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http://www.chudov.com/projects/Welding/00-Hobart-CyberTig-Welder/Hobart-Cyber-Tig-150-Manual.pdf
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HOW TO USE THIS MANUAL - This manual, identified by an "OM" prefixed number, usu-
ally covers just the underlined specification or assembly numbers in the listing
below. If none of the numbers are underlined, they are all covered.
EQUIPMENT IDENTIFICATION - The unit's identification number (either a Specifi-
cation number, or an Assembly number), model, and serial number usually appear on
a nameplate attached to its control panel. Equipment which does not have a con-
trol panel, such as gun and cable assemblies, are identified only by Spec. (or
six-digit assembly) numbers printed on the outside of the shipping container.
Record this number for future reference,
A "specification number" starts out with a "series number” (first four-digit num-
ber with a possible letter suffix). A "dash number” (-1, -2, etc.) must follow
the series number to make a complete "Specification number”. For example,
1234A-1, 1234A-2, etc. In the same manner, a "dash number" (-1, -2, etc.) must
follow a six-digit assembly number, to identify specific equipment. See below
for identifying equipment covered by this manual.
OWNER'S MANUAL NO. 0M-223
CT-150-DC-S, Solid-State,
TIG/STICK Welding Machine
This manual covers units displaying any
one of the following specification num-
bers with exceptions as noted in the
first paragraph above.
6426-1 6604-1 6835-1
6426-2 6604-2 6835-2
6426-3 6604-3 6835-3
6426-5 6604-4
6426-6 6604-5
6426-7
Issued: Jan 8/82
Revised: Dec 14/90
Table of Contents
Page
SAFETY WARNINGS
SOLID-STATE EXCHANGE POLICY
INSTRUCTIONS 1
RECEIPT OF EQUIPMENT }
DESCRIPTION 1
Description of Equipment 1
Description of TIG Process 2
Controls and Connections 2
Meter Panel 2
Bottom Panel 3
INSTALLATION 6
Location 6
Direction Radiation From Welding Machine 6
0M-223
TABLE OF CONTENTS (CONTINUED)
Direct Radiation From Welding Leads 6
Radiation From Power Lines 5
Wiring in the Welding Area 6
Re-Radiation 6
Wiring Changes 7
Use in Metal Buildings 7
7
Grounding
Connection to Line Voltage 9
Connection to Line Contactor 11
Connection to Fused Disconnect Switch 11
Welding Adjustments 12
Welding Leads 12
Remote Control Cables (When Used) 12
Certifícation Notice 12
Indivídual Installation Certification 12
Responsibility for Interference 12
Input Voltage Changeover 12
Programmer and Remote Control Connections 13
Preparation for Use 13
OPERATION 15
Presetting Controls for TIG Welding 15
Functions of Printed Circuit Boards 15
MAINTENANCE 16
Lubrication 16
Inspection and Cleaning 16
Spark Gaps 16
SCRs 16
TROUBLESHOOTING 17
DETAILED TROUBLESHOOTING INSTRUCTIONS 27
PARTS LIST
DIAGRAMS
WARRANTY
Hobart Brothers Company ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Troy, Ohio 45373 instruction 910081
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
á WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUC-
TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe ail safety rules and take precautionary actions.
Safe practices have deveioped from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Certain of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard 249.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and
other guides to what you shouid learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill. 6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down оп the ground or the work surface. Do
not touch holders connected to two welding machines at the
same time or touch other people with the holder or electrode.
Touching live electrical parts can cause fatal shocks
—7 or severe burns, The electrode and work circuit is
electrically live whenever the outputis on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or auto-
matic wire welding, the wire, wire reel, drive roll 8. Do not use worn, damaged, undersized, or poorly spliced ca-
housing, and aii metal parts touching the welding bles.
wire are electrically live. Incorrectly installed or im- 9. Do not wrap cables around your body.
properly grounded equipment is a hazara. 10. Ground the workpiece to a good electrical (earth) ground.
1. Do not touch live electrical parts. 11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace dam-
aged parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
Wear a safety harness to prevent falling if working above fioor
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentaily. 14,
5. Properly install and ground this equipment according to its level.
Owner's Manual and national, state, and local codes. 15. Keep ail panels and covers securely in place.
ARC RAYS can burn eyes and skin; 1. Weara weiding helmet fitted with a proper shade of filter (see |
NOISE can damage hearing. ANSI Z49.1 listed in Safety Standards} to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
Se Arc rays from the welding process produce intense — 3, Use protective screens ar barriers to protect others from flash
e oll heat and strong ultraviolet rays that can burn eyes and glare: warn others not to watch the arc.
a and hos Noise from some processes can damage 4, Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection,
5. Use approved ear plugs or ear muffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Electrode Size Filter Electrode Size Filter
Welding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade
Operation or Welding Current No. Operation or Welding Current No.
Torch soldering — 2 Gas metal-arc welding (MIG)
Torch brazing - З ог 4 Non-ferrous base metal All 11
Oxygen cutting Ferrous base metal Ali 12
Light Under 1 in., 25 mm 3or4'! Gastungsten arc welding (TIG) Alí 12
Medium 1 to 6 in, 25-150 mm 40r5|) Atomic hydrogen welding All 12
Heavy Over 6 in., 150 mm 50r6|| Carbon arc welding All 12
Gas welding Plasma arc welding All 12
Light Under 1/8 in., 3 mm 4or5|| Carbon arc air gouging
Medium 1/8 to 1/2 in., 3-12 mm 50r6 Light | 12
Heavy Over 1/2 in., 12 mm 60r8 Heavy 14
Shielded metal-arc welding Under 5/32 in., 4 mm 10 Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 4to 6.4mm| 12 Light Under 300 Amp 9
Over 1/4 in., 6.4 mm 14 Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
March 24, 1993 2-1
Replaces April 1, 1992
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
Hobart Brothers Company
Troy, Ohio 45373
FUMES AND GASES can be hazardous
to your health.
Weiding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
. If ventilation is poor, use an approved air-supplied respirator.
. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer's instruction for metals, consumables, coatings,
and cleaners. ,
. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
weiding can displace air causing injury or death. Be sure the
breathing air is safe.
. Do not weld in locations near degreasing, cieaning, or spraying
operations. The heat and rays of the arc can react with vapors
to form highly toxic and irritating gases.
. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, uniess 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.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work-
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
RE
. Protect yourseif and others from flying sparks and hot metal.
‚ Do not weld where flying sparks can strike flammable material.
. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers,
. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
Do not weid on closed containers such as tanks or drums.
. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibiy
unknown paths and causing electric shock and fire hazards.
. Do not use welder to thaw frozen pipes.
. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
Ba
. Wear approved face shield or safety goggles. Side shields
recommended.
. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shieiding gas cylinders contain gas under high pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, me-
chanical shocks, and arcs,
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
. Keep cylinders away from any welding or other electrical cir-
cuits.
. Never allow a weiding electrode to touch any cylinder.
. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated paris in good condition.
. Turn face away from valve outlet when opening cylinder valve.
. Keep protective cap in place over valve except when cylinder is
in use or connected for use,
. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
4 WARNING
“Ulea | ENGINE EXHAUST GASES can Kill.
Engines produce harmful exhaust gases.
ENGINES can be hazardous.
. Use equipment outside in open, well-ventilated areas.
2. H used in a closed area, vent engine exhaust outside and away
from any building air intakes.
April 1, 1992
Replaces June 2, 1987
Hobart Brothers Company
Troy, Ohio 45373
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 910081
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
/
77
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. if possible, check and add
fuel to cold engine before beginning job.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
a
1. Keep alt doors, panels, covers, and guards closed and securely
in place.
2. Stop engine betore installing or connecting unit.
3. Have only qualified people remove guards or covers for main-
tenance and troubleshooting as necessary,
4. To prevent accidental starting during servicing, disconnect neg-
ative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can burn
eyes and skin.
Batteries contain acid and generate explosive
gases.
. Always wear a face shield when working on a battery.
. Stop engine before disconnecting or connecting battery cables.
. Do not allow tools to cause sparks when working on a battery.
. Do not use welder to charge batteries or jump start vehicles.
. Observe correct polarity (+ and -) on batteries.
Ob WN =
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
| NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence
in à single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk
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 the body.
About Pacemakers:
or to offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
4. Keep welding power source and cables as far away from body as
practical.
5. Connect work clamp to workpiece as ciose to the weld as
possible.
The above procedures are among those aiso normally recommended for pacemaker wearers. Consuit your doctor for complete information.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANS! Standard Z49.1, from American
Weiding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Weiding and
Cutting of Containers That Have Held Hazardous Substances, Amer-
ican Welding Society Standard AWS F4.1, from American Welding
Society, 550 NW. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, 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 Pro-
tection, ANS| 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.
March 24, 1993
Replaces April 1, 1992
2-3
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Hobart Brothers Company
instruction 910081 Troy, Ohio 45373
This page intentionally left blank.
2.4 April 1, 1992
Replaces June 2, 1987
HOBART
E
OM-223
CERTIFICATION NOTICE
HIGH FREQUENCY STABILIZER
Serial No.
Model No.
This equipment may be reasonably expected to meet radiation limits of ten microvolts per meter at one mile, provided
installation, operation, and maintenance is in accordance with the instructions of the manufacturer.
Hobart Brothers Company
Troy, Ohio
USER CERTIFICATE
The above equipment has been installed in accordance with manufacturer's instructions, and is being operated and
maintained as outlined in these instructions.
USER:
Date:
THIS CERTIFICATION NOTICE MUST BE POSTED NEAR THE WELDING MACHINE
SOLID STATE ELECTRONIC CONTROL MODULE EXCHANGE SERVICE POLICY
Because of the definite superiority
of certain solid-state control com-
ponents over conventional electro-
mechanical relays and regulators,
Hobart Brothers Company product
lines now incorporate solid-state
controls for applications in which
they may be used to advantage. To
facilitate testing and servicing,
these control components and cir-
cuits have been assembled as modules
on printed circuit boards, mounted
in such a manner as to be quickly
and easily removed. Electrical con-
nections to other components of the
unit are by means of plug-in or
"Faston" connectors.
In recognition of the fact that most
users of this equipment lack the
facilities and specially trained
personnel necessary to service and
repair solid-state electronic equip-
ment, Hobart Brothers Company has
established a control module ex-
change service plan.
Under the Control Module Exchange
Plan, the owner of the equipment may
exchange the entire module in which
fault has developed for a replace-
ment. A standard exchange price has
been established for each module
design which applies, without regard
to the amount of repair required to
the original turned ín, which is ap-
plied against the cost of the re-
placement. Exchange prices for
specific modules may be determined
by contacting an authorized Hobart
distributor or by writing to the
factory, giving the SPECIFICATION or
ASSEMBLY, MODEL, and SERIAL numbers
of the unit in which the module {is
installed.
This Exchange Plan applies only to
specified solid-state control com-
ponents and circuitry which have
fajled due to electrical fault or
normal deterioration resulting from
use and age. The plan does not
cover parts which have been physi-
cally damaged through accident or
abuse, or to which unauthorized re-
pairs have been made or attempted.
HOBART BROTHERS COMPANY
TROY, OHIO 45373 U.S.A.
CAUTION: Printed
circuits
and other devices may be
affected by
static elec-
tricity. Handling precau-
tions required.
Oct 6/82 Revised
[a-218]
HOBART
E
Instructions
OM-223
RECEIPT OF EQUIPMENT
Check the equipment received against
the Hobart Brothers Company invoice
to make certain that the shipment is
complete and undamaged. If the
equipment has been damaged in
“transit, notify the carrier (rail-
road, trucking company, etc.) at once
and file a claim for damages. If you
require assistance with a damage
claim, furnish Hobart Brothers Com-
pany with full information about the
claim. If the shipment is in error,
contact: Order Department, Hobart
Brothers Company, 600 West Main
Street, Troy, Ohio 45373.
Give the MODEL, SPECIFICATION, and
SERIAL numbers of the equipment, and
a full description of the parts in
error. Refer to EQUIPMENT IDENTIFI-
CATION on front page of this manual
for an explanation of the specifica-
tion numbers.
Best results will be obtained with
this equipment ONLY if the respon-
sible operating and maintenance рег-
sonnel have access to this manual,
and are familiar with the instruc-
tions contained herein. Additional
copies may be obtained at a small
cost per copy by writing to: Hobart
Brothers Company, 600 West Main
Street, Troy, Ohio 45373. Be sure
and give the SPECIFICATION, SERIAL,
and MODEL numbers of your equipment,
and the OM number of this manual, or
PL number of Parts Lists, and number
of copies desired when ordering addi-
tional manuals or parts lists.
Generally, it is good practice to
move the equipment to the site of in-
stallation before uncrating. Use
care in uncrating in order to avoid
damage to the equipment when bars,
hammers, etc., are used. A lifting
eye extending through the top of the
cabinet has been provided so that the
equipment may be handled with a crane
or hoist.
DESCRIPTION
DESCRIPTION OF EQUIPMENT
The three-phase DC welding machine
requires a three-phase AC power in-
put. It has a duty cycle of 100%.
The output current of the machine can
be either straight or reverse polar-
ity DC. The maximum no-load voltage
rating is 85 volts. The input volt-
age for these units is 230/460, 34/17
amperes, at 60 Hz, or 200/230/460
volts, 39/34/17 amperes or
220/380/415 volts, 36/21/19 amperes,
at 50 Hz. See Spec. numbers on front
sheet.
The Programmer is a self-contained
unit which slides in and out of the
welding machine console like a draw-
June 18/85 Revised
er, for easy adjustment or service of
internal components, or for changing
from one type of programmer to
another. Any remote controls in use
connect to plugs on the front control
panel. The programmer controls weld-
ing current parameters, plus water
and gas flow as described in greater
detail in the programmer instruction
manual.
The welding current supply, located
in the bottom panel on the welding
machine console, serves as connection
point for the welding leads, plus
water and gas hoses, when used. It
also contains the polarity reversing
Page 1
DESCRIPTION OF EQUIPMENT (Continued)
switch, high frequency ON/OFF Switch
and high frequency intensity control.
The 1l5-volt auxiliary output recep-
tacles are also located on this panel,
See Figures 1 and 2 for these de-
tails.
DESCRIPTION OF TIG PROCESS
Gas Tungsten Arc Welding (GTAW) is the
descriptive name of the welding pro-
cess whereby the arc 1s maintained
between a non-consumable metal elec-
trode (usually tungsten) and the work,
the arc zone being shielded by an
inert gas such as argon or helium.
For simplicity and uniformity, any
reference to the process in this man-
ual will be made with the term
"TIG".
This process can be used for making
clean, sound welds on most metals and
alloys, irrespective of their composi-
tion. In many instances, it provides
the only suitable method for joining
certain metals. Cleaning is reduced
to a minimum and frequently is elim-
inated, both before and after welding.
Flux is unnecessary in this process.
Because of certain inherent character-—
istics of the TIG welding process,
special consideration must be given to
the design of a welding machine which
will best serve the requirements of
the process. This Hobart inert gas
welding machine has been designed and
built with these requirements in mind.
It will give long, satisfactory ser-
vice producing welds that are correct
and sound if it is properly installed,
used and maintained.
Welding currents for the TIG process
depend upon the size of the tungsten
electrode used, the material being
welded, welding speed, size and shape
of the material, and other factors.
Following is a rough guide for usable
current ranges for various tungsten
electrode sizes:
Page 2
OM—223
Electrode [DC Straight DC Reverse
Diameter Polarity Polarity
In. mm
.020 10.51 5-35
040 11,02 30-100
1/16 11.59 70-150 10-20
3/32 12.40 150-225 15-30
1/8 13.20 200-275 25-40
5/32 13.95 250-350 40-55
3/16 14.80 300-500 80-125
1/4 6.35 400-650 80-125
Tungsten Electrode Sizes
Table 1
The inert gas flow should be con-
trolled accurately with a regulator
and flowmeter. No specific recommen-
dations for rates of flow can be
given, as this depends entirely on
the welding conditions and the torch
and nozzle used. Correct argon flow
is usually between 8 and 35 cubic
feet (226 to 990 liters) of gas per
hour; and helium flow is between 18
and 85 cubic feet (510 to 2410
liters) per hour.
More specific information concerning
the torch configurations available,
and the gas flow for each, can be ob-
tained from the manufacturer of the
torch equípment.
CONTROLS AND CONNECTIONS
This description of controls and con-
nections concerns only the welding
machine (referred to as the "console"
in many cases). The controls and
functions of operation of the pro-
grammer which must become a part of
this unit for welding operation, are
contained in a separate manual, for
the specific programmer being used.
METER PANEL - Controls contained here
are at the top front panel, above the
programmer.
VOLTMETER - This 0-100 volt range
voltmeter indicates the welding arc
voltage.
Revised Feb 4/85
CONTROLS AND CONNECTIONS (Continued)
AMMETER - This meter, scaled 0-200
amperes, indicates welding current.
NOTE: In some instances,
the VOLTMETER and AMMETER
described above are not
mounted on this panel, but
are located at another lo-
cation, if supplied at all.
One such case is when the
machine is used with some
DABBER Welding Systems.
When so used, consult the
CONTROL CABINET ASSEMBLY
manual for details on the
(Optional) METER PANEL. An
(Optional) Hour Meter may
be installed in the place
of these meters on the pan-
el, in some cases, also.
POWER ON OFF SWITCH - Removes pow-
er supply from the pilot transformer,
deenergizing internal circuits in the
meter panel and the bottom panel.
TIG/STICK SELECTOR SWITCH - This
switch allows selection of either the
TIG torch mode of welding, or regular
covered electrode (stick) welding
mode. In the TIG position, it pre-
sets the arc force control (described
below) to MINIMUM, In the STICK po-
sition, it deenergizes the gas and
water valves, as well as the high
frequency starter circuit.
ARC FORCE AMPERE CONTROL (Only ad-
justable when the TIG/STICK Switch is
in the STICK position) - Varies the
short-circuit (welding arc) current
and produces an increase of amperage
when arc length is shortened, such as
in a tight groove. This control pro-
vides more arc force and eliminates
the tendency of snuffing out the arc
when using electrode manipulation.
The control is especially suited for
use with E-6010, E-7018, and 718 LMP
welding electrodes for pipe welding
applications.
Feb 4/85 Revised
OM-223
FUSES:
10 ampere - Protects the 115 volt
auxiliary receptacles from overload.
5 ampere — Protects the internal
115 volt circuitry.
BOTTOM PANEL — The controls and con-
nections on the bottom panel furnish
the basic welding mode necessities.
POLARITY SELECTOR SWITCH -
Two-position rotary switch that al-
lows selection of STRAIGHT DC or RE-
VERSE DC welding polarity. When set
to the STRAIGHT DC position, both the
TIG torch terminal and the STICK ter-
minal are negative polarity with
respect to the WORK terminal. There-
fore, the switch must be set for RE-
VERSE polarity for stick welding.
HIGH FREQUENCY SWITCH - In the
AUTO position, the high frequency
starter circuit is energized when
there is open-circuit voltage at the
output terminals. Once an arc is es-
tablished, the high frequency circuit
is automatically deenergized. (The
TIG/STICK SWITCH must be in the TIG
mode.)
REMOTE HIGH FREQUENCY (Optional) -
Connection point for remote high fre-
quency control, when receptacle is
supplied (115 V AC connection).
HIGH FREQUENCY : INTENSITY CONTROL
- This single-turn potentiometer con-
trols intensity of the high fre-
quency.
115 VOLT DUPLEX RECEPTACLES —
Provides 115 volt AC power for aux-
iliary equípment (9 amperes maximum).
TIG TORCH TERMINAL - This terminal
is for connection of the Tig torch,
and is connected through the high fre-
quency coil.
Page 3
Voltmeter Ammeter
Power ON/OFF
\ | \ Switch
OM-223
5 Amp Fuse
\
| 10Amp
Fuse
7
Tig/Stick
Selector Switch
Arc Force Control
A-036
Meter Panel
Figure 1
CONTROLS AND CONNECTIONS (Continued)
BOTTOM PANEL (Continued)
GAS-TO-TORCH CONNECTOR ~ Provides
connection point for feeding inert
gas to the torch.
GAS—FROM-CYLINDER CONNECTOR - Pro-
vides connection point for inert gas
from the supply cylinder to the
panel.
WATER-TO~TORCH CONNECTOR - Provides
connection point for feeding cooling
water to the torch.
Page 4
WATER-SUPPLY-CONNECTOR — Provides
connection point for water supply
from factory (city) water supply, or
from circulating system, such as a
Hobart Circoolator.
STICK TERMINAL - Electrode lead
connects here for stick (covered
electrode welding). When using this
terminal, be sure that the TIG/STICK
Switch on Meter Panel (see Figure 1)
is set on STICK.
WORK TERMINAL - Provides “ground”
connection to the work, or material
being welded, to complete the secon-
dary circuit.
Revised Feb 4/85
OM-223
Twist- Lok Receptacie {OpTional)
{Timed 115V AC To Remote
H.F. Starter)
Polarity High Frequency High Frequency SV
Switch Intensity К To a
- | » de Je
© 19068
Out put
Terminal
Cover
N
em Presa? ag
PAN AS | AR |
(X) LE | пе
ГМИ ta v=)
No Pole] — —_— - -— 1 y
NE NA SR ng TI!
boto Pre U (da а! |
LL AA Y | => |
—F 1 De
WORK STICK Gas Water Water TiG TORCH
Terminal Terminal To Toreh From To Torch Terminal
Supply
Gas From
Feb 4/85 Revised
Cylinder
[A- 037]
Bottom Front Panel
Figure 2
Page 5
OM-223
INSTALLATTON
LOCATION
For best operating characteristics
and longest unit life, take care in
selecting an installation site. When
installing the equipment, avoid loca-
tions exposed to high humidity, dust,
high ambient temperature or corrosive
fumes. Moisture condenses on machine
parts and electrical controls, caus-
ing corrosion which can seriously af-
fect operation and efficiency. Dust
and dirt cause extra wear on all mov-
ing parts. Therefore, use care to
locate the equipment so that excess
moisture, dust, or corrosive fumes
will not be drawn into the unit.
Adequate air circulation is needed at
all times in order to assure proper
operation. Provide a minímum of 24
inches (610 mm) of free alr space at
both front and rear of the unit,
Make sure that the ventilator open-
ings are not obstructed. Air enters
through the rear panel.
Because high frequency stabilized arc
welding machines inherently radiate
power at frequencies which may inter-
fere with radio communication, in-
cluding commercial, police, and avia~
tion broadcasts, their operation is
subject to control by the Federal
Communications Commission.
Some general information on radio
frequency radiation from high fre-
quency stablized arc welding machines
is given below:
DIRECT RADIATION FROM WELDING MACHINE
The manufacturer controls direct rad-
lation from the welding machine by
proper design of the unit. If the
user complies with the installation
and operation instructions furnished
by the manufacturer, direct radiation
from the machine will be relatively
low.
DIRECT RADTATION FROM WELDING LEADS
The initial radiation, due almost en-
tirely to the welding leads acting as
Page 6
an antenna, decreases rapidly with
the distance from the leads. This
radiation can be kept to a minimum by
making the welding leads as short as
possible, The frequency spectrum
emitted by а particular unit can be
altered substantially by changing the
length or position of the welding
leads and by differences in loading
caused by operation with the elec-
trode arcing to the work.
RADIATION FROM POWER LINES
High frequency voltage which is con-
ducted from the welding machine to
the power line may cause radiation
from the line itself. This radiation
can be kept to a minimum by careful
design of the unit and, in some
cases, by the use of line filters.
Ina welding machine that has been
certified by the manufacturer, the
radiation from the power line is gen-
erally small when compared to the di-
rect radiation from the welding
leads.
WIRING IN THE WELDING AREA
The term "welding area” refers to the
area in which the welding machine,
the welding leads, and the welding
work are located.
RE-RADIATION
Ungrounded metallic objects in close
proximity to the welding area can act
as antenna which will pick up, con-
duct and re-radiate the high fre-
quency generated by the welding ma-
chine. Unshielded wires in the im-
mediate vicinity may conduct radia-
tion, and re-radiate it. Therefore,
no unshielded conductors shall be lo-
cated within 50 feet (15,250 mm) of
the welding area.
This means that all electrical power
or lighting wiring within 50 feet
(15,250 mm) of the welding area shall
be enclosed in grounded rigid metal-
lic conduit, copper braid, or some
Revised Feb 4/85
RE-RADIATION (Continued)
other material having an equivalent
shielding efficiency, or shall con-
sist of lead-covered cable. (Ord-
inary flexible helically wrapped
metallic conduit is generally not
suitable.) The shielding or cable
covering shall be grounded at 50-~foot
(15,250 mm) intervals. Good electri-
cal bonding shall be maintained be-
tween conduit sections.
Wiring, other than electrical power
and lighting wiring within 50 feet
(15,250 mm) of the welding area,
shall be shielded and the shields
shall be grounded. [This includes
wiring located within 50 feet (15,250
mm) of the welding machine in a
vertical or vertical-diagonal direc-
tion. |
The foregoing procedure shall apply
even if:
l. The welding area is not a fixed
location.
2. There are exposed wires off the
premises but within 50 feet (15,250
mm) of the welding area.
WIRING CHANGES
All changes in power and lighting
wiring shall be made by a qualified
electrician, Any shielding or relo-
cation of telephone or signal wires
must be done by the service company
concerned or with their specific per-
mission.
This type of radiation can be kept to
a minimum by installing the welding
machine in accordance with the in-
stallation procedures outlined in
this instruction manual.
USE IN METAL BUILDINGS
Where the welding area is enclosed
within a metal building, proper pre-
cautions must be taken to insure that
the building is properly grounded.
Feb 4/85 Revised
OM-223
This can be accomplished by placing
several good electrical grounds
around the periphery of the building.
Refer to following grounding pro-
cedure,
The Installation procedures described
in this publication shall be observed
even if the welding machine 1s oper-
ated within a shielded structure.
GROUNDING
The frame of this welding machine
should be grounded for personnel
safety. Where grounding 1s mandatory
under state or local codes, it is the
responsibility of the user to comply
with all applicable rules and regula-
tions. Where no state or local codes
exist, it is recommended that the Na-
tional Electrical Code be followed.
Refer to Table 2 for wire sizes.
The work or work table must also be
grounded by using a conductor at-
tached to a driven ground or water
pipe as described below. See Figures
3, & and 5,
The requirements and recommendations
for grounding apply to rubber tire
mounted equipment. In addition to
the usual function of protecting per-
sonnel against the hazard of electri-
cal shock due to fault in the equip-
ment, grounding serves to discharge
the static electrical charges which
tend to build up on the surfaces of
tire mounted equipment. These static
charges sometimes cause painful shock
to personnel, and in some instances,
lead to the erroneous conclusion that
an electrical fault exists in the
equipment.
Use an input-power cable assembly
which includes a grounding conductor
to connect this equipment to the in-
put power supply. When included in
the cable assembly, the grounding
conductor will be green or green with
a yellow stripe, or bare. Connect
Page /
GROUNDING (Continued)
the grounding conductor to the equip-
ment grounding terminal, if provided,
and if not, to the equipment frame,
taking care to see that good electri-
cal contact is made between conductor
and frame. Connect the other end of
the grounding conductor to the system
ground.
If, for any reason, an input cable
which does not include a grounding
conductor is used, the equipment may
be grounded with a separate conductor
if permitted under applicable code,
or by special permission of the
jurisdictional body responsible for
enforcement of the code. Minimum
size and color coding requirements
must be in accordance with any ap-
plicable state or local code, or the
National Electrical Code.
If metallic
is used, the
duit must be
required by
the National
armored cable or conduit
metal sheathing or con-
effectively grounded as
state or local code, or
Electrical Code.
If a system ground is not available,
the welding machine must be connected
to a driven ground rod (see Figures 3
and 4) or to a water pipe that enters
20-30 Ibs. (9.1— 13.6 kg) Soil Treating Material
{copper sulphate, magnesium sulphate or rock salt)
placed in circular trench and covered
ith earth,
" г Grounding Conductor
ground clamp.
NN
Арргох. | 2+. (305 тт)
(8 Inches —
(457 mm) Not less than 8 Ft. (2438 mm)
Approx
Ground we
Outside Ground
Figure 3
Page 8
Fasten Grounding Conductor
to the rod with an approved
6 Inches (152 mm) Approx
OM-223
the ground not more than 10 feet
(3,048 mm) from the machine. Refer
to the WIRE AND FUSE SIZE CHART,
Table 2 for selection of the proper
grounding conductor.
NOTE: The grounding con-
ductor must be as short as
possible in order to pro-
duce the most efficient in-
stallation.
TREATING AN OUTSIDE GROUND - The
soil treating materials are placed in
a circular trench around the rod, but
not in direct contact. The crystals
are gradually dissolved by surface
waters and the solution is carried
into the most useful area of earth
surrounding the electrode (rod).
Flood the trench several times when
making original installation. See
Figure 3.
TREATING AN
the diameter of
INSIDE GROUND - Reduce
the hole to 6 inches
(152 mm), pour soil treating material
in around the rod. Add enough water
to dissolve 8 pounds (3.62 kg) of
soil treating material. Flood the
hole every 6 months and replace the
soil treating material when it is all
dissolved. See Figure 4.
Fasten Grounding Conductor Grounding
to the rod with an approved Conductor
ground clamp.
Removable
Cover
Fioor
A
a
a Add Fr
DD
Not less than 8 Ft.
(2438 mm)
Inside Ground
Figure 4
Revised Feb 4/85
CONNECTION TO LINE VOLTAGE
Refer to Table 2 for wire sizes re-
quired. The power supply wires serv-
ing the welding machine shall be com-
pletely enclosed for a distance of at
least 50 feet (15,250 mm) (in any di-
rection) from the machine in solid
metallic conduit closely braided
copper sheathing. This shielding
shall be connected to the ground at
the extreme end of the shielding.
(See Figure 5.) The shielding shall
be solidly connected to the case so
as to make good electrical contact
and there shall be no gaps in the
shielding run. (Ordinary flexible
helically wrapped metal conduit is
generally not suitable.)
or
CAUTION: Conductor
shali be selected
NEC, CE Code,
codes and
sizes
to meet
and local
shali be modi-
Line
S
6426
or
{6835
res in
Wire ¡Conductor
e
OM-223
fied as required for line
voltage drop and anbient
temperature.
This welding machine operates on a
three-phase, AC input. See nameplate
of the machine to determine required
input voltage and frequency. Make
certain that the welding machine is
connected for the power supply volt-
age available, See Voltage Change-
over Connection Diagram in the back
of this manual, or inside the ma-
chine. The input power cables should
be connected to the power supply
through a fused disconnect switch
(furnished by the customer). Refer
to the identification nameplate to
determine the rating of the machine,
then consult the local power company
for wire and fuse size code. If no
code exists, use the size of wire and
fuses listed in Table 2 following.
Air
unding
Conductor
Size
с
ng
n
Groun
res
Fuse |
Size
E IE I
Line Wire
Size Size
#10 #10 #10
10
10
1 1
10
1
8
Table 2
June 18/85 Revised
Page 9
ОМ-223
CONNECTION TO LINE VOLTAGE (Contin- CAUTION: The flow of
ued) cooling air through
the welding machine is
WARNING: When 4-conductor carefully directed by
rubber-covered cable is baffles. Never operate
used, the grounding con- the machine with any
ductor must be green in panels removed or open,
color. When flexible ar- as serious damage to
mored cable or conduit is the components may
required by local codes, result.
install it properly to
insure an adequate ground
of the equipment. With
the machine frame ground- CAUTION: Make certain
ed, the operator is al- that the ground lead
ways assured full protec-— attached to the work
tion, even in the uniike- is connected securely
ly event of insulation at both the work and
failure, or of accidental at the machine and
ground of the power sup- that the lead is in
ply. good condition.
rn A
*50Ft(15250mm }-»
aximum Le— 7 FIiZI35mm) |
Power Line Conduit
Al [lo o 00 artist
” Work” E
Terminal
Remote Contwmi WORK
{Faot Or Torch) Or
WORK TABLE
Ground Rod | 25Ft (7620 mm) >
ses
Grounding
Ground Rod Instructions
А
Terminai T
Wiring Precautions
Figure >
Page 10 Revised Feb 4/85
Primary Connection
Terminals
(Green Wire)
Three-Phase Input Connections
Figure 6
WARNING: The fused dis-
connect switch: Open or
place in the OFF position
and remove the fuses. To
avoid an accident, make
the electric power connec-
tions to the welding ma-
chine first, then to the
fused disconnect switch.
This will prevent an ac-
cidental application of
power while the machine is
being connected.
CONNECTION TO LINE CONTACTOR
l. Remove the top cover from the
welding machine,
2. The line contactor for input power
connections is mounted on the back of
the inner vertical panel. See Figure
6.
3. The electric ground terminal is
located about three inches (76 mm)
from the line contactor, on the
vertical panel.
Feb 4/85 Revised
ОМ-223
4, Run the power cable through the
hole at the rear of the machine.
Loosen the cable clamp as required to
accommodate the cable.
5. Remove about 10 inches (254 mm)
of the outer insulation that holds
the wires of the cable together.
6. Strip approximately 1/2 inch
(12.7 mm) of insulation from the end
of each wire.
7. Install the green wire securely
to the grounding terminal.
8. Install the other wires to the
line contactor as illustrated in Fig-
ure 6.
9. Pull the cable back through the
hole sufficiently to remove excessive
slack, but not enough to permit the
cable to be under tension.
10. Secure the cable under the cable
clamp. The cable clamp should be
sufficiently tight to prevent any
movement when it is pulled.
CAUTION: Do not tighten
the cable clamp enough to
damage cable insulation or
wires.
11. Refer to instructions under INPUT
VOLTAGE CHANGEOVER to assure that the
machine is connected internally to
match the available line voltage.
12. Replace top cover and securely
fasten in place.
CONNECTION TO FUSED DISCONNECT SWITCH
l. Connect the black cable wire to
the terminal in the fused disconnect
switch that leads through the fuse
and the switch to the black input
power wire.
Page 11
CONNECTION TO FUSED DISCONNECT SWITCH
(Continued)
2. Connect the white cable wire to
the terminal in the fused disconnect
switch that leads through fuse and
switch to the white input power
wire.
3. Connect the red cable wire to the
terminal in the fused disconnect
switch that leads through fuse and
switch to the red input wire.
4, Connect the green cable wire to
the fused disconnect switch ground
and to an external ground.
WELDING ADJUSTMENTS
Keep spark gaps set at 0.006 inch
(0.152 mm). Set high frequency con-
trol to lowest possible setting con-
sistent with good welding.
CAUTION: When the machine
is in operation, make sure
that the top is in place,
and all access holes
covered in the cabinet.
Proper flow of cooling air
must be directed through
the unit to avoid over-
heating. Make no changes
or adjustments not covered
in this manual, as modifi-
cation might affect radia-
tion and thus void the
manufacturer's certifica-
tion.
WELDING LEADS
The TORCH lead and the WORK lead must
each be 25 feet (7620 mm) or less in
length and run together at floor
level whenever possible except the
last 7 feet (2140 mm) at the torch or
"whip" end. (See Figure 5.) Use No.
1 gauge copper cables.
REMOTE CONTROL CABLES (When used)
The remote control cables for gun
trigger or foot control switch must
also be 25 feet (7620 mm) in length,
or less, and must be brought out
close to and parallel to the welding
leads.
Page 12
OM-223
CERTIFICATION NOTICE
In order to comply with F.C.C. regu-
lations after the unit has been in-
stalled in accordance with the pre-
ceding instructions, the user must
post the certification notice at the
location of the welding machine. A
convenient form is enclosed in the
front of this book which may be used
for this purpose after it has been
properly filled out.
INDIVIDUAL INSTALLATION CERTIFICATION
1. The user may waive any of the re-
quirements outlined in these special
installation requirements if he de-
sires to exercise the option of hav-
ing an installation test survey made.
This survey shall be made by ¿a com-
petent engineer in accordance with
the test procedure requirements set
forth in Part 18 of the Federal Com-
munications’ Rules and Regulations.
2, Certification may cover a unit in-
stallation or may be included in the
certification of a complete plant.
RESPONSIBILITY FOR INTERFERENCE
In the event this equipment causes
interference, it is the user's re-
sponsibility to take steps in elimi-
nating the interference.
INPUT VOLTAGE CHANGEOVER
Refer to the voltage changeover dia-
gram at the back of this manual.
Closely follow accompanying instruc-—
tions.
WARNING: Before proceed-
ing, place fused discon-
nect switch in “OFF” posi-
tion and remove the
fuses.
Remove the top from the cabinet to
gain access to the voltage changeover
panel. Voltage may be changed by re-
moving the copper links and arranging
them according to the instructions on
the Voltage Changeover Diagram. When
placing links in the 4560-volt ar-
rangement, use two links on each po-
sition.
Revised Feb 4/85
PROGRAMMER AND REMOTE CONTROL CON-
NECTIONS
Refer to Figure 5 as a rough guide-
line, but be sure to use the Program-
mer instruction manual to determine
the exact connection procedure.
PREPARATION FOR USE
COOLING WATER CONNECTIONS - Refer
to Figure 7 when making connections
to a "Circoolator”. Refer to Figure
8 when making connections to the city
(factory) water supply. In both
cases, the cooling water exits the
torch through the hollow electric
cable.
NOTE: All water fittings
have left-hand threads.
CAUTION: Do not connect
cooling water lines to the
welding machine if a pump-
type "Circoolator” is
used. Connect the torch's
water line directly to the
pump with a non-metallic
hose. The use of Teflon
thread sealing tape is
recommended on the
threaded water fittings,
except for the torch cable
connection to the welding
machine Electrode or Tig
Torch terminal. The only
thread sealant allowed on
this torch cable connec-
tion is electrical joint
compound. This compound
is available from Hobart
Brothers Company in 5 oz.
(141.8 в) tubes (Hobart
part no. 903170).
Feb 4/85 Revised
OM-223
SHIELDING GAS CONNECTIONS — Refer
to Figure 7 when making connections
to a "Circoolator” cooled torch. Re-
fer to Figure 8 when making connec-
tions to a city water cooled torch.
Refer to Figure 9 when making connec-
tions to a gas cooled torch. Only in
the case of the gas ("air") cooled
torch does the gas flow to the torch
through the hollow electric cable.
NOTE: All gas fittings
have right-hand threads.
Shielding gas loss due to
poor connections results
in gas waste and possibly
poor welds.
ELECTRICAL CONNECTIONS TO TORCH AND
WORKPIECE - The “torch” and “work”
power leads, plus the remote or torch
switch cables, must each be 25 feet
(7620 mm) in length or less. Refer
to Figure 5. Securely connect the
"electrode" (stick) lead to the STICK
Terminal (if performing stíck-
electrode welding only) or to the TIG
TORCH Terminal (if performing TIG
welding). Securely connect the
“work” lead to the WORK Terminal in
any case.
NOTE: Make sure all con-
nections are clean and
tight. Thread sealant
may be used as specified
in the CAUTION note in
the section entitled:
COOLING WATER CONNEC-
TIONS. When using high
frequency, keep both
welding leads as short as
possible and as far away
as practical from other
power lines and metallic
objects.
Page 13
| Welding
Machine
©) Bottom Panel}
<
E (©) Cirevotator
ON/OFF Switch
EE
—— [4-034]
Heiding
Machine
{Sotiom Pons)
Ragulator
Water
Supply —
} [A-9039]
/ Waiding
Machine
{Bottom Panei)
Regulator
Page 14
OM-223
Circoolator
Cooled
Torch
Figure 7
City (Factory) Water
Supply Cooled Torch
Figure 8
Gas (Air) Cooled
Torch
Figure 9
Revised Feb 4/85
0M-223
OPERATION
NOTE: For operating in-
structions, the Programmer
Instruction manual will
have to be consulted. It
will instruct in detail
for the particular pro-
grammer which is being
used in this machine.
PRESETTING CONTROLS FOR TIG WELDING
Refer to Figure 1, 2 and Programmer
Instruction Manual.
HIGH FREQUENCY SWITCH - AUTO posi-
tion, high frequency mode ¡is initi-
ated, in OFF position, the high fre-
quency circuitry is deenergized.
HIGH FREQUENCY INTENSITY CONTROL -
Lowest setting that will consistently
initiate the arc.
POLARITY SWITCH - Set in either
DCEN (electrode negative) for
STRAIGHT polarity; or in DCEP (elec-
trode positive) for REVERSE polarity
welding mode.
POWER ON/OFF SWITCH - Place in ON
position to supply power to the
panel.
TIG/STICK SELECTOR SWITCH - Place
in TIG position for TIG welding, or
in STICK for covered electrode weld-
ing. In STICK position, gas and
water and high frequency are deener-
gized.
ARC FORCE CONTROL - Use only with
stick welding. See details under
Controls and Connections text in DE-
SCRIPTION section.
Feb 4/85 Revised
FUNCTIONS OF PRINTED CIRCUIT BOARDS
CONTROL AND FIRING CIRCUIT P.C.
BOARD 1369096 - The Cyber-Tig II
power source uses SCRs to control and
rectify the welding current. The
conduction of the output rectifier
SCRs is activated by this P.C. Board.
See Figure 13 and consult callouts
and legend for layout of components.
Refer to diagram 369096 in back of
manual under DIAGRAMS, also.
SCR BACKGROUND CIRCUIT PRINTED CIR-
CUIT BOARD 368043-1 —- Refer to dia-
grams 368043 and 369284 in back of
- manual. This circuit provides the
open-circuit voltage and the welding
current below 5 amperes. The back-
ground 5CRs are gated ON by the
Cyber-Tig II programmer after the
preflow timer times out.
Open-circuit voltage appears at the
output terminals of the machine until
a welding arc is struck. At very low
welding currents the conduction angle
of the main SCRs is so small that the
current is erratic. The background
circuit SCRs override the main SCRs
and provide a stable weld current
down to about 3 amperes.
SOLID-STATE RELAY PRINTED CIRCUIT
BOARD 368036 — Refer to diagrams
369284 and 368036 in back of manual
under DIAGRAMS. The input voltage
(control voltage) is 24 volts DC.
The output contacts are for 120 volt
AC (7 amperes).
Two solid-state relays are used. One
energizes the high frequency starter
circuit, and the other one energizes
the gas and water valves. The input
voltages for these relays are 24
volts DC signals from the pro-
grammers.
Page 15
OM-223
MAINTENANCE
LUBRICATION
The fan motor incorporates sleeve
bearings. You can expect the life of
this motor to exceed 50,000 hours
without relubrication. Periodically
cleaning the motor and lubricating
the bearings will extend the life of
the motor. The following table will
furnish a recommended guide to the
frequency of this lubrication if de-
sired.
Type of Duty [Lubrication Interval |]
Light (up to
6 hrs./day)
Moderate (7 to
15 hrs./day)
Heavy (16 to
24 hrs. /day)
Every 12 months
Every 6 months
Every 3 months
NOTE: Apply 1-12 drops of
20W non-detergent oil at
each end of bearing.
INSPECTION AND CLEANING
For uninterrupted, satisfactory ser-
vice from this welding machine, it is
necessary to keep the machine dry,
and well ventilated. Dirt and dust
may be blown or wiped from the inside
of the welding machine and the pro-
grammer drawer.
Page 16
WARNING: Disconnect line
voltage from the unit be-
fore attempting any ser-
vicing inside the machine.
Turn the fused disconnect
switch to OFF position,
and remove its fuses.
Be sure to wipe the fan blades clean.
All electrical connections should be
checked and tightened at regular in-
tervals to eliminate unnecessary
losses and avoid subsequent trouble
from overheating or open circuits.
CAUTION: The flow of air
through the welding ma-
chine is carefully di-
rected by baffles. Never
operate the welding ma-
chine with any side or top
panels removed or open, as
serious damage to the rec-
tifiers might result.
SPARK GAPS
Set to 0.006 inch (0.15 mm) or less.
Check gaps frequently, as gap erosion
is normal.
SCRs
See Detailed Troubleshooting Instruc-
tions.
Revised Feb 4/85
OM-223
TROUBLESHOOTING
The following chart contains information which can be used to diagnose and cor-
rect unsatisfactory operation or failure of various components of the welding
machine. Fach symptom of trouble is followed by a list of probable causes and
the procedure necessary to correct the problem. In addition to the chart, de-
tailed instructions for checking and adjusting and/or setting components on the
Printed Circuit Board and SCRs are given.
TROUBLE PROBABLE CAUSE REMEDY
Welding machine la. Power switch OFF |à. Place power switch in ON
will not start. position.
b. Power lines dead b. Check voltage.
C. Broken power lead с. Repair.
de Wrong line voltage de Check power supply.
e. Incorrect input power e. Check connections against
connections at weld- wiring diagram.
ing machine
f. Open circuit to power f. Repair, Check for broken
switch or control wire or loose connections
transformer at terminals.
в. Fuse on pilot trans- g. Remedy cause. Replace
former blown fuse.
h. Broken lead at con- h. Repair.
tactor
i. Mechanical obstruc- L, Remove obstruction.
tion on contactor
j» Defective contactor ]. Replace.
coil
Fan will not a. Power switch OFF a. Place power switch in ON
start. position.
b. Power lines dead be Check voltage.
c. Broken power lead ce Repair.
d. Wrong line voltage d. Check power supply.
e. Incorrect input power e. Check connections. Refer
connections at welding to Voltage Changeover
machine Diagram in DIAGRAMS Section
of this manual.
Feb 4/85 Revised Page 17
OM-223
TROUBLE PROBABLE CAUSE REMEDY
= ==" E A E E LL EEE CEE EEE EE e E E = = PURES IEEE EEE E E EE EEE
Fan will not f. Blown line fuses f. Check for cause, replace.
start. (cont'd)
g« Blown fuse on front g. Check for cause, replace.
panel
h. Fan motor failed h. Replace.
ie Control transformer i. Replace.
failed
je Loose connections at js» Reconnect,
contactor, control
transformer or switch
Si
k. Loose connections at k. Reconnect.
control transformer
Contactor hums. a. Dirt on pole faces of a, Clean faces of magnet.
contactor
b. Broken shading coil b. Replace contactor.
(copper ring) on con-
tactor core
Contactor chat- a. Line leads too small a. Use larger leads.
ters.
b. Low line voltage b. Check line voltage.
Contactor oper- | a. Wrong line voltage a. Check nameplate of welding
ates and blows machine for line voltage to
fuse in supply use, check line voltage.
circuit.
b. Links on voltage b. Check connections. Refer to
changeover panel Voltage Changeover Diagram
incorrectly con- in DIAGRAMS Section of this
nected manual.
c. Fuse too small с. Install proper size fuses.
(See wire and fuse size
chart in INSTALLATION Sec-
tion of this manual.)
d. SCR failed - (output d. Replace SCR. See MAIN-
rectifier) TENANCE Section of this
manual.
e. Short circuit in pri- e. Remove short circuits.
mary connections
f. Transformer failed fe Repair or replace.
Page 18 Revised Feb 4/85
OM—223
TROUBLE
Pr EEE EE EI EA EE
Welding machine
delivers welding
current but soon
shuts down.
Contactor oper-
ates but welding
machine will not
deliver current.
as
а,
cs
PROBABLE CAUSE
Welding machine over-
loaded, and duty
cycle too high
Thermostat S57 on out-
put rectifier open,
which opens the line
contactor (K3)
Power leads too long
or too small in cross
section, Voltage drop
through leads causes
machine overload
Ambient temperature
too high
Ventilation blocked
Fan not operating
Electrode lead or
holder may be ground-
ed
Polarity switch not
in positive position
Water pipe connected
to TIG torch terminal
Transformer winding
open
Transformer secondary
failed
SCR failed (output
rectifier)
See Troubleshooting
Section of Programmer
Manual also
E E E—E|
de
be
Е.
De
f.
[E - 28 35 + 058 a A Raha EE ES AE ACE
REMEDY
Reduce load - overload can
be carried only for a short
time.
Do not operate continually
at overload currents.
Replace with larger diam-
eter leads. See wire and
fuse chart in INSTALLA-
TION Section of this man-
ual.
Operate at reduced loads
when temperature exceeds
100°F (38°C).
Check air intake and ex-
haust openings for obstruc-
tion and remove any found.
Check bearings, discon-
nect leads and apply
motor nameplate voltage
to check.
Use only lead and holder
with sound insulation.
Set exactly in DCEN or DCEP
position.
from torch|
terminal.
Remove. Run lead
lug to TIG torch
Have transformer
paired.
Le-
Have transformer
pairad.
re-
Replace SCR. See MAIN-
TENANCE Section of this
manual.
Feb 4/85 Revised
Page 19
OM-223
TROUBLE
Eu IE A AER EEE E E =ЕЛ
Welding arc is
loud and spatters
excessively
(stick electrode
welding)
Welding arc
sluggish
Contactor oper-—
ates, but welding
machine will not
deliver welding
current, and open
circuit voltage
is present at the
output when gun
switch is de-
pressed.
Current control
does not control
welding current.
de
be.
de
as
Ca
PROBABLE CAUSE
pr EA AAA AE LL LE A EEE ALE E LE EE EE
Current setting too
high
Polarity wrong
Filter coil short
circuited
Arc Force set too
high
Current too low
Poor connections
Leads too long or
too small in
diameter
Low line voltage
No ground connections
at work
Welding leads not
connected
Polarity switch
See Programmer Manual.
de
Ce
de
as
A.
Ce
a LS E E E A E CELE EE CEA EA TT ICAC E FE
REMEDY
Check setting and output
with ammeter, or reduce
current.
Check polarity, try re-
versing polarity.
Replace filter.
Lower Arc Force setting.
Check output and current
recommended for electrode
being used.
Check all electrode
holders, electrode lead
and work lead connec-
tions.
Check lead voltage drop,
use larger lead. (See
Table 2.)
Check power source. Noti-
fy power company if nec-
essary.
Make connections.
Make connections.
Check to be sure switch is
in position.
Page 20
Revised Feb 4/85
OM-223
~ TROUBLE PROBABLE CAUSE REMEDY
Welding machine a. Electrode or ground a. Clean and tighten all con-
operates but lead connections loose nections, check ground re-
welding current at machine, ground or turn circuit.
falls off. work
b. Programmer set wrong b. Recheck Programmer setting.
Also see "welding ma-
chine delivers welding
current but soon shuts
down”.
Low open-circuit (a. Open SCRs in background a. Replace SCRs.
voltage in output rectifier
(SCR Р.С, Board
36804 3-1)
Arc difficult to (a. Loose connection a. Check connections.
strike
b. Wrong type electrode b. Use proper electrode.
с. Start level pot set с. See Programmer Manual.
wrong
Operator gets a. Case of welding machine a. Ground welding machine
shock when weld- not grounded case.
ing machine case
is touched
Abnormal current |a. Loose cable connections a. Check for overheated con-
fluctuation, nections and tighten.
voltage nearly
constant b. Control board failure b. See DETAILED SETTING AND
TROUBLESHOOTING OF PC
BOARD.
Contactor fails a.» Contactor contacts a. Clean contacts.
to open sticking
Very noticeable, a. Control circuit a. Same as "b" above.
rough, sputtering board failure
arc. Loss of
control. Minor
starting prob-
lems.
Feb 4/85 Revised Page 21
OM-223
TROUBLE
DA RE GEA ECC E TE
Arc is unstable
Torch “spits”
tungsten into
work
de
PROBABLE CAUSE
+ XA 3 ¥ FTE ON E CET IEEE EEE E TEA
Dirt, grease, or oil
on work piece
Joints too narrow. Arc
jumps from side to
side.
Electrode too large;
arc moves around on
electrode.
Arc too long
Also see "Torch spits
tungsten into work”.
Tungsten is balled for
reverse polarity
Arc length too long
Tungsten too small
Current too high
Sharp point ground on
tungsten
Postflow time too
short causing air
contamination of
tungsten
Tungsten touching work,
causing contamination
of tungsten and work
Leaky "0" rings in
torch or leaky hoses
in gas line
Hoses previously
used to carry oil,
acetylene or gases
de
be
Ca
а,
Te
SE TTR HE NE EEE CE =
REMEDY
EE SS ae rT =
Degrease and clean to
bare metal by chemical or
abrasive means if nec-
essary.
Increase spacing of work
pieces or shorten arc
length. Reduce high fre-
quency setting.
Use smaller electrode or
grind point. A polished
electrode sometimes
helps.
Shorten arc length.
Ball by grinding only.
Shorten arc.
Increase size of tungsten.
Decrease current.
As rated current of tung-
sten is approached, re-
duce sharpness of point.
Increase postflow time un-
til tungsten stays bright
after gas shuts off.
Break off end of tungsten.
Replace.
Use new hoses.
Page 22
Revised Feb 4/85
OM-223
TROUBLE PROBABLE CAUSE REMEDY
“Weld is dirty Ta, Dirty work metal la. Clean work metal with de-
greasing compound, soap and
water compound or wire brush.
be. Dirty filler rod b. Keep filler rod in location
where it will not become
dirty.
Ce Insufficient gas с. Increase gas flow. Check
flow for pinched hoses.
d. Leaky gas hoses d. Replace.
e. Hoses previously used e. Use new hoses.
to carry oil, acety-
lene or other gases,
causing scum on weld
f. Loose connections in f. Tighten.
gas system
On DC-TIG a. Use of pure tungsten a. Use thoriated tungsten on
straight polarity DC straight polarity
welding, high welding.
frequency jumps
gap between elec—{b. Use of helium gas be. Use argon gas for best arc-
trode and work, initiating properties.
but DC power does
not follow to с. Electrode held very с, After high frequency spark
initiate the arc. near work after high jumps, withdraw torch
frequency has begun slightly.
jumping
d. Tungsten too large d. Use smaller tungsten or
grind point.
e. Torch fuse blown e. Replace, check to see if
water is flowing. Reduce
current if overloading
torch.
f. Tungsten used too long f. Break off 1/4".
a time
g. See Programmer
Manual
High frequency a. Rough tungsten a. Use ground and polished
and arc extend | tungsten.
from side of
tungsten.
Feb 4/85 Revised Page 23
OM-223
TROUBLE
Arc unstable at
low current weld-
ing on DC straight
polarity TIG.
Arc crater at end
of weld
Arc wanders
Tungsten dis-
colors after
weld
de
b.
Ce
as
de
be
а,
PROBABLE CAUSE
ESE E oF R= TE FE SET CTT TER CE CF. RE TR ITER EE ERE
Arc extends from
side of tungsten
Arc length too long
Arc wanders
Background P.C. Board
(368043-1) defective
Torch withdrawn before
arc is extinguished
Tungsten contami-
nated by carbon
Arc blow
Air drafts
Electrode too large;
arc moves around on
electrode
Joint too narrow; arc
jumps from side to
side
Insufficient gas post-
flow
as
REMEDY
Use ground and polished
tungsten.
Use shortest arc length
possible.
See section on "Arc wan-
ders”.
Replace P.C. Board.
Snap torch back quickly.
alternate solution is to
cut off the current with
the remote switch before
the torch is withdrawn
from the work. Still
another solution is to use
the remote rheostat control
to reduce the current be-
fore withdrawing the elec-
trode from the work and
filling in the crater in
this manner.
Break off end of tungsten
and grind clean. Do not
use carbon block for
striking arc.
Change position of ground
clamp.
Shield arc from air drafts.
Use smaller electrode or
grind point. A polished
electrode sometimes helps.
Grind point on electrode.
Increase spacing of work
pieces or shorten arc
length. Reduce high fre-
quency setting.
Increase setting of post-
flow time.
Page 24
Revised Feb 4/85
ОМ-223
TROUBLE
Tungsten dis-
colors after
weld (continued)
Water to torch
flows too slowly
or not at all
Water or gas will
not shut off
Porous welds
be
Ce
Ade
be
Ce
de
de
PROBABLE CAUSE
E = EE TEE EL EE AT YA CEC. UE ESCALA CAE EL
Postflow timer sticks
Gas valve sticks
Loose connections in
gas system
Insufficient gas flow
Leaky hoses
Solid-state Relay P.C.
Board defective
Insufficient water
pressure
Water shut off
Water valve sticks
Tig/Stick switch set
on "STICK"
Water hose pinched
Solid-state Relay P.C.
Board defective
Postflow timer set
too high
Postílow timer mal-
function
Valves stuck open
Solid-state Relay P.C.
Board defective
Postflow too long or
cold water flows
continuously; causes
condensation in inert
gas section of torch;
will not happen with
Circoolator; water is
at room temperature.
b.
Ce
а,
Es
ade
De,
f.
de
De
Г * ———— — E E
REMEDY
ERs ap forge E. E RA E E EEE
Replace or clean contacts.
Replace.
Tighten.
Increase.
Replace.
Replace P.C. Board.
Increase water pressure.
Turn on water.
Replace water valve.
Set switch to TIG position.
Remove object pinching
hose,
Replace P.C. Board.
Decrease postflow timer
setting.
See Programmer Manual.
Replace valves.
Replace P.C. Board.
Shorten postflow or use
Circoolator for cooling
Water.
Feb 4/35 Revised
Page 25
OM—223
TROUBLE
Porous welds
(continued)
Weak high fre-
quency and no
welding power
High frequency
will not cut off
after arc is
struck
A EEE RP EE RE ER
be
de
PROBABLE CAUSE
Leaky "0" rings in
torch
Torch fuse blown
See Programmer Manual
Solid-state relay P.C.
Board (368036) defec-
tive
b.
а,
de
FE E LEC E AECE A arr 3} kana =
REMEDY
Replace "0" rings.
Replace; check to see if
water is flowing. Reduce
current if overloading
torch.
Follow manual instruc-
tions.
Replace P.C. Board.
Page 26
Revised Feb 4/85
Hobart Brothers Company
Troy, Ohio 45373
OM-223
Detailed Troubleshooting Instructions
The CT-150-DC-S machines are solid-state weld-
ing machines. The method of troubleshooting is
different, but is not more difficult than troubleshoot-
ing a conventional unit. Do not overlook the obvious.
As in the case of all electrical equipment, loose
connections are the primary cause of malfunction
both internal and external to the power source. Do
not overlook bad grounds, shorted control cables,
wrong settings, blown fuses, worn contactors, mis-
connections from auxiliary equipment, misapplica-
tions, etc. The only equipment needed to propery
detect a problem on this power source is a simple
voltohmmeter, although an oscilloscope is the best
method to quickly "see" the problem.
Voltages of Interest — Refer to Diagrams 369283
and 369284.
1. Across the secondary on all three phases — 115
V AC + 10%.
2. From the center bus bar on secondaries to the
top or bottom of the secondary — 58 V AC + 10%.
3. X4-X5 on center phase of transformer — 115 V
AC + 10%.
4. X1-X3 on fuse block — 36 V AC + 10%.
5. X1-X2 and X2 to X3 from fuse block to output
rectifier — 18 V AC + 10%.
NOTE: The + 10% value indicates the pos-
sibility of having a high or low voltage on
the input line.
Symptoms
SCR Firing PC Board Failure — If a board failure
occurs, the following situations will probably hap-
pen:
1. Loss of welding arc completely.
2. Rough, sputtering arc, very noticeable.
3. Loss of welding arc control.
4. Difficulty in starting arc.
Malfunction in SCRs — The following situations
will probably exist:
1. Blown line fuses in the case of a shorted SCR
(similar to a shorted diode).
2. One SCR does not turn on [either it is open or
gate signal is not being received by the SCR (gate
circuit open)] and a very small change will occur at
the welding arc and will be difficult to detect by the
average welding operator. Generally when this hap-
pens, it will be necessary to adjust the current con-
trol on the front of the power source, increasing the
current to obtain the same welding current that was
being produced before the SCR defect occurred.
3. Two SCRs do not turn on, the welding arc
becomes more erratic and unstable.
Voltage Test — In the Cyber-Tig I| power source
the Background SCR P.C. Board (368043-1)
provides the open-circuit voltage. The open-circuit
voltage will not drop if an output SCR is open.
— Therefore, use the following procedure to detect a
malfunction in one or more of the output rectifier
SCRs.
1. Short the WORK terminal to the STICK terminal
on the power source.
2. Turn the Current Control to minimum.
3. Turn High Frequency switch to OFF.
4. Turn Arc Force to minimum.
5. Apply rated voltage to machine, and turn Power
Switch to ON.
6. Turn Current Control to get 100 amperes output
current.
7. Using a conventional VOM meter, measure the
AC voltage across anode to cathode of each of the
six SCRs. (A digital multimeter is not recommended
for this measurement.) The voitage can be
measured from the common octagon heat sink to
the channel heat sink on each SCR. See diagram
369283.
The voltage should be about 60 + 10 Y AC. If one
SCR or more is reading about 15 or 20 volts more
thanthe other SCRs, it should be suspected. Inspect
the SCR to make sure it is clamped in the heat sink
correctly. Also check to determine that the gate and
anode leads are connected, and not pinched in the
clamp. If these items appear to be satisfactory,
change the faulty SCR, per the following proce-
dures.
Mounting Procedure for SCRs
1. Thoroughly clean heat sink surface to eliminate
any dirt or contamination.
December 14, 1990 Revised
Page 27
OM-223
2. Apply a thin coat of Alcoa #2 compound to
cleaned surface. Alcoa #2 is available from Hobart
Brothers Company, part number 903870.
3. Positively locate the SCR in place in the heat
sink. A small spring pin in the extruded heat sink will
locate the SCR.
4. Place the clamp in position with the bolts
through the holes in the heat sink, and proceed in
following manner.
5. Tighten the nuts evenly until finger tight.
6. Tighten each bolt in 1/4 turn increments using
correct size hex key.
7. Place the Force Indicator Gauge (903878) firmly
againstthe springs as shown. Be sure both ends and
the center are in firm contact with the springs. The
gauge notch location will indicate the spring deflec-
tion or force. Correct mounting force is indicated as
shown below.
8. Spring deflection over 2-1/4 inches of spring is
037" + .002" for all clamps.
9. All clamps to be set at 4° mark. This corresponds
to the VE3000-VE2500 section on the gauge label.
Force Gage, shown in
position (903878)
Clamp(405140)
Heat Sink
ta
Figure 10
Hobart Brothers Company
Troy, Ohio 45373
Top edges lined up
A—488
Less than rated Correct rated Excessive
force. Tighten force. force. Loosen
nuts alternately both nuts and
1/4 turn at a time start over.
until points coin- Never adjust
cide. force by back-
ing off the nuts.
Friction will
produce a false
reading. Al-
ways start from
Step 1.
Figure 11
To Calibrate Force Gauge:
Ifthe gauge is suspected of being out of calibration
due to wear or damage, check it on a flat surface as
shown below.
True flat surface
(or straight edge)
If the calibration edges do not line up, calibrate the
gauge by filing the bottom contact points.
Figure 12
Page 28
December 14, 1990 Revised
Hobart Brothers Company
Troy, Ohio 45373
Detailed Setting and Troubleshooting of Printed
Circuit (PC) Board
Test Points — There are several test points on the
PC Board which will aid in determining if the defect
is in the board. First, be certain that all wiring to the
board is in good shape, and input (X1-X3) leads are
in place. The following voltage checks (Table 3)
should be made in sequence.
CAUTION: Do not connect a machine to
a line in which the voltage varies more
than + 10% of nominal line voltage. For
example, ona 460-volt line, the operating
voltage is 414 to 504 volts.
Balance Adjustment Check — Balancing conduc-
tion angles of SCRs.
Condition — Open circuit
Description — The test points for this adjustment
are 7, 8,9, with 7 as the reference point. The voltage
between 7 and 8, 7 and 9, and 8 and 9 should be
equal to zero + .05 volts DC. If these voltages are
not equal to a voltage of less than .05 V DC, adjust
potentiometers R28 and R48 until they are equal.
OM-223
December 14, 1990 Revised
Page 29
OM-223
REO R83
TPA CRS REY REY
o Lar ‘
155
я
© R28 (6)
CRI3
| -Tx8 El
TPD O
сте O TPG R99 ;
sx 1 2 я О
О ТРЕ TPH |
C27}x 6 : Q
(@)ras
TPEO Ra! 9
Printed Circuit Board
Figure 13
TEST TEST POINTS VOLTAGE CONDITIONS REMARKS
T1 | Ell to TPe [+15 V DC | Open Circuit |Checks output of regulator
2 TPH to TPG |-15 V DC Open Circuit |Checks output of regulator
3 l to TPG +24 V DC+10% Open Circuit |Checks solid state contac-
tor control
4 2 to TPG +9.1 V DC+10% Open Circuit |Checks reference voltage
5 TPA to TPG (2.9 V DC+IO% Open Circuit |Checks timer operation
TPC to TPG 2.9 V DC+10% Open Circuit
TPE to TPG 2.9 V DC+10% Open Circuit
6 TPB to TPG 17 V DC+10% Open Circuit |Checks timer operation
TPD to TPG 17 Y DC+10% Open Circuit
TPF to TPG 17 V DC+10% Open Circuit
7 4 to TPG 17 V DC+10% Open Circuit |Checks gate circuit
5 to TPG 17 Y DC+10% Open Circuit
6 to TPG 17 Y DC+10% Open Circuit
If any of the above tests fail, there is a high probability of a
defective PC board.
Table 3
Page 30 Revised Feb 4/85
DETAILED SETTING AND TROUBLESHOOTING
OF PRINTED CIRCUIT (PC)
BOARD (Con-
tinued)
BALANCE ADJUSTMENT CHECK (Contin-
ued)
lowing is a brief description
the potentiometers are
NOTE: All potentiometer
operating values are pre-
set at the factory, and
normally should not have
to be reset in the field.
If a need arises that
would indicate the need
for field adjustments,
please contact the fac-
tory.
POTENTIOMETER SETTINGS — The fol-
of how
adjusted, and
the conditions.
I.
Pot R69 —- Main SCR Adjustment
Conditions - Two 100 ohm, 100 watt
resistors connected in parallel
across “Work” and “Stick” termi-
nals. Set current control to MAX-
IMM setting. Using a “jumper”
wire, connect terminal #1 to ter-
minal #6 on the 12-station termi-
nal block at the back of the Pro-
grammer.
Description - Adjust for maximum
voltage on welding machine volt-
meter, then decrease to 2 volts
less than maximum.
Pot R89 - Arc Force Voltage
Setting
Condítions - Unit is loaded to a
18 volts at 50 amps
force control set to
load value of
or more. Arc
mimimua
the voltage
force con-
Description — Adjusts
point at which the arc
Feb 4/85 Revised
3.
OM-223
trol begins, causing the output
current to increase. At the above
load this adjustment is made such
that the output of op amp U9 (Pin
6 to TPG) is zero.
Pot R96 - Arc Force Short Circuit
Setting
cur—
set to
is set
Conditions —- Short circuit
rent, arc force control is
maximum and current control
to minimum.
Description - Adjusts the maximum
short circuit current obtainable
with the arc force control. It is
set such that the short circuit
current increases 200 amps above
the short circuit current obtained
when the arc force control 1s set
to mimimum.
Pot R/9 - High Current
Setting
Output
Conditions - Welding arc current
or load bank, arc force control
ser to minimum. Set current con-
trol on Programmer to 200 amperes
or 5.0 turns on dial.
Description - Adjusts R79 such
that the reading on the DC ammeter
on the front of the welding ma-
chine reads 200 amperes.
Pot R71 Current
Setting
- Low Output
Conditions — Same as step 4 except
current control to be 20 amperes,
or 0.5 turns on dial.
Description — Adjust R71 until 20
amperes is indicated on the DC am-
meter on the front panel of the
welding machine. Repeat steps 4
and 5 until no further adjustment
is required.
Page 31
HOBART
E
PL-223
Parts List
EQUIPMENT IDENTIFICATION - An identification plate on the unit's control panel
shows its model number, serial number, and specification number. Whenever order-
ing parts or making inquiries, furnish all these numbers.
NOTE: A "specification number”, in some cases, must have a "dash
number" suffix (-1, -2, -3, etc.) in order to be a complete number.
HOW TO USE THIS PARTS LIST - The part name listings may be indented to show part
relationships as indicated ín the following example.
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 21 №. №. №. Description Assembly Code
|-- 123456 Assembly (Not Shown) 1
234567 + A detail of assembly 1
345678 + A sub-assembly 1
456789 . . A detail of sub-assy (item 2) 1
567891 . . A sub-assembly of item 2 1
678910 . . . А detail of sub-assy (item 4) I
ow ho +
The parts list contains a breakdown of the equipment into assemblies, subassem-
blies, and detail parts. All parts of the equipment are listed except standard
hardware items, bulk items such as wire, cable, sleeving, tubing, etec., and per-
manently attached parts which lose their identity by being welded, soldered, riv-
eted, etc.
Locate the specification number below that appears on your unit, and note the
"APPLICATION CODE” letter adjacent to it. (If no application code appears below,
the parts list is applicable to only the one specification number that appears
below.) After locating the desired part In the following figures and parts
lists, if the "Application Code” column says "All", proceed to order the part.
If there are several part numbers after the same "Item No.", order only the part
number corresponding to the “Application Code” letter that you selected above.
SPEC NO. APPLICATION CODE SPEC NO. APPLICATION CODE SPEC NO. APPLICATION CODE
6426-1 A 6426-5 D 6835-1 G
6426-2 B 6426-6 E 6835-2 H
6426-3 C 6426-7 F 6835-3 J
HOW TO SELECT RECOMMENDED SPARES - The parts list has a column heading entitled
"Recomm. Spares, Class 1 and Class 2”. Class | recommended spare parts are parts
that are consumed or may need replacement in two years or less, depending on op-
erating hours. Class 2 spares are parts that may need replacement under unusual
service conditions or because of additional operating hours. The quantities
listed are suggested quantities based on expected usage or the minimum quantity
package. Class 1 spares are repeated under Class 2 but the quantities may be
larger to allow for the additional operating hours. Contact your Hobart equip-
ment dealer for assistance in establishing a spare parts program based on your
needs.
Jan 11/85 Revised Page 1
PL-223
Bottom Front Panel
Figure 1
Page 2 Revised May 3/83
PL-223
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
l 2 | No. No. No. Description Assembly Code
1- 1 369475 Cover - Output Terminal 1 All
369482-1 Panel - Front, Bottom, Assy I BCDHJ
369482-3 Panel - Front, Bottom, Assy 1 AEFG
2 369469 » Panel ~ Front, Bottom 1 All
3 370851 . Adapter - Water, Left Hand 2 All
4 370447 + Adapter - Gas, Right Hand 2 All
5 400248 . Knob - Rheostat | All
6 16DA-1997-11 . Button - Hole Plug 1 BCDHJ
- 100GH-770 . Receptacle - Remote Control,
Twist Lock 1 AEFG
* 7 402670 « Receptacle — Duplex, 3 Wire 1 All
8 405506-1 . Resistor - Adj., 100 № 1 All
* 9 402662 « Switch - Toggle 1 All
10 402219 s Rheostat —- 150 Watt, 400 Ohm 1 All
1 11 402882-1 . Valve - Solenoid, Water 1 All
12 W-10892-1 « Elbow - Street, 90°, Brass 4 All
1 13 402882—2 « Valve — Solenoid, Gas 1 All
14 No Number . Screw - 1/2-13 x 1-3/4 HHC
ST. 1 All
15 No Number ., Washer - 1X. ST. 1/2 4 All
16 No Number « Washer —- FL. Steel, 1/2 7 All
17 368875 . Board - Insulator, Output,
Terminal 3 All
18 368874 » Bus —- Cable Stud 1 All
19 No Number ‚ №5 - 1/2-13, Hex, Jam, ST. 1 All
- No Number e Screw ~ 1/2-13 x 1-1/4 HHC
Steel 2 All
20 No Number . Screw - 1/2-13 x 3/4, HHC,
Steel 3 All
368877 « Board ~- H.F. Return Assy. 1 All
21 368876 « « Board 1 All
22 402802 » Capacitor - Mallory 3 yF 1 All
23 402879 . Clamp - Cap. 1 All
24 362909 . Resistor - 10,000 Ohm Assy 1 All
25 3687052 . Capacitor - „О47 uF, 400 V
DC Assembly 1 All
368865 » Bracket - Components, H.F.
Assembly 1 All
26 368866 . Bracket — Mounting 1 А11
27 368705-1 . « Capacitor - W/Leads Assy 1 All
28 W—-9026-10 « « Resistor 1 All
29 401427—2 ‚ „ Capacitor ~ Radial Lead 1 All
368633 . Switch - Reversing, Assembly 1 All
30 368634 . . Plate - Mtg. Rear 1 All
31 12RT-285 ‚ « Ring - Contact Switch 1 All
Jan 11/85 Revised
These parts and
their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369423-1.
Not Illustrated
Page 3
PL-223
Page 4 Revised May 3/83
PL-223
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
| 2 | No. No. No. Description Assembly Code
1- 32 AW-459 . « Catch - Friction Ball 1 All
33 12RT-238 » e Contactor - Movable 4 All
34 410541 . Spring - Pressure 2 All
35 368726 » Plate - Front 1 All
36 SW-167—0 ‚ ». Washer —- Thrust 1 All
37 16DA-4249-8 + + Ring - Snap 1 All
38 365123 . + Handle - Range Switch 1 All
39 369390 ‚ Transformer 1 All
40 368718-1 . Bar - Bus, О.Т. Бо Sw. 1 All
41 369079 . Bar - Bus 1 All
42 368685 » Bus — Reversing Switch 1 All
43 AW-894 . Shunt - Meter l ABCEGH
369844 . Shunt - Meter l F
4DN-662 + Shunt —- 500 Amp, 50 MV 1 DJ
- 400078 ‚ж Bracket — Resistor 2 All
44 368696 + Bus — Cable Stud 2 A11
45 W-9234-336 . Cable - Sw. Reversing to
High Freq. Coil 1 All
- 490965-4 « Guard - Edge 3 All
- 369069-2 Bar - Bus, #106 1 All
- 369069-1 Bar —- Bus, #107 1 All
—* 405206-1 Plug - Six Pin Male I All
- 405319-16 Label - CT-150-DC-5 1 All
- 4909655 Guard - Edge, Trim l All
—* 369419-1 Chart - Wire l All
Jan 11/85 Revised
These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369423-1.
Not Illustrated
Page 5
PL-223
5 E
N ~ , de >
- Zu o Ne 3
\ ` E. <
Fh
Frame Group
Figure 2
Page 6 Revised May 3/83
PL-223
Quantity
Recomn.
Spares Quantity
Class Fig. Item Part per Application
1 2 | No. No. No. Description Assembly Code
2- l 404040-1 Nameplate 1 All
2 369467 Support - Meter Panel 1 All
369472-1 Panel - Front, Top, Assembly 1 All
3 369471 » Panel - Front, Top 1 All
4 402658 . Holder - Fuse 1 А11
1 5 401972-2 + Fuse — MDX (Slow Blow) 5 Amp 1 All
1 Kk 6 W-10502-15 . Fuse - FNM (Slow Blow) 10 Amp | All
7 400248 . Knob —- Potentiometer 1 All
8 405521-12 . Meter - DC, Ammeter 1 ABCDEGH
406221-1 « Meter - DC, Ammeter 1 F
9 4055204 . Meter - DC, Voltmeter 1 ABCDE
406221-2 . Meter - DC, Voltmeter 1 F
- 404472-1 . Jack - Insulated, Red 2 GH
10 368705-5 . Capacitor - .047 pF, 400 V DC 1 All
- 404472-2 . Jack - Insulated, Black 1 GH
AR ll 402682 .» Switch - Toggle 1 All
*% 12 401428-8 . Potentiometer —- 2 Watt 1 All
XA 13 402151 . Holder - Fuse 1 All
** 14 402662 + Switch - Toggle 1 All
- 369422-1 . Harness — Upper, Front 1 All
15 12CW-2170 Grommet - Yoke 1 All
16 369464 Top 1 All
17 369461 Angle - Front, Right 1 All
3690551 Starter - H.F. 1 All
18 369054 ‚ Base - Arc Stop 1 All
19 8RT-654 . Washer - Rubber 2 All
20 FTW-328-0 » Capacitor - Mica 1 All
21 368472 . Board - Suppression 1 All
22 368690 . Choke —- R.F. Axial Leads 2 All
23 FTW-413 . Spark Gap - Assembly 1 All
24 368706-1 » Transformer - High Voltage
Assembly 1 All
25 369460 Angle - Front, Left l All
369333 Panel - Dustproof, Assembly 1 All
26 369334 . Panel —- Dustproof 1 All
27 369492 + Slide - Drawer, Programmer 4 All
28 369491 s Guide —- Drawer 2 A11
369430-1 Yoke - Lifting, Assembly 1 All
29 369446 . Yoke 1 All
30 405402 . Contactor - Line 1 All
31 404960-3 . Transformer - Control 1 All
32 W-10502-25 » Fuse - Slow Blow, 6 Amp 1 All
33 422241 . Insulator - Tube 1 All
1 34 368043-1 . Board - P.C. SCR Background
Circuit 1 All
Хх
Jan 11/85 Revised
These parts and
their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369422-1.,
Not Illustrated
Page 7
PL-223
Quantity
Recomm,
Spares Quantity
Class Fig. Item Part per Application
1 2 No. No, No. Description Assembly Code
-2- 405770 . Label ~ Fuse 1 All
*%% 35 405129-1 . Holder - Fuse 1 All
- 367579 . Insulator - Fuse Block 1 Ali
1 XXX 36 W-11166-9 ‚ Fuse - Fast Blow, AGC, 1 Amp 6 All
- 405362-1 « Grommet 2 All
1 37 368036 » Board - P.C. Assembly (Relay
Solid State) 1 All
- 4044 72-1 ‚ ТасК - Insulated, Red 1 All
- 404472-2 ‚ Jack - Insulated, Black 1 All
— 405157 . Label - Fuses 1 All
1 38 369096-1 « Board - P.C., SCR Firing 1 All
39 369463 Panel - Rear 1 All
40 367769 Shroud - Fan 1 All
41 367584 Bracket - Fan Motor 1 All
1 42 12TW-595-1 Motor - Fan 1 All
43 8RT-609 Blade - Fan 1 All
**— 405205-1 Receptacle - 6 Pin, Female 1 All
365827-3 Resistor - Assembly 3 All
44 AAW-3981 » Mount — Resistor 2 All
45 16DA-3493 . Insulator — Resistor 4 All
46 4051541 + Resistor 2 All
369279-1 Rectifier - Output, Assembly 1 All
47 367620 « Heat Sink - Rect. 1 All
48 367625 . Heat Sink - SCR 6 All
- 16DA-954-12 . Pin - Spring 6 All
3 49 405825 » Rectifier - Silicon,
Controlled 6 All
50 405140-1 s Clamp —- Mounting 6 All
51 36/634A-1 + Suppressor - Surge, Assembly 2 All
1 52 404044-1 . Thermostat - Overload 1 All
53 401937-9 « Block - Terminal 2 All
54 368705-6 » Capacitor — Assembly 6 A11
55 367606 . Brace - Mtg. Rect. 2 All
56 367605 +» Insulator - Mtg. Rect. 2 All
57 367687 » Shunt - Feedback 1 All
- 368697 . Bar - Bus 1 Ali
58 369462 Panel - Side 2 All
59 405774 Label ~ Cyber Tig 2 AB
407166 Label —- CT-150 DC-S 2 CDFGHJ
60 369455 Base - Assembly 1 All
61 368454-2 Reactor - Filter 1 All
62 368526-1 Transformer - Interphase 1 All
= Not Illustrated
X* These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369422-1.
hk These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369421-1.
Page 8 Revised Jan 11/85
PL-223
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 No. No. No. Description Assembly Code
2- 63 369476 Transformer - Power 1 ABCDEF
369789 Transformer - Power 1 GHJ
64 CW-811 Link —- Voltage Changeover 6 All
65 367170-5 Board - Voltage Changeover 1 ABCDEF
367229-6 Board - Voltage Changeover 1 GHJ
66 369658 Brace - Voltage Changeover Board 2 All
*x* 67 401564—-4 Receptacle - Jl and J2, 12 Pin,
Female 2 All
XXX 405398-8 Receptacle - J3, 12 Pin, Female 1 All
xxx 405206-3 Plug - J4, 15 Pin, Male 1 All
- W-9234-272 Cable — 101 1 All
XxX 405206-1 Plug - 6 Pin, Male 1 All
~ 40203 7-4 Grommet - Harness 4 All
- 369277 Kit - Caster (Opt.) 1 All
REX 369417-1 Chart - Wire 1 All
- 405651 Receptacle - 4 Pin Amphenol
(Mounts on Rear Panel) 1 CDFJ
- 85640 Cable - 4 Conductor Shielded 5! CDJ
- 472761 Panel - Cover, Meter Hole 1 CDJ
xXx These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369421-1.
= Not Illustrated
Jan 11/85 Revised
Page 9
Ш
PL-223-1
Parts List
EQUIPMENT IDENTIFICATION - An identification plate on the unit's control panel
shows its model number, serial number, and specification number. Whenever order-
ing parts or making inquiries, furnish all these numbers.
NOTE: A “specification number”, in some cases, must have a “dash
number” suffix (-1, -2, -3, etc.) in order to be a complete number.
HOW TO USE THIS PARTS LIST - The part name listings may be indented to show part
relationships as indicated in the following example.
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 21 No. No. No. Description Assembly Code
1- 123456 Assembly (Not Shown) 1
234567 . A detail of assembly 1
345678 . A sub-assembly 1
456789 . . A detail of sub-assy (ítem 2) 1
567891 . . A sub-assembly of item 2 1
678910 . . . A detail of sub-assy (item 4) 1
un ~~ Lo bo —
The parts list contains a breakdown of the equipment into assemblies, subassem-
blies, and detail parts. All parts of the equipment are listed except standard
hardware items, bulk items such as wire, cable, sleeving, tubing, etc., and per-
manently attached parts which lose their identity by being welded, soldered, riv-
eted, etc.
Locate the specification number below that appears on your unit, and note the
“APPLICATION CODE” letter adjacent to it. (If no application code appears below,
the parts list is applicable to only the one specification number that appears
below.) After locating the desired part in the following figures and parts
lists, if the "Application Code” column says "All", proceed to order the part.
If there are several part numbers after the same "Item No.", order only the part
number corresponding to the “Application Code” letter that vou selected above.
SPECIFICATION NO. APPLICATION CODE SPECIFICATION NO. APPLICATION CODE
6604-1 A 6604-4 D
6604-2 B 6604-5 Е
6604-3 C
HOW TO SELECT RECOMMENDED SPARES — The parts list has a column heading entitled
"Recomm. Spares, Class 1 and Class 2". Class 1 recommended spare parts are parts
that are consumed or may need replacement in two years or less, depending on op-
erating hours. Class 2 spares are parts that may need replacement under unusual
service conditions or because of additional operating hours. The quantities
listed are suggested {quantities based on expected usage or the minimum quantity
package. Class 1 spares are repeated under Class 2 but the quantities may be
larger to allow for the additional operating hours. Contact your Hobart equip-
ment dealer for assistance in establishing a spare parts program based on your
needs.
Feb 6/85 Revised Page 1
PL-223-1
Bottom Front Panel
Figure |
Page 2 Revised Feb 4/85
PL-223-1
Quantity
Recomn.
spares Quantity
Class Fig. Item Part per Application
1 2 No. No. No. Description Assembly Code
1- 1 369475 Cover - Output Terminal 1 All
369482-1 Panel - Front, Bottom, Assy 1 BCDE
369482-3 Panel - Front, Bottom, Assy 1 А
2 369469 . Panel - Front, Bottom 1 All
3 370851 . Adapter - Water, Left Hand 2 All
4 370447 . Adapter — Gas, Right Hand 2 All
5 400248 . Knob - Rheostat 1 All
6 16DA-1997-11 . Button - Hole Plug 1 BCDE
- 100GH-770 » Receptacle - Remote Control,
Twist Lock 1 A
* 7 402670 + Receptacle - Duplex, 3 Wire 1 All
8 405506-1 . Resistor - Adj., 100 W 1 All
* 9 402662 . Switch - Toggle 1 All
10 402219 . Rheostat —- 150 Watt, 400 Ohm 1 All
1 ll 402882-1 » Valve - Solenoid, Water 1 All
12 W-10892-1 . Elbow - Street, 90°, Brass 4 All
l 13 402882-2 . Valve - Solenoid, Gas 1 All
14 No Number . Screw - 1/2-13 x 1-3/4 HHC
ST. 1 All
15 No Number . Washer - LK. ST. 1/2 4 All
16 No Number +» Washer - FL. Steel, 1/2 7 All
17 368875 + Board - Insulator, Output,
| Terminal 3 All
18 368874 . Bus - Cable Stud I All
19 No Number « Nut - 1/2-13, Hex, Jam, ST. 1 All
- No Number . Screw — 1/2-13 x 1-1/4 HHC
Steel 2 All
20 No Number + Screw - 1/2-13 x 3/4, HHC,
Steel 3 All
368877 + Board - H.F. Return Assy. 1 All
21 368876 . « Board 1 All
22 402802 » +» Capacitor —- Mallory 3 uF 1 All
23 402879 e « Clamp - Cap. 1 All
24 362909 . « Resistor — 10,000 Ohm Assy 1 All
25 3687052 . Capacitor - .047 uF, 400 V
DC Assembly 1 All
368865 » Bracket - Components, H.F.
Assembly 1 All
26 368866 » Bracket - Mounting 1 All
27 368705-1 » « Capacitor - W/Leads Assy 1 l All
28 W-9026-10 . « Resistor 1 All
29 401427-2 « «e Capacitor - Radial Lead l All
368633 . Switch — Reversing, Assembly 1 All
30 368634 . « Plate — Mtg. Rear 1 All
31 12RT-285 . » Ring - Contact Switch 1 А11
* These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369423-1,
- Not Illustrated
Feb 6/85 Revised Page 3
PL-223-1
Page 4 Revised Feb 4/85
PL-223-1
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 | No. No. No. Description Assembly Code
1- 32 AW-459 . Catch - Friction Ball 1 All
33 12RT-238 . . Contactor - Movable 4 All
34 410541 . Spring - Pressure 2 All
35 368726 « . Plate ~ Front 1 All
36 SW—-167-0 . +» Washer - Thrust 1 All
37 16DA-4249-8 s Ring - Snap 1 All
38 365123 . « Handle - Range Switch 1 All
39 369390 . Transformer 1 All
40 368718-1 . Bar - Bus, О.Т. Бо бя. 1 All
41 369079 . Bar - Bus 1 All
42 368685 . Bus —- Reversing Switch 1 All
43 AW-894 Shunt - Meter 1 ABCD
4DW-662 . Shunt - Meter 1 E
— 400078 . Bracket - Resistor 2 All
44 368696 . Bus - Cable Stud 2 All
45 W-9234-336 . Cable - Sw. Reversing to
High Freq. Coil 1 All
- 490965-4 . Guard - Edge 3 All
= 369069-2 Bar - Bus, #106 1 A11
- 369069-1 Bar - Bus, #107 1 All
—* 405206-1 Plug - Six Pin Male 1 All
- 407166 Label - CT-150-DC-S 1 All
— 490965-5 Guard - Edge, Trim 1 All
—* 369419-1 Chart - Wire 1 All
- 405999 Label - Warning 1 All
These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369423-1.
Not Illustrated
Feb 6/85 Revised
Page 5
PL-223-1
Frame Group
Figure 2
Page 6 Revised Feb 4/85
PL-223-1
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 No. No. No. Description Assembly Code
2- 1 404040-1 Nameplate 1 All
2 369467 Support - Meter Panel 1 All
369472-1 Panel - Front, Top, Assembly 1 All
3 369471 + Panel —- Front, Top 1 All
4 402658 . Holder — Fuse 1 All
1 5 401972-2 . Fuse - MDX (Slow Blow) 5 Amp | All
1 xx 6 W-10502-15 +. Fuse - FNM (Slow Blow) 10 Amp 1 All
7 400248 ‚ Knob - Potentiometer 1 All
8 405521-12 . Meter - DC, Ammeter 1 All
9 405520-4 . Meter — DC, Voltmeter 1 All
10 368705-5 . Capacitor - .047 uF, 400 V DC 1 All
** 11 402682 e Switch - Toggle 1 All
kk 12 401428-8 . Potentiometer - 2 Watt 1 All
kk 13 402151 . Holder - Fuse 1 All
kk 14 402662 . Switch ~ Toggle 1 All
— 369422-1 » Harness - Upper, Front 1 All
15 120W-2170 Grommet — Yoke 1 All
16 369464 Top 1 All
17 369460 Angle - Front, Right 1 All
3690552 Starter — H.F. 1 All
18 369054 . Base - Arc Stop 1 All
19 8RT-654 . Washer - Rubber 2 All
20 FTW-328-0 .» Capacitor — Mica 1 All
21 368472 » Board - Suppression 1 All
22 368690 « Choke - R.F. Axial Leads 2 All
23 FTW-413 » Spark Gap — Assembly 1 All
24 368706-2 « Transformer - High Voltage
Assembly 1 Ali
25 369461 Angle - Front, Left l All
369333 Panel - Dustproof, Assembly 1 All
26 369334 » Panel - Dustproof 1 All
27 369492 + Slide - Drawer, Programmer 4 All
28 369491 . Guide - Drawer 2 All
369430-3 Yoke - Lifting, Assembly 1 All
29 369446 . Yoke 1 All
30 405402 . Contactor - Line 1 All
31 404960-8 s Transformer - Control } All
32 W-10502-25 . Fuse - Slow Blow, 6 Amp 1 All
33 422241 . Insulator - Tube 1 All
1 34 368043-1 . Board - P.C. SCR Background
Circuit 1 All
xx These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369422-1.
Feb 4/85 Revised
Not Illustrated
Page 7
PL-223-1
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 No. No. No. Description Assembly Code
—-2- 405770 . Label - Fuse 1 All
*%% 35 405129-1 » Holder — Fuse l All
- 367579 . Insulator — Fuse Block 1 All
1 kkk 36 W-11166-9 . Fuse - Fast Blow, AGC, 1 Amp 6 All
— 405362-1 . Grommet 2 All
1 37 368036 . Board - P.C. Assembly (Relay
Solid State) 1 All
- 404472-1 . Jack — Insulated, Red 1 All
— 404472-2 . Jack — Insulated, Black 1 All
- 405157 « Label - Fuses 1 А11
1 38 369096-1 . Board - P.C., SCR Firing 1 All
39 369463 Panel - Rear 1 All
40 473596 Panel —- Side, Left 1 All
- 369462 Panel - Side, Right 1 All
41 405774 Label - Cyber Tig 2 All
1 42 12TW-595-1 Motor - Fan 1 All
43 8RT-609 Blade - Fan 1 All
Ak 405205-1 Receptacle - 6 Pin, Female 1 All
365827-3 Resistor — Assembly 3 All
44 AAW-3981 . Mount - Resistor 2 A11
45 L6DA-3493 Insulator - Resistor 4 All
46 405154-1 . Resistor 2 All
369279-1 Rectifier — Output, Assembly 1 All
47 367620 . Heat Sink - Rect. 1 All
48 367625 . Heat Sink - SCR 6 All
- 16DA-954-12 . Pin - Spring 6 All
3 49 405825 . Rectifier - Silicon,
Controlled 6 All
50 405140-1 » Clamp - Mounting 6 All
51 367634A-1 . Suppressor — Surge, Assembly 2 All
1 52 404044—1 . Thermostat - Overload 1 All
53 401937-9 . Block — Terminal 2 All
54 368705-6 . Capacitor - Assembly 6 All
55 367606 . Brace - Mtg. Rect. 2 All
56 367605 Insulator - Mtg. Rect. 2 All
57 367687 + Shunt - Feedback 1 All
- 368697 . Bar - Bus 1 All
58 367769 Shroud — Fan 1 All
59 367584 . Bracket - Fan Motor 1 All
60 369455 Base - Assembly 1 All
61 3684542 Reactor — Filter 1 All
62 368526-1 Transformer - Interphase 1 All
- Not Illustrated
Xx These parts and their quantities are shown in relationship to
their location in the wachine, but they are all components of
Wire Harness Assembly 369422-1.
kik These parts and their quantities are shown in relationship to
Page 8
their location in the
Wire Harness Assembly 369421-1.
machine, but they are all components
of
Revised Feb 6/85
PL-223-1
Quantity
Recomm.
Spares Quantity
Class Fig. Item Part per Application
1 2 No. No. No. Description Assembly Code __
2- 63 369562 Transformer - Power 1 All
64 CW-811 Link - Voltage Changeover 6 All
65 367229-9 Board - Voltage Changeover 1 All
66 369658 Brace — Voltage Changeover Board 2 All
*x** 67 401564-4 Receptacle - J1 and J2, 12 Pin,
Female 2 All
Kk 405398-8 Receptacle - J3, 12 Pin, Female 1 All
AA 405206-3 Plug — J4, 15 Pin, Male 1 All
- W-9234-272 Cable - 101 1 All
Kh 405206-1 Plug - 6 Pin, Male 1 All
- 4020374 Grommet — Harness 4 All
= 369277 Kit - Caster (Opt.) 1 All
RA -- 369417—1 Chart - Wire 1 All
- 405651 Receptacle - 4 Pin Amphenol
(Mounts on Rear Panel) 1 CDE
- 85640 Cable - 4 Conductor Shielded 5" CDE
— 472761 Panel - Cover, Meter Hole 1 CDE
- 405970 Label - Warning 1 All
68 16DA-4029 Bracket — Mtg. Socket, Relay 1 D
69 16DA-4052-1 Socket - 8 Pin 1 D
70 L6DA-4004A-7 Relay - 2 PDT, 24 V DC Coil 1 D
71 16DA-4253-1 Retainer - Spring 1 D
- W-9917-4 Meter - Hour Running (Mts. on
Item 3) 1 D
kk% These parts and their quantities are shown in relationship to
their location in the machine, but they are all components of
Wire Harness Assembly 369421-1.
— Not Illustrated
Feb 6/85 Revised
Page 9
Diagrams
l. Note the specification number shown on the equipment nameplate.
2.
3.
HOBART
E
Locate these numbers in the specification number columns below.
Use only those diagrams and instructions that are applicable.
Voltage
Model | Spec Connection | Schematic |¡Changeover | Outline
No No. Diagram | Diagram Diagram Dimension
CT- [6426-11 200904 200903 369528 369483
bons 6426-2 | 369283 369284 369528 369483
6426-3 472760 472759 369528 369483
6426-5
6426-6] 473642 473643 369528 | 369483
6426-7 | 472760 472759 369528 369483
6604-1| 200904 200903 369374 369483
6604-2 | 369283 369284 369374 369483
6604--3 | 472760 472759 369374 369483
6604-4 | 472779 472780 369374 369483
6604-5 | 472760 472759 369528 369483
6835-1] 200904 200903 369371 369483
6835-2 | 369283 369284 369371 369483
6835-3| 4727600 472759 369371 369483
D-223
Mar 5/85 Revised
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