-

nections are the same for units using

NEMA 6−5OP MVP plug (see Section

5−6.)

Connect plug to properly installed
receptacle.

Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Ref. Input10 2015−04 − 279230

OM-278400 Page 19

6-1. Controls

A. Stickmate 160i

. A complete Parts List is available at www.HobartWelders.com

SECTION 6 − OPERATION

1

1 Amperage Adjustment Control
Use control to select desired weld

amperage.
2 Power Indicator Light
Lamp goes on when unit is on.
3 Over Temperature Light
Light goes on when unit has

stopped due to overheating (see
Section 4-6). Light goes off and
weld output returns when unit has
cooled.

4 Power Switch
Use switch to turn unit on and off.

2

3

4

OM-278400 Page 20

279230 / 276288

. A complete Parts List is available at www.HobartWelders.com

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

Every

3

Months

l Unreadable Labels ~ Weld Terminals nl Weld Cables

Every

6

Months

~ Inside Unit

OR

7-2. Troubleshooting

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

Trouble Remedy

No weld output; unit completely inop­erative; Power Indicator light is off.

No weld output; Power Indicator light is
on.

No weld output; high temperature light
is on.

Fan not operating. Check for and remove anything blocking fan movement.

Erratic or improper welding arc or
output.

Electrode freezing to work. Increase amperage setting (see Section 6-1).

Place Power switch in the On position.

Be sure power cord is plugged in and that receptacle is receiving input power.

Place line disconnect switch in On position.

Check and replace line fuse(s), if necessary, or reset circuit breaker.

Check and secure loose weld cable(s) into receptacle(s).

Check and correct poor connection of work clamp to workpiece.

Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-6).

Reduce duty cycle or amperage.

Check and correct blocked/poor airflow to unit (see Section 5-1).

Have Factory Authorized Service Agent check fan motor and control circuitry.

Use proper size and type of weld cable (see your Distributor).

Clean and tighten weld connections.

Reduce amperage setting (see Section 6-1).

Use dry, properly stored electrodes.

Shorten arc length.

Check and reverse polarity; check and correct poor connections to workpiece.

Increase arc length.

Use dry, properly stored electrodes.

OM-278400 Page 21

. A complete Parts List is available at www.HobartWelders.com

SECTION 8 − PARTS LIST

8-1. Recommended Spare Parts

Dia.

Mkgs. Quantity

1 254330 Adapter, Power Cable 5−15PXL630R (120V/15A) 1... .......... .. .......................

2 ♦254331 Adapter, Power Cable 5−20PXL630R (120V/20A) 1... ......... .. .......................

3 254328 Adapter, Power Cable 6−50PXL630R (240V/50A) 1... .......... .. .......................

4 *770026 Holder, Electrode 200A 1... .......... .. ..............................................

5 *770770 Clamp, Work 200A 1... .......... .. ..................................................

6 208548 Strap, Shoulder Double Buckle 1... .......... .. .......................................

♦OPTIONAL
* Available at farm and tool supply retailers.
** Available at Hobart/Miller welding distributors.

Part

No.

**PA532 Holder, Electrode 200A 1................ .. ..............................................

**240697 Clamp, Work 200A 1............... .. ..................................................

Description

Notes

OM-278400 Page 22

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Stickmate 160 Model

279190-A

OM-278400 Page 23

SECTION 10 − GUIDELINES FOR STICK WELDING (SMAW)

10-1. Stick Welding Procedure

! Weld current starts when

electrode touches work­piece.

! Weld current can damage

electronic parts in vehicles.

Tools Needed:

Equipment Needed:

Constant Current

Welding Power Source

5

4

2

3

6

1

7

Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.

. Always wear appropriate per-

sonal protective clothing.

1 Workpiece
Make sure workpiece is clean be-

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

possible.
3 Electrode
Before striking an arc, insert an

electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Fol­low recommendations of the elec­trode manufacturer 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 to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode di­ameter. Examine the weld bead to
determine if the arc length is cor­rect.

Arc length for 1/16 and 3/32 in. dia­meter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
and 5/32 in. electrodes should be
about 1/8 in. (3 mm).

7 Slag
Use a chipping hammer and wire

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

OM-278400 Page 24

stick 2018-01 − 151593

10-2. Electrode And Amperage Selection Chart

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

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

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

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

HORIZ*

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

MED

LOW

LOW
LOW

USAGE

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

! Weld current starts when elec-

trode touches workpiece.

1 Electrode

1

2

3

1

2

3

2 Workpiece
3 Arc

Scratch Technique

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

Tapping Technique

Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.

S-0049 / S-0050

OM-278400 Page 25

10-4. Positioning Electrode Holder

1

90° 90°

Groove Welds

10°-30°

1 End View Of Work Angle
2 Side View Of Electrode

Angle

After learning to start and hold
an arc, practice running beads
of weld metal on flat plates using
a full electrode.

2

Hold the electrode nearly per­pendicular to the work, although
tilting it ahead (in the direction of
travel) will be helpful.

. To produce the best results,

hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
constant rate as it melts.

1

45°

45°

Fillet Welds

10-5. Poor Weld Bead Characteristics

1

10°-30°

2

2

S-0060

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

4

3

5

S-0053-A

10-6. Good Weld Bead Characteristics

1

OM-278400 Page 26

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 welded.

4 No Overlap

5234

5 Good Penetration into Base

Metal

S-0052-B

10-7. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Small

Electrode Angle

10° - 30°

Drag

. Weld bead shape is affected

by electrode angle, arc length,
travel speed, and thickness of
base metal.

Angle Too Large

Spatter

Arc Length

Too Short

Travel Speed

Slow

Normal Too Long

Normal Fast

10-8. Electrode Movement During Welding

1

3

S-0061

. Normally, a single stringer

bead is satisfactory for most
narrow groove weld joints;

2

however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side to Side

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

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

10-9. Welding Lap Joints

30°
Or Less

2

S-0054-A

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.

30°
Or Less

1

3

1

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

OM-278400 Page 27

10-10. Welding Groove (Butt) Joints

1

1/16 in.

(1.6 mm)

3

30°

1 Tack Welds
Prevent butt joint distortion by tack

welding the materials in position
before final weld.

Workpiece distortion occurs when
heat is applied locally to a joint.
One side of a metal plate will curl

2

4

up toward the weld. Distortion will
also cause the edges of a butt joint
to pull together ahead of the elec­trode as the weld cools.

2 Square Groove Weld
3 Single V-Groove Weld
4 Double V-Groove Weld
Materials up to 3/16 in. (5 mm)

thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
ensure good welds.

The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on ma­terials up to 3/4 in. (19 mm) thick
and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxy­acetylene or plasma cutting equip­ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.

10-11. Welding T-Joints

1

45°

Or

2

Less

S-0062

1 Electrode
2 Fillet Weld
Keep arc short and move at defi-

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

For maximum strength weld both
sides of upright section.

3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section

1

10-8. Remove slag before making
another weld pass.

2

3

OM-278400 Page 28

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

10-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

2
1

10-13. Troubleshooting

1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction shown. A good weld

bends over but does not break.
If the weld breaks, examine it to determine the cause.

3

2 To 3 in.

(51-76 mm)

2

1

Porosity − small cavities or holes resulting from gas pockets in weld metal.

If the weld is porous (many holes), the arc length was
probably too long.

If the weld contains bits of slag, the arc may have been
too long or the electrode was moved incorrectly which
allowed molten slag to be trapped in the weld. This may
happen on a V-groove joint made in several layers and
calls for additional cleaning between layers.

If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed.

S-0057-B

Possible Causes Remedy

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

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

Possible Causes Remedy

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Possible Causes Remedy

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

welding.

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

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding

weld bead.

Improper welding technique.

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

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.

welding.

OM-278400 Page 29

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration

Possible Causes Remedy

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.

Excessive Penetration

Possible Causes Remedy

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

Good Penetration

Reduce travel speed.

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

Good Penetration

Increase and/or maintain steady travel speed.

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

Possible Causes Remedy

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

Increase and/or maintain steady travel speed.

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Remedy

Unsteady hand. Use two hands. Practice technique.

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Remedy

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

Make tack welds along joint before starting welding operation.

OM-278400 Page 30

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

Notes

Warranty Questions?

Call
1-800-332-3281
8 AM − 5 PM EST

Service

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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.

Assistance

Visit the Hobart website:

www.HobartWelders.com

Effective January 1, 2020

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a

serial number preface of NA or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, dba Hobart Welding Products,
Appleton, Wisconsin, warrants to its original retail purchaser
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. THIS WARRANTY IS EXPRESSLY
IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart/Miller will
repair or replace any warranted parts or components that fail
due to such defects in material or workmanship. Hobart/Miller
must be notified in writing within thirty (30) days of such defect
or failure, at which time Hobart/Miller will provide instructions
on the warranty claim procedures to be followed. Notifications
submitted as online warranty claims must provide detailed
descriptions of the fault and troubleshooting steps taken to
diagnose failed parts. Warranty claims that lack the required
information as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.

Hobart/Miller shall honor warranty claims on warranted
equipment listed below in the event of a defect within the
warranty coverage time periods listed below. Warranty time
periods start on the delivery date of the equipment to the
original retail purchaser, or 12 months after the equipment is
shipped to a North American or international distributor,
whichever occurs first.

1. 5 Years — Parts and Labor
* Original Main Power Rectifiers only to include SCRs,

diodes, and discrete rectifier modules
* Reactors
* Stabilizers
* Transformers

2. 3 Years — Parts and Labor Unless Specified
* Drive Systems
* Idle Module
* PC Boards
* Rotors, Stators and Brushes
* Solenoid Valves
* Switches and Controls

3. 1 Year — Parts and Labor Unless Specified
(90 days for industrial use)

* Accessories (Kits)
* Contactors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* HF Units
* MIG Flowgauge Regulators (No Labor)
* MIG Guns/TIG Torches
* Motor-Driven Guns
* Plasma Cutting Torches
* Relays
* Remote Controls
* Replacement Parts (No labor) − 90 days
* Running Gear/Trailers
* Spoolguns

no other guarantees or warranties expressed or implied.

4. 6 Months — Parts
* Batteries

5. Engines and tires are warranted separately by the
manufacturer.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

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

3. Equipment that has been modified by any party other than
Hobart/Miller, 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

4. Defects caused by accident, unauthorized repair, or
improper testing.

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

The exclusive remedies for warranty claims are, at
Hobart’s/Miller’s option, either: (1) repair; or (2) replacement;
or, if approved in writing by Hobart/Miller, (3) the pre-approved
cost of repair or replacement at an authorized Hobart/Miller
service station; or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon use).
Products may not be returned without Hobart’s/Miller’s written
approval. Return shipment shall be at customer’s risk and
expense.

The above remedies are F.O.B. Appleton, WI, or
Hobart’s/Miller’s authorized service facility. Transportation
and freight are the customer’s responsibility. TO THE
EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES
REGARDLESS OF THE LEGAL THEORY. IN NO EVENT
SHALL HOBART/MILLER BE LIABLE FOR DIRECT,
INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT) REGARDLESS
OF THE LEGAL THEORY. ANY WARRANTY NOT
PROVIDED HEREIN AND ANY IMPLIED WARRANTY,
GUARANTY, OR REPRESENTATION, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, ARE EXCLUDED
AND DISCLAIMED BY HOBART/MILLER.

Some US states do not allow limiting the duration of an implied
warranty or the exclusion of certain damages, so the above
limitations may not apply to you. This warranty provides
specific legal rights, and other rights may be available
depending on your state. In Canada, some provinces provide
additional warranties or remedies, and to the extent the law
prohibits their waiver, the limitations set out above may not
apply. This Limited Warranty provides specific legal rights,
and other rights may be available, but may vary by province.

for the equipment.

Hobart warr 2020-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Thank you for purchasing Hobart. Our trained technical support team is
dedicated to your satisfaction. For questions regarding performance, op­eration, or service, contact us!

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Service Center:

Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:

Call 1-800-332-3281
8 AM to 5 PM EST − Monday through Friday

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

For Assistance:

Call 1-800-332-3281

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2020-01