Hobart Welding Products CYBERTIG 350LX User Manual

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OM-356 188694J

October 2000

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Descriptio n

Arc Welding Power Source

CYBERTIG 350LX

Visit our website at

www.HobartWelders.com

And Non-CE Models

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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. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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TABLE OF CONTENTS

The following terms are used interchangeably throughout this manual: TIG = GTA W Stick = SMAW

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section

25249.5 et seq.)

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

1-1. 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 UTILISATION 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. Manufacturer’s Rating Label For CE Products 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions And Weights 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle 16. . . . . . . . . . . . . . . . . . . . .

3-9. Electrical Service Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Placing Jumper Links And Connecting Input Power 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Output Selector Switch 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Process Control 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Current Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Output Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Start Mode 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Meters 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Amperage Adjustment Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Balance/DIG Control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Preflow Time Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Postflow Time Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Setting Pulse Controls 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. High Frequency Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Optional Sequence Controls 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Sequence Selection Switch 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. Start Time/Spot Time Control And Start Current Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17. Crater Time Control And Final Current Control 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-18. Start/Crater Sequence Controls 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19. 4T Sequence Selection Controls 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20. Spot Time Control 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21. Timer/Cycle Counter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Circuit Breaker CB1 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Adjusting Spark Gaps 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Voltmeter/Ammeter Help Displays 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – HIGH FREQUENCY 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – PARTS LIST 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

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

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Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

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

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

repair this unit.

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

ELECTRIC SHOCK can kill.

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

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

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

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

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

there is a danger of falling.

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

unit.

D Disconnect input power or stop engine before installing or

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

D Properly install and ground this equipment according to its

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

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

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

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

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

replace cord immediately if damaged – bare wiring can kill.

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

power circuit and machine internal circuits are also

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

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

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

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

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

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

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

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

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

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

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

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

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

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

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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.

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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 W elding 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.

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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.

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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

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

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

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

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

vent être confiés qu’à des personnes qualifiées.

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

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

pas de trous.

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

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

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

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

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

procédé de soudage le demande.

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

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

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

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

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

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

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

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

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

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

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

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

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

sante ou mal épissés.

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

câble distinct.

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

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

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

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

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

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

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

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

avec tout objet métallique.

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

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

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

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer

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

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

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

tion d’air homologué.

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

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

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

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

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

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

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

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

les fumées.

OM-356 Page 5

Page 10

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

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

des brûlures dans les yeux et sur la peau. Des étincelles sont projetées

pendant le soudage.

D Porter un casque de soudage muni d’un écran de filtre approprié pour

protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

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

trop élevé.

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

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

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

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

(ultraviolets et infrarouges) susceptibles de provoquer

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

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

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

d’utiliser le pistolet ou la torche.

LE SOUDAGE peut provoquer un incendie ou une explosion.

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

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

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

métal chaud.

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

des substances inflammables.

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

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

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

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

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

mité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

telles qu’un allumeur au butane ou des allumettes.

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

DES PARTICULES VOLANTES peuvent blesser les yeux.

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

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

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

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

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

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

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

LE BRUIT peut affecter l’ouïe.

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

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

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

manipuler avec précaution.

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

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

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

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

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

cuits électriques.

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

bouteille.

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

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

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

bouteille.

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

lisation ou de branchement de la bouteille.

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

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

font normalement partie du procédé de soudage, les

OM-356 Page 6

Page 11

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

et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

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

mité de surfaces infllammables.

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

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

LA CHUTE DE L’APPAREIL peut blesser.

D Utiliser l’anneau de levage uniquement pour sou-

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

D Utiliser un engin d’une capacité appropriée pour

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

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

soulever l’appareil.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

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

recommancer le soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Rester à l’écart des organes mobiles comme le

ventilateur.

D Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

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

D Le rayonnement haute frequence peut provoquer

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

D Demander seulement à des personnes qualifiées familiarisées

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

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

qualifié les interférences résultant de l’installation.

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

reil.

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

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

de sécurité et les ordinateurs.

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

LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

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

DES ORGANES MOBILES peuvent provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

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

reçu l’instruction.

