CT-300+TM-462+Spec-5159D-1-2-3-4-5283D-1-2-3-4

CT-300+TM-462+Spec-5159D-1-2-3-4-5283D-1-2-3-4
 HOBART
OWNER’S MANUAL
IMPORTANT: Read these instructions before instailing, operating, or
servicing this product.
Specifications covered by this manual:
TECHNICAL MANUAL NO, TM=462
for MODEL CT-300 AC/DC
300 Ampere AC/DC "“CYBER-TIG" Welder
BOTD-1-
51590-1 528303
515702 528304 3010-2
51590-3 52890-1 3010-3
51590 -4 52890 -2 53010-4
52832 -1 5289D +3
52830-2 52890 4
IDO NOT DESTROY
HOBART BROTHERS COMPANY, TROY, OHIO 45373, U.S.A.
Manufacturers of Arc Welding Systems/Aircrait Ground Power Equipment/Industriai Battery Chargers
Lo]
| HOBART |
—— A
HOW TO USE THIS MANUAL - This manual, identified by a "TM=" prefixed number, usually
covers just the underlined specification number in the listing below; in which case, the dia-
grams at the rear of this manual cover only that particular spec. number . If none of the spec,
numbers are underlined, they're all covered.
EQUIPMENT IDENTIFICATION = The unit’ specification, model, and serial numbers appear
on a nameplate, usually attached to its control panel. À "specification number" starts out
with a "series number” (first 4-digit number, with a possible letter suffix) which dees not cover
a complete unit. A "dash number” (=1, -2, etc.) must follow the "series number" to make
a complete “specification number”, For example: 1234A-1, 1234A-2, ete
TECHN ICAL MANUAL NQ, TM=4462
!
for MODE L CT-300 AC/DC Important!
This listing is of special
importance to the per-
formance of this unit, |
Refer to the appropriate
section of this manual
300 Ampere AC/DC "CYBER-TIG" Welder
This manual covers units displaying any
one of the following specification numbers ,
with exceptions as noted in the first parc-
graph above. for details. |
51590 -1 52830 -3 3301D-1- . Clean internal com-
51590 -2 52830 -4 5301D-2 ponents cn a regular
5159D-3 5289D =] 53010-3 schedule.
51590 -4 5289D -2 53010 4
5283D -1 528903 . Make sure unit and
5283D -2 52890 -4
‘workpiece are always |
we il grounded, |
ksued: Mar 24/76
Revised: July 15/91
Table of Contents
Page | Page
SAFETY WARNINGS Welder Panels 10
| Welding Cables 10
INSTRUCTIONS Certification Notice 10
Receipt of Equipment | Individuel Installation
Location 2 Certification 10
Description of the "TIG” Process 2 Respors ibility for Interference 10
Installation 3 Input Voltage Changeover Ш
Wir ing in We iding Area Vicin ity 4 Programmer and Remote Control
Wiring Changes 4 Connections a
Use in Metal Buildings 5 Description of Equipment Ц
Grounding 3 Controls and Connectors 12
Connection to Line Voltage ó Are Booster 14
We Ider Adjustments 10 Preparation for Use 15
Ш.
"HOBART
TM-462
Table of Contents
Page Page
Cooling Water Connections 15 High Frequency or
Shielding Gas Connections 15 | Pulsing Circuits
Electrical Connections to Torch Troubleshooting 18
and Workpiece 15 Troubleshooting 19
Install Programmer 17
Operation 17 PARTS LIST
Maintenance 17
Lubrication 17 ~~ DIAGRAMS
Inspection and Cleaning 17
Spark Gaps 18
Replacement of Silicon =
Rectifiers 18
Revised May 24/76
Revised Feb 7/78
Hobart Brothers Company ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Troy, Ohio 45373 Instruction 910081
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
A 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 all safety rules and take precautionary actions.
Safe practices have developed 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 shouid 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 Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and
other guides to what you should 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 on the ground or the work surface. Do
not touch hoiders 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
— or severe burns. The electrode and work circuit is
лу electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or auto-
matic wire welding, the wire, wire reel, drive roll 8. Do not use worn, damaged, undersized, or poorly spliced ca-
housing, and ail metal parts touching the weiding bles.
wire are electrically live. Incorrectly installed or im- 9. Do not wrap cables around your body.
properly grounded equipment is a hazard. 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 uniess it is equipped with a voltage reducer. Use
equipment with DC output.
2. Wear dry, hole-free insulating gioves 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
accidentally. 14. Wear a safety harness to prevent falling if working above floor
5. Properly install and ground this equipment according to its level. |
Owner's Manual and national, state, and local codes. 15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin; 1. Wear a welding 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.
Le Are rays from the welding process produce intense 3. Use protective screens or barriers to protect others from flash
eat and strong ultraviolet rays that can burn eyes and glare; warn others not to watch the arc.
ane = о 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.
<
N
[
Electrode Size Filter Electrode Size Filter
Weiding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade
eration or Weiding Current No. Operation or Welding Current No.
Torch soldering — 2 Gas metal-arc welding (MiG)
Torch brazing — Зог 4 Non-ferrous base metal All 11
Oxygen cutting Ferrous base metal All | 12
Light Under 1 in, 25 mm Bor4i Gastungsten arc welding (TIG) All 12
Medium 1 to 6in., 25-150 mm 4or5| Atomic hydrogen welding All 12
Heavy Over 6 in., 150 mm 5or6|| Carbon arc weiding Alf 12
Gas welding Plasma arc weiding Ali 12
Light Under 1/8 in., 3 mm 4or5|| Carbon arc air gouging
Medium 1/8 10 1/2 in., 3-12 mm 5or6 Light | 12
Heavy Over 1/2in., 12 mm бог 8 Heavy 14
Shielded metal-arc welding Under 5/32 in., 4 mm 10 Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 410 6.4 mmi 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
TA to your health.
EN
— Welding 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. HF inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases,
3. Hf 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
welding can displace air causing injury or death. Be sure the
breathing air is safe.
. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the ar¢ 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, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
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.
Ds
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material,
3. Remove all flammabies within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. 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
10.
can cause fire on the hidden side.
. Do not weld 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, possibly
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 weids
cool, they can throw off slag.
LI
. Wear approved face shield or safety goggles. Side shields
recommended.
. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pres-
sure. if damaged, a cylinder can explode. Since gas
cylinders are normaily part of the welding process,
be sure to treat then 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 welding electrode to touch any cylinder.
. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts 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 foliow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
4 WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
ENGINES can be hazardous.
. Use equipment outside in open, weil-ventilated areas.
2. if used in a closed area, vent engine exhaust outside and away
from any building air intaxes.
2-2
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.
у
aL,
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. H 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.
Ww
1. Keep all doors, panels, covers, and guards closed and securely
in place,
2. Stop engine before 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. Reinstali 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.
RON.
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 a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk
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:
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 cabies around the body.
About Pacemakers:
4. Keep welding power source and cables as far away from body as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
The above procedures are among those aiso normally recommended for pacemaker wearers. Consult your doctor for complete information.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard 249.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 28 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Amer-
ican Welding Society Standard AWS F4.1, from American Weiding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
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 MSW 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANS! Standard 287.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 518, 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, Chio 45373
This page intentionally left blank.
2-4 April 1, 1992
Replaces June 2, 1987
Hobart Brothers Company PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Troy, Ohio 45373 Instruction 910309
PRECAUTIONS DE SECURITE EN SOUDAGE A LARC
LE SOUDAGE À L'ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OÙ LA MORT. NE LAISSEZ PAS LES
ENFANTS S'APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU'ILS N'AIENT CONSULTE UN
MEDECIN). CONSERVEZ CES INSTRUCTIONS. LUSEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D'INSTALLER,
UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n'adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires,
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l'expérience passée. Ces pratiques doivent être apprises
par étude ou entraînement avant d'utiliser l'equipement. Toute personne n'ayant pas suivi un entraînement intensif en soudage et coupage
ne devrait pas tenter de souder, Certaines pratiques concernent jes équipements raccordés aux lignes d'alimentation alors que d'autres
s'adressent aux groupes électrogènes.
La norme Z49.1 de "American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présents las pratiques sécuritaires à
suivre. Ce document ainsi que d'autres guides que vous devriez connaître avant d'utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D'INSTALLATION, DE REPARATION, D'ENTRETIEN ET
D'ESSAI
L'ELECTROCUTION PEUT ETRE 6. Arrêtez tout équipement après usage. Coupez l'alimentation de
MORTELLE. l’équipement s'il est hors d'usage ou inutilisé.
7. N'utilisez que des porte-électrodes bien isoiés, Ne jamais plon-
ger les porte-6lectrodes dans l'eau pour les refroidir. Ne jamais
les laisser traîner par terre ou sur les pièces à souder, Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en même temps. Ne jamais toucher quelqu'un d'autre avec
— Une décharge électrique peut tuer ou briller grave-
=, ment. L'électrode et le circuit de soudage sont sous
tension dés la mise en circuit. Le circuit
d'alimentation et les circuits internes de
l'équipement sont aussi sous tension dès la mise en ' rte-ólectrod
marche. En soudage autornatique ou semi-au- électrode ou le po | 9.
tomatique avec fil, ce dernier, le rouleau ou labob- | & N'utilisez pas de câbles électriques usés, endommagés, mai
ine de fil, le logement des galets d'entrainement et épissés ou de section trop petite. ‘
toutes les pièces métalliques en contact avec le fil 9. N'enroulez pas de câbles électriques autour de votre corps.
de soudage sont sous tension. Un équipement = 10. N'utilisez qu'une bonne prise de masse pour la mise 4 la terre
inadéquatement instailé ou inadéguatement mis á la terre est dan- de la pièce à souder.
gereux. 11. Ne touchez pas a 'électrode lorsqu’en contact avec le circuit de
1. Ne touchez pas à des pièces sous tension. soudage (terre).
2. Portez des gants et des vêtements isolants, secs et non troués. 12. N'utilisez que des équipements en bon état. Réparez ou
3. Isciez-vous de la pièce à souder et de la mise à la terre au moyen remplacez aussitôt les pièces endommagées.
de tapis isolants ou autres. 13. Dans des espaces confinés ou mouillés, n'utilisez pas de source
le moteur avant de l'installer ou d'en faire l'entretien. Bicquez le tension. Utilisez plutôt une source de courant continu.
commutateur en circuit ouvert ou enlevez les fusibles de 14, Portez un harnais de sécurité si vous travaillez en hauteur.
l'alimentation afin d'éviter une mise en marche accidenteile. 15. Fermez solidement tous les panneaux et les capots.
5. Veuillez a installer cet équiperent et à le mettre à la terre selon
le manuel d'utilisation et les codes nationaux, provinciaux et
locaux applicables.
pour vous protéger le visage ot les yeux lorsque vous soudez ou
que vous observez l'exécution d'une soudure.
LE RAYONNEMENT DE L'ARC PEUT 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
BRÛLER LES YEUX ET LA PEAU: LE “sont recommandés.
> BRUIT PEUT ENDOMMAGER L'QUIE. 3. Entourez l'aire de soudage de rideaux ou de cioisons pour
L'aré de soudage produit une chaleur et des protéger les autres des coups d'arc ou de l'ébiouissement;
pre rayons ultraviolets intenses, susceptibles de avertissez les observateurs de ne pas regarder l'arc.
brûler les yeux et la peau. Le bruit causé par 4. Portez des vêtements en matériaux ignifuges et durables (laine
certains procédés peut endommager l'ouïe. et cuir) et des chaussures de sécurité.
1. Portez une casque de soudeur avec filtre oculaire de nuance 5 Portez un casque antibruit ou des bouchons d'oreille approuvés
appropriée (consultez la norme ANSI Z49 indiquée ci-après) lorsque le niveau de bruit est élevé.
30-X-92 2-1
13-IV-88 Révisée
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 910309
Hobart Brothers Company
Troy, Ohio 45373
SELECTION DES NUANCES DÉ FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPÂGE ET SOUDAGE
{ selon AWS A8.2-73)
Opération Dimension d'électrode cu Nuance de
de Epaisseur de métal ou de filtre
Coupage ou soudage Intensité de courant oculaire
Brasage tendre au chalumeau toutes conditions 2
Brasage fort au chalumeau toutes conditions Зоч 4
Oxycoupage
mince _ moins de 1 po. (25 mm) 20u3
moyen de 1 à & po. (25 à 150 mm) 40u5
épais plus de 6 po. (150 mm) 509 6
Soudage aux gaz
mince moins de 1/8 po. (3 mm) 40u5
moyen de 1/8 à 1/2 po. (3 à 12 mm) 5 ou 6
épais plus de 1/2 po. {12 mm) 6 0u 8
Soudage à l'arc avec moins de 5/32 po. (4 mm) 10
electrode enrobées (SMAW) de 5/32 à 1/4 po. {4 à 6.4 mm) 12
plus de 1/4 po. (6.4 mm) 14
Soudage à l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux toutes conditions 11
métaux ferreux toutes conditions 12
Soudage à l'arc sous gaz
avec électrode de tungstène (GTAW) toutes conditions 12
Soudage à l'hydrogène ;
atomique (AHW) toutes conditions 12
Soudage à l'arc avec
électrode de carbone (CAW) toutes conditions 12
Soudage à l’arc Plasma {PAW) toutes dimensions 12
Gougeage Air-Arc avec
électrode de carbone
mince 12
épais 14
Coupage à l’arc Plasma (PAC)
mince Moins de 300 ampères 9
moyen de 300 a 400 amperes 12
épais plus de 400 ampères 14
1. Eloignez la tête des fumées pour éviter de les respirer.
2. À l'intérieur, assurez-vous que l'aire de soudage est bien
ventilée ou que les fumées et les vapeurs sont aspirées à l'arc.
3. Si la ventilation est inadequate, portez un respirateur à adduc-
tion d'air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consurnmables, aux
revêternents et aux produits nettoyants.
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses À respirer.
5. Ne travaillez dans un espace confiné que s'il est bien ventilé;
sinon, portez un respirateur à adduction d'air. Les gaz pro-
tecteurs de soudage peuvent déplacer l'oxygène de l'air et
ainsi causer des malaises ou la mort. Assurez-vous que l'air est
propre a la respiration.
. Ne soudez pas á proximité d'opérations de dégraissage, de
nettoyage ou de puivérisation. La chaleur at les rayons de l'arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
. Ne soudez des tôles galvanisées ou plaquées-au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si 'espaca est bien ventilé; si nécessaire portez un respirateur
à adduction d'air. Car ces revêtements et tout métal qui conti-
ent ces éléments peuvent dégager des fumées toxiques au
moment du soudage.
2-2
30-X-92
13-1V-88 Révisée
Hobart Brothers Company
Troy, Ohio 45373
PRECAUTIONS DE SECURITE EN SOUDAGE À L’ARC
Instruction 910309
LE SOUDAGE PEUT CAUSER UN IN-
CENDIE OU UNE EXPLOSION
L'arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l'équipernent surchauffé peuvent
causer ur incendie et des brûlures. Le contact
accidentel de l’électrode ou du fil-électrode avec un
i
A.
objet métallique peut provoquer des étincelles, un échauffement
ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métai chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou
des projections peuvent atteindre des matériaux inflammables.
3. Enievez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l'arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections bruiantes de soudage suscepti-
bles de pénétrer dans des aires adjacentes par de petites
ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de
la main.
6. N'oubliez pas qu'une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l'autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir qu un baril.
8. Connectez le câble de soudage le plus près possible de ia zone
de soudage pour empêcher ie courant de suivre un long
parcours inconnu, et prévenir ainsi les risques d'électrocution
et d'incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l'électrode du porte-électrode ou coupez le fil au tube-con-
tact lorsqu'inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, ur pantalon revers, des bottines
de sécurité et un casque.
LES ETINCELLES ET LES PROJEC-
TIONS BRULANTES PEUVENT
CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules métalliques
volantes. En refroidissant, la soudure peut projeter du éclats de
laitier. |
1. Portez un écran facial ou des lunettes protectrices approuvéss.
Des écrans latéraux sont recommandés,
2. Portez des vêtements appropriés pour protéger la peau.
LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font
normailernent partie du procédé de soudage,
traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, ies chocs et tes arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou á un
cadre fixe pour les empêcher de tomber ou d'être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Empéchez tout contact entre une bouteille et une électrode de
soudage. |
5. N'utilisez que des bouteiiles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent
être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en piace ie chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publica-
tion P-1 de la CGA, identifiée dans la liste de documents
ci-dessous.
MISE EN GARDE
LES GAZ D'ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d'échappement
nocifs.
LES MOTEURS PEUVENT ETRE DANGEREUX
1. Utilisez l'équipement à l'extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d'échappement doivent être envoyées à l'extérieur, loin
des prises d'air du bâtiment.
LE CARBURANT PEUR CAUSER UN IN-
CENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant où de faire le plein.
2. Ne faites pas le plein en fumant ou proche d'une source
d'étincelies ou d'une flamme nue.
3. Si c'est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d'en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l'espace pour son expansion.
5. Faitesattention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
30-X-92
13-1V-88 Révisée
2-3
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
instruction 910309
Hobart Brothers Company
Troy, Ohio 45373
DES PIECES EN MOUVEMENT PEUV-
ENT CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et
ve
mains, qu accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d'installer ou de connecter un système, arrêtez le Moteur.
3. Seules des personnes qualifiées doivent démonter des pro-
tecteurs ou des capots pour faire l'entretien ou le dépannage
nécessaire.
4, Pour erpêcher un démarrage accidentel pendant l'entretien,
débranchez le câble d'accumulateur à la borne négative.
5. N'approchez pas les mains ou les cheveux de pièces en mouve-
ment; elles peuvent aussi accrocher des vêtements amples et
des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entratien et avant de faire démarrer le
moteur.
DES ETINCELLES PEUVENT FAIRE EX-
PLOSER UN ACCUMULATEUR;
L'ELECTROLYTE D'UN ACCUMU-
LATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l'électrolyte
acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-
lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbies d'accumulateur.
3. N'utilisez que des outils anti-étincelles pour travailler sur un
accurnulateur.
4, N'utilisez pas une source de courant de soudage pour charger
un accumulateur ou survoiter momentanément un véhicule.
S. Utilisez la polarité correcte {+ et —) de l'accurnuiateur.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d'un radiateur peut
être brûlant et sous pression.
1. N'ôtez pas ie Douchon de radiateur tant que ie moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s'échapper avant d'êôter complètement le
bouchon.
PRINCIPALES NORMES DE SECURITE
Safety in Welding and Cutting, norme ANSI 249.1, American Wald-
ing Society, 550 N.W. LaJeune Rd, Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
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,
norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
National Electrica! Code, norme 70 NFPA, National F:re Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Ariington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada MSW 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, norme ANSI 287.1, American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269,
2-4
30-X-92
13-1V-88 Révisée
HOBART
E
TM-462
—= a
mu
— О
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
î
instructions, and is being operated and maintained as outlined in these instructions.
USER:
Date:
Fog
“т
- ’ =" : “
“HIS CERTIFICATION NOTICE MUST BE POSTED NEAR THE WELDER!
Mar 24/76
HOBART
E
TM-462
instructions
TE нтк —
NOTE: Thi equipment cannot be operated without the. programmer.
Both this insiruction manual and the programmer instruction manual
should be read before attempting to install, wire, or operate the
equipment. | |
Thvoice to make certain that the shipment is complete and undamaged. If the equipment has
been damaged in transit, notify the carrier (railroad, trucking company, etc.) at once and
file a claim for damages. If you require assistance with a damage claim, furnish Hobart
Brothers Company full information about the claim.. If the shipment is in error, contact:
Order Department, Hobart Brothers Company, Troy, Ohio 45373.
Give the MODEL, SPEC IFICATION, and SERIAL numbers of the equipment, and a full des-
cription of the paris in errar. Refer to the PARTS LIST section of this manual for an explana=
tion of the specification numbers.
Generally, it is good practice to move the equipment to the site of installation before un-
crating. Use care in uncrating in arder to avoid damage to the equipment when bars, ham
mers, etc., are wed. Lifting eyes which extend through the top of the cabinet have been
provided to facilitate handling with a crane or hoist.
a ma A Ba
м. pm aes ie = Ari at dl ul
- . „== ао 1 ll a A
oo — A ден me —] r
Check that the following items correspond to the unit ordered.
1. Correct we lder console with single-phase AC, and correct input voltage /current rating.
— -
2. Correct optional meter panel.
3. Standard high-frequency starter or optional arc booster.
4, Jumper "dummy" plug on the programmer remote control connector.
5. Correct optional remote control.
6. Carect optional accessories such as casters, carts, etc.
7. Front panel knobs, handles, connectors, etc., in place and not damaged.
8. All screws and panels securely in place,
9. Correct programmer instruction manual and welder instruction manual,
10. Remove one of the side panels and inspect the interior for lose or damaged components,
Mar 24/76 Page 1
HOBART
E
TM-462
. a -
Best resulis with this equipment will be obtained ONLY if the responsible operating and
- maintenance personnel have access to and are familiar with these instructions and the pro-
grammer instructions. Additional copies may be obtained at small cost per copy by writing
to: Hobart Brothers Company, Troy, Ohio 45373. о
Give the SPEC, SERIAL, and MODEL numbers of your equipment and the number of copies
needed. |
NOTE: The programmer-has- ¡is own identification plate.
LOCATION = For best operating characteristics and longest unit life, take care in selecting
an installation site. When installing the equipment, avoid locations exposed to high humidity,
dust, high ambient temperature or сотсв ме fumes. Moisture condenses on machine parts
and electrical controls, causing carrosion which can seriously affect operation and efficiency.
Dust and dirt cause exira wear on all. moving parts. Therefore, we care to locate the equip-
ment so that excess moisture, dust, or corrcsive fumes will not be drawn into the unit.
Adequate air circulation is needed at all times in order to assure proper operation. Provide
a minimum of 12 inches (305 mm) of free air space at both front and rear of the unit. Make
sure that the ventilator openings are not obstructed.
DESCRIPTION OF THE "TIG" PROCESS = "Inert Gas Metal Arc Welding, Non-Comsumable "
is the descriptive name of the welding process whereby the arc is maintained between a non-
consumable metal electrode (usually tungsten) and the work == the arc zone being shielded
by an inert gas such as argon or helium. Various trade names, such es "Heliare", "Heliweld", -
"Argowe ld" (and perhaps others) are frequently used when referring to this particu lar process.
For simplicity and uniformity, any reference to the process in this manual will be made with
the term "ТС". |
This process can be used far making clean, sound welds on most metals and alloys, imrespec-
tive of their composition. In many instances, it provides the only suitable method for joining
certain metak. Cleaning is reduced to a minimum and frequently & eliminated, both before
and after welding. Flux is unnecessary in this process.
Because of certain inherent characteristics of the TIG welding process, special consideration
must be given fo the design of a welding machine which will best serve the requirements of the
process. This Hobart inert gas welder has been designed and built with these requirements
in mind. It will give long satisfactory service producing welds that are correct and sound
if it is properly installed, used, and maintained.
Page 2 Mar 24/76
HOBART
Ш
TM-462
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:
=r
We Iding Current
Electrode
Diameter А.С. ‚D.C. - Straight Polarity D.C. - Reverse Polarity
.020 5-35
. 040 15-60 30-100 |
1/16 60-100 70-150 10-20
3/32 100-160 150=225 15-30
1/8 140-220 200-275 25-40
5/32 200-275 250-350 40-55
3/16 250-400 300-500 80-125
1/4 300-500 400-650 80-125
Tungsten Electrode Sizes
C7 Table 1
The inert gas flow should be controlled accurately with a regulator and flow meter. No
specific recommendations for rates of flow can be given as this depends entirely on the we ld-
ing conditions and the torch and nozzle used. Correct argon flow 5 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.
‘Mere specific information concerning the torch configurations available and the gas flows
for each, can be obtained from the manufacturer of the torch equipment.
INSTALLATION - Because high frequency stabilized are welders inherently radiate power at
frequencies which may interfere with radio communication; including commercial, police,
and aviation broadcasts; their operation is subject to conirol by the Federal Communications
Commission.
Some general information on radio frequency radiation from high frequency stabilized arc
welders is given be low:
“ DIRECT RADIATION FROM WE LDER - The manufacturer controls direct radiation from the
welder by