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

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

D L’énergie électromagnétique risque de provoquer

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

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

patible électromagnétiquement.

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

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

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

électronique sensible.

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

conformément à ce mode d’emploi.

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

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

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

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

OM-356 Page 7

Page 12

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

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

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

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

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

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

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

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

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

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

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

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. T outefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

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

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

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

votre corps.

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

vous.

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

soudure.

Consignes relatives aux stimulateurs cardiaques :

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

OM-356 Page 8

Page 13

SECTION 2 – DEFINITIONS

2-1. Warning Label Definitions

1 1.1 1.2

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. Don’t 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-356 Page 9

Page 14

2-2. Manufacturer’s Rating Label For CE Products

OM-356 Page 10

Page 15

2-3. 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) Spot Timer

High Frequency -

Start

High Frequency -

Continuous

Shielded Metal Arc

Welding (SMAW)

High Frequency

Increase/Decrease

Of Quantity

Input

Voltage (A verage)

Balance Control Maximum Cleaning

Electrode

Negative

Rated No Load

Primary Current

Degree Of Protection

Electrode Work Thickness Gauge Spark Gap

Seconds Final Current Start Time Start Amperage

Peak Time Spot Sequence

1eff

Crater Time Meter Single-Phase

Primary Voltage

Rated Welding

Current

Maximum Effective

Supply Current

1max

Maximum

Penetration

Conventional Load

Voltage

Duty Cycle

Rated Maximum

Supply Current

Start/Crater Se-

quence

Electrode Positive

Line Connection

Single-Phase

Combined AC/DC

Power Source

Start Sequence

Hertz

Crater Sequence Pulser Background Amps Pulse Frequency

4 Step Trigger Op-

eration Sequence

OM-356 Page 11

Page 16

SECTION 3 – INSTALLATION

3-1. Selecting A Location

Movement

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

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

OM-356 Page 12

18 in (460

mm)

18 in (460

mm)

Ref. ST-117 264-C / ST-801 971

Page 17

3-2. Dimensions And Weights

Front

G 4 Holes

3-3. Specifications

Rated

Welding

Output

NEMA Class I

(60) – 300

Amperes, 32

Volts AC, 60%

Duty Cycle

NEMA Class II

(40) – 350

Amperes, 34

Volts AC, 40%

Duty Cycle

*While idling **Power Factor Correction

PFC

200V 220V 230V 400V 440V 460V 520V 575V

PFC With

PFC9869*

PFC With

PFC

1295*117

1505*1375*131

118

69*

Ref. ST-184 046

Amperes Input at AC Balanced Rated Load Output,

50/60 Hz, Single-Phase

63*

107 63*

112

60*

103 60*

65 3*

35*

75 3*

35*

31*

30*

26*

Dimensions

Height

Width 22-1/2 in (572 mm)

Length 25 in (635 mm)

A 25 in (635 mm) B 23-5/8 in (600 mm) C 1-3/8 in (35 mm) D 7/8 in (22 mm) E 19-15/16 (506 mm) F 22-1/4 (565 mm) G 1/2 in (13 mm) Dia

38-1/4 in (972 mm) with retract-

able lifting eye down

Weight

515 lbs (234 kg)

Amperage

Range

KVA KW

452*21.8

0.9*

19.3

24*

14.0*

532*24.5

0.9*

23.9

24*

14.0*

14.3

0.4*

14.0

0.4*

17.7

0.4*

17.7

0.4*

3 – 400A 80V

Max

OCV

OM-356 Page 13

Page 18

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 350 Amperes (60 Hz Models Only)

4 Minutes Welding 6 Minutes Resting

Overheating

3-5. Volt-Ampere Curves

Minutes

60% Duty Cycle At 300 Amperes

6 Minutes Welding 4 Minutes Resting

Reduce Duty Cycle

duty1 4/95 / SB-190 276

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-356 Page 14

ssb1.1 10/91 – ST-

Page 19

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

*The remaining sockets are not used.

Ref. ST-801 972

Socket* Socket Information

A 24 volts dc.

B Contact closure to A completes 24 volts dc contactor control circuit.

C Command reference; 0 to +10 volts dc output to remote control.

D Remote control/feedback circuit common.

E 0 to +10 volts dc input command signal from remote control.

K Chassis common.

F Current feedback, 1 volt per 100 amperes.

H V oltage feedback, 1 volt per 10 arc volts.

OM-356 Page 15

Page 20

3-8. 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 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

Ref. ST-801 972 / Ref. ST-801 973 / Ref. ST-157 858

OM-356 Page 16

Page 21

3-9. Electrical Service Guide

NOTE

All values 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 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor

Length In Feet (Meters) Min Grounding Conductor Size In AWG/

Kcmil

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

200 220 230 400 440 460 520 575 129 117 112 65 58 56 49 45

175 150 150 80 70 70 60 60

4 4 4 8 8 8 8 10

111 (34)

6 6 6 8 8 8 10 10

134 (41)

146 (45)

196 (60)

238 (72)

260 (79)

332

(101)

273 (83)

50/60 Hertz Models With Power Factor Correction Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or

Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil

200 220 230 400 440 460 520 575

98 89 85 49 44 43 37 34

150 125 125 70 70 60 60 50

4 4 4 8 8 8 10 10

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/ Kcmil

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

117 (36)

6 6 6 8 8 10 10 10

141 (43)

154 (47)

204 (62)

246 (75)

269 (82)

230 (70)

281 (86)

OM-356 Page 17

Page 22

3-10. Placing Jumper Links And Connecting Input Power

230 VOLTS 460 VOLTS200 VOLTS

LL LL LL

230 VOLTS

460 VOLTS

S-083 566-C

575 VOLTS

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 3-9.

4 Line Disconnect Device Select type and size of overcurrent

protection using Section 3-9. 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 .

Green

Connect GND/PE Conductor First

GND/PE Earth Ground

Tools Needed:

OM-356 Page 18

Connect GND/PE Conductor First

3/8 in

Ref. ST-801 973-A

Page 23

SECTION 4 – OPERATION

4-1. Controls

A. For 200/230/460 Volts And Non CE Units

1234

. Top row of lights in upper left corner are

On for SMAW. Bottom row are On for GTAW.

1 Process Control See Section 4-3. 2 Current Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Button See Section 4-6. 5 Voltmeter See Section 4-7 6 Ammeter

See Section 4-7 7 Amperage Adjustment

Control See Section 4-8. 8 Output Selector Switch See Section 4-2. 9 Power Switch Push Buttons Use buttons to turn unit Off and On. 10 Postflow Time Control See Section 4-11. 11 Preflow Time Control See Section 4-10. 12 Balance/DIG Control

See Section 4-9.

Pulse Controls:

13 Pulser On/Off Switch See Section 4-12. 14 Background Amperage Control See Section 4-12. 15 Pulses Frequency Control See Section 4-12. 16 Peak Time Control See Section 4-12. 17 Sequence Controls (Optional) See Section 4-14. 18 High Frequency Control See Section 4-13.

Ref. ST-183 200-A / Ref. ST-183 260-A / Ref. ST-801 972

OM-356 Page 19

Page 24

B. For CE Units

1234

. Top row of lights in upper left corner are

On for SMAW. Bottom row are On for GTAW.

1 Process Control See Section 4-3. 2 Current Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Button See Section 4-6. 5 Voltmeter See Section 4-7 6 Ammeter

See Section 4-7 7 Amperage Adjustment

See Section 4-9.

Pulse Controls:

OM-356 Page 20

Ref. ST-191 372 / Ref. ST-191 371-A / Ref. ST-801 972

Page 25

4-2. Output Selector Switch

(CE Nameplate Shown)

1 Output Selector Switch

Y Do not use AC output in

damp areas, if movement is confined, or if there is dan-

ger 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 without changing weld output cable connections.

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.

Ref. ST-191 372

4-3. Process Control

(CE Nameplate Only)

1 Process Control Use control to select Shielded Met-

al Arc Welding (SMAW) or Gas Tungsten Arc W elding (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 mode.

When Output Selector switch position changes, LED may change position, based upon last selection.

Ref. ST-191 372

OM-356 Page 21

Page 26

4-4. Current Control

4-5. Output Control

(CE Nameplate Only)

1 Current Control Use control to select front panel or

remote current control. For front panel current control,

press button to toggle LED to Panel position.

For remote current control, press button t o toggle LED to Remote 1 4 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.

1 Output Control

Y Weld output terminals are

energized when power is On, and Output On LED is lit.

Use control to select front panel or remote output control.

For weld output, press button to toggle L E D t o O n p o s i t i o n .

For remote output control, press button t o toggle LED to Remote 1 4 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.

When Output On is selected, HF and gas control are disabled.

OM-356 Page 22

Page 27

4-6. Start Mode

(CE Nameplate Only)

Lift-Arct Start Method

“Touch”

1 – 2

Seconds

1 Start Mode For SMAW welding, press button to toggle

LED to Off position. For GTAW welding, use control to select Of f

for no HF, Lift-Arct, HF for arc starting only, or continuous HF. See Section 4-13 for adjusting high frequency intensity.

Application:

When O ff is selected, use the scratch method to start an arc for both the SMAW 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 t o workpiece for 1-2 seconds,

Do NOT Strike Like A Match!

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. This allows 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.

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 GTAW 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.

OM-356 Page 23

Page 28

4-7. Meters

4-8. Amperage Adjustment Control

(CE Nameplate Only)

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.

1 Amperage Adjustment Control Use control to adjust amperage,

and preset amperage on ammeter (see Sect i o n 4 - 7 ) . T h i s c o n t r o l m a y

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 3 to 200 A.

For pulse welding, use Amperage Adjust control to select from 3–400 amps of peak amperage (see Section 4-12).

For spot welding, use Amperage Adjust control to select from 3–400 amps of peak amperage (see Section 4-15).

OM-356 Page 24

Page 29

4-9. Balance/DIG Control

Balanced

More Penetration

More Cleaning

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 Only)

1 Balance/DIG Control

Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control

ArcSetting

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

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.

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.

4-10. Preflow Time Control

(CE Nameplate Only)

Ref. S-0795-A

1 Preflow Time Control Use control to set length of time that

gas flows (0–10 seconds) before arc starts.

Application:

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

OM-356 Page 25

Page 30

4-11. Postflow Time Control

(CE Nameplate Only)

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 until 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.

OM-356 Page 26

Page 31

4-12. Setting Pulse Controls

(CE Nameplate Only)

Percent (%) Peak

Time Control Setting

(50%)

Balanced

Peak Amp

More Time

At Peak

Amperage

More Time At

Background

Amperage

(20%)

(80%)

Pulsed Output Waveforms

PPS

Bkg Amp

1 On/Off Switch

Use switch 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 A range 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 (3–400 amps), is set with the Amperage Adjustment control (see Section A). 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.

OM-356 Page 27

Page 32

4-13. High Frequency Control

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.

4-14. Optional Sequence Controls

Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing t h e 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.

Ref. ST-801 972

1 Sequence Selection Switch See Section 4-15. 2 Start Time/Spot Time Control

See Section 4-16. 3 Start Current Control See Section 4-16. 4 Crater Time Control See Section 4-17. 5 Final Current Control See Section 4-17.

OM-356 Page 28

(CE Nameplate Only)

Ref. ST-191 372

Page 33

4-15. Sequence Selection Switch

(CE Nameplate Only)

4-16. Start Time/Spot Time Control And Start Current Control

1 Sequence Selection Switch Switch controls Off, Start, Cra-

ter, Start/Crater, 4t, and Spot functions. Place switch in desired position.

Off– Place switch in Off position when Sequence Selection functions are not desired.

(CE Nameplate Only)

1 Sequence Selection Switch Place switch in Start position. 2 Start Time/Spot Time Control Use control to select 0–15 seconds

of start time. 3 Start Current Control Use start control to select a starting

current (3–400 amps) that is differ- ent from the weld current. Note: Start current can be used with or without a remote control.

Application:

Start current can be used while GTAW welding to assist in preheating cold material prior to depositing filler material, or to ensure a soft start. Start current can also be used for SMAW to ensure a more consistent arc strike.

OM-356 Page 29

Page 34

4-17. Crater Time Control And Final Current Control

(CE Nameplate Only)

1 Sequence Selection Switch Place switch in Crater position. 2 Crater Time Control Use control to reduce current

over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control.

3 Final Current Control Final current is the current to

which weld current has sloped down t o ( 0 –100% of current set on Amperage Adjust control).

Application:

Crater T ime should 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.

OM-356 Page 30

Page 35

4-18. Start/Crater Sequence Controls

(CE Nameplate Only)

1 Sequence Selection Switch Place switch in Start/Crater posi-

tion.

2 Start T ime/Spot Time

Control

Use control to select 0–15 seconds of start time.

3 Start Current Control Use start control to select a start-

ing current (3–400 amps) that is different from the weld current.

4 Crater Time Control Use control to reduce current

over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control.

5 Final Current Control Final current is the current to

which weld current has sloped down to (0–100% of current set on Amperage Adjust control).

Application:

Start current can be used while GTAW welding to assist in preheating a cold material prior to depositing filler material. Start current can also be used for SMAW to ensure a more consistent arc strike.

Crater Time can be used while GTAW welding when material being welded is crack sensitive, and the operator is using an on/off type control to start and stop the welding process.

NOTE: Use this method when the function of a remote control is desired, but only a remote on/off control is available.

OM-356 Page 31

Page 36

4-19. 4T Sequence Selection Controls

(CE Nameplate Only)

1 Start Sequence Switch –

4T Position

(Specific trigger method) Press and hold torch trigger to start Preflow Time and arc at the Start Current level. The arc will remain at the Start Current level as long as the trigger is depressed. Release trigger to change to main weld current. To end main weld current, press and hold trigger. Crater Time begins, and arc drops to Final Current level and remains there until trigger is released, at which time arc goes out, and Postflow Time begins.

While i n 4 T mode, there is a feature available during the main weld sequence that allows the operator t o toggle between weld current and final current. To switch from weld current to final current, press and release torch trigger within 3/4 of a second. To return to weld current, press and release torch trigger within 3/4 of a second again.

2 Start Time/Spot Time

Control

Use control to select 0–15 seconds of start time.

3 Start Current Control Use start control to select a start-

ing current (3–400 amps) that is different from the weld current.

4 Crater Time Control Use control to reduce current

over a set period of time (0–15 seconds) at the end of the weld cycle when not using a remote control.

5 Final Current Control Final current is the current to

which weld current has sloped up/down to (0–100% of current set on Amperage Adjust control).

Application:

Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

OM-356 Page 32

Page 37

4-20. Spot Time Control

(CE Nameplate Only)

1 Sequence Selection Switch –

Spot Position

Used with the (GTAW) TIG Spot process, generally with a direct current electrode negative (DCEN) setup.

2 Start T ime/Spot Time Control Use control to select 0–15 seconds

of spot time. Use Amperage Adjust control (see

Section 4-8) 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.

4-21. Timer/Cycle Counter

(CE Nameplate Only)

1 2 3

4 5 6

1 2 3

4 5 6

1 Current Control 2 Output (Contactor) Control To read timer/cycle counter, hold

Current and Output (contactor) buttons while turning on power.

3 Timer Display The hours and minutes are dis-

played on the volt and amp meters for the first five seconds, and are read as 1, 234 hours and 56 min-

utes. 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-356 Page 33

Page 38

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

Repair Or

Replace

Cracked

Weld

Cables

Gas Hose

6 Months

Blow Out Or Vacuum Inside,

During Heavy Service, Clean Monthly

Y Warranty is void if machine fails

due to contaminates inside.

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 1 15 volts ac duplex receptacle stop. Press button to reset breaker.

OM-356 Page 34

Ref. ST-801 972

Page 39

5-3. Adjusting Spark Gaps

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 Loosen screws. Place gauge of

proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until

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

Reinstall access door.

Tools Needed:

0.012 in (0.305 mm)

5/32 in

Ref. ST-801 972-A

OM-356 Page 35

Page 40

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 Help 1 Display Not used. 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

1 4

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.

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.

2 5

7 Help 7 Display Not used. 8 Help 8 Display 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).

HLP

––0

HLP

––6

HLP

––1

HLP

––7

HLP

––2

HLP

––8

HLP

––3

HLP

––9

HLP

––4

HLP

–10

HLP

––5

HLP

–11

OM-356 Page 36

Page 41

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 not 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

Place line disconnect switch in On position (see Section 3-10). Check and replace line fuse(s), if necessary (see Section 3-10).

Check for proper input power connections (see Section 3-10).

Check for proper jumper link position (see Section 3-10).

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).

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.

Make sure Amperage switch 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.

OM-356 Page 37

Page 42

Trouble Remedy

Check for water in torch, and repair torch if necessary.

Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to

protect against overheating.

OM-356 Page 38

Page 43

SECTION 6 – ELECTRICAL DIAGRAM

Figure 6-1. Circuit Diagram

SC-187 950-C

OM-356 Page 39

Page 44

SECTION 7 – HIGH FREQUENCY

7-1. Welding Processes Requiring High Frequency

Work

TIG

7-2. Incorrect Installation

Weld Zone

11, 12

50 ft

(15 m)

1 High-Frequency V oltage TIG – helps arc jump air gap

between torch and workpiece and/ or stabilize the arc.

high_freq 12/96 – S-0693

10 9 8

4 5 6

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-356 Page 40

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

Page 45

7-3. Correct Installation

Ground all metal objects and all wiring in welding zone using #12 AWG wire.

Nonmetal

Building

Weld Zone

50 ft

(15 m)

Ground workpiece if required by codes.

50 ft

(15 m)

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

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.

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-356 Page 41

Page 46

SECTION 8 – PARTS LIST

. Hardware is common and

not available unless listed.

OM-356 Page 42

ST-802 012-F

Figure 8-1. Main Assembly

Page 47

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-1. Main Assembly

1 191 011 PANEL, side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 PC1 196 254 CIRCUIT CARD, interface (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 914 7 SEGMENT LED DISPLAY (LED’s 18 – 23) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13, 15 131 054 CONNECTOR W/SOCKETS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 165 484 CONNECTOR W/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131 055 CONNECTOR W/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14 167 333 CONNECTOR W/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 512 STAND-OFF, No. 6-32 x .645lg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PC2 183 101 CIRCUIT CARD, pulser 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC3 ♦183 105 CIRCUIT CARD, timer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S5 187 467 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

021 795 TUBING, stl .375 OD x 18ga 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131 055 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CR1-3 052 964 RELAY, encl 24VDC DPDT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SN1-3 118 625 SNUBBER 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 C2 031 668 CAPACITOR, electlt 4000uf 100 VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168 976 INSULATOR, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 108 105 CLAMP, capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 184 067 CONTROL BOX, HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 T3 074 398 TRANSFORMER, high voltage 115V pri 360 OV 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

199 856 HOLDER, points 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 455 POINT, spark gap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 855 BASE, spark gap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 184 068 BRACKET, spark gap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 C3 201 197 CAPACITOR, polyp met film .002uf 4400 VAC pnl mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 C1.11 ,18,19 191 944 CAPACITOR, polyp met film 10uf 250 VAC 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 R8 188 067 RESIST OR, ww fxd 100 W 200 ohm w/clips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 R2 189 132 RESISTOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 R1 186 468 RESIST OR, ww fxd 100W 50 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 HD1 168 829 TRANSDUCER, current 1000A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 C20-24 ♦125 781 CAPACITOR. polyp film 150 uf 250 VAC 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦129 201 BRACKET, mtg capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 184 052 BRACKET, capacitor power factor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 187 447 BAFFLE, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 SR1 187 449 RECTIFIER, si diode (Figure 8-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 184 080 BRACKET, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 184 048 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 187 806 BRACKET, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 155 903 BUSHING, lift eye 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 155 905 LIFT, eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 184 077 SUPPORT, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 187 807 FAN BRACKET 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 FM1,2 148 808 MOTOR, fan 230 V 1550 RPM 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 150 783 BLADE, fan 9.000 5wg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 184 058 FAN PLENUM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 199 312 BLOCK, terminal fast-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 023 LINK, jumper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 191 010 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 272 CONNECTOR, clamp cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

184 057 DOOR, pri 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 GS 133 873 VALVE, 24 VDC 2way custom port 1/8 orf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 227 NUT, .750-14 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 184 060 BAFFLE, panel rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 187 416 CONTACTOR w/BRACKET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 192 574 TRANSFORMER/STABILIZER ASSEMBLY 200/230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 192 577 TRANSFORMER/STABILIZER ASSEMBLY 230/460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 191 562 TRANSFORMER/STABILIZER ASSEMBLY 220/400/440/520 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TH1 188 431 THERMISTER, NTC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-356 Page 43

Page 48

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-1. Main Assembly

42 TE1 034 587 TERMIMAL ASSEMBLY, 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C5,6 111 634 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 184 044 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 R3 118 459 RESISTOR, ww fxd 10W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 SR2 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 F1 085 874 FUSE, mintr slo-blo 10A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 172 731 HOLDER, fuse mintr .250 x 1.250 clip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 R4 186 949 RESIST OR, ww fxd 175W 20 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 184 061 PANEL, relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 083 147 GROMMET, scr No. 8/10 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 R5 198 547 RHEOSTAT, ww 25W 1.5 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 C13,14 187 254 CAPACITOR ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 010 381 CONNECTOR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 CB1 093 995 CIRCUIT BREAKER, man reset 1P 250 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 RC2 189 033 RECEPTACLE, str dx grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C12 135 664 CAPACITOR, cer disc .01uf 500VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 PC4/RC2 198 761 CIRCUIT CARD, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18 165 484 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 157 317 HOLDER, HF coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 T4 187 499 COIL, HF coupling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 157 318 HOLDER, HF coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 120 854 FITTING, gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 184 065 LOWER HF PANEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 097 421 TERMINAL, pwr output red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 097 922 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 +184 050 DOOR ASSEMBLY HF PANEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

127 363 LABEL, warning electric shock can kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 169 136 PIN, handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 175 952 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 192 547 RECESS, handle switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 183 260 NAMEPLATE, (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 191 009 PANEL, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 S7 185 196 SWITCH, push button (Figure 8-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 184 066 DOOR, spark gap access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 174 991 KNOB, pointer As Rq’d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 183 332 KNOB, pointer As Rq’d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 778 ACTUATOR, push button switch 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 198 093 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183 200 PLATE, indicator syncrowave 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 190 311 BAFFLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦ 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 Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-356 Page 44

Page 49

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

185 196

Figure 8-2. Switch, Push Button (Fig 8-1 Item 62)

1 059 885 BUTTON, push reset red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 018 606 SPRING, compression 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 186 303 PUSH BUTTON, w/cable and housing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 081 008 BRACKET, mtg switch PB 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 178 856 SWITCH, limit leaf actuating SPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

ST-080 214-B

Figure 8-2. Switch, Push Button

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-3. Rectifier, Si Diode (Fig 8-1 Item 23)

1 C7-10 031 689 CAPACITOR, rectifier 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 166 667 CLAMP, spring rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 D1 037 956 DIODE, rect 275A 300V SP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TH2 188 431 THERMISTOR, NTC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SCR1-4 115 114 THYRISTOR, SCR 300A 300V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 173 714 CLAMP, thyristor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

028 516 PIN, spring CS .125 x .250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 115 092 CONNECTOR PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

ST-120 205-A

Figure 8-3. Rectifier, Si Diode

OM-356 Page 45

Page 50

Page 51

Warranty Questions?

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

Service

Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

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

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

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

1. 5 Years Parts – 3 Years Labor

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

2. 3 Years — Parts and Labor

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

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

3. 1 Year — Parts and Labor

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

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

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

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

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

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

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

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

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

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

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

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

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

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

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

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

hobart standard 7/00

Page 52

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor, retail or service location:

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

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

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

Contact your Distributor for:

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

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

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

For Technical Assistance:

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

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

Hobart Welding Products CYBERTIG 350LX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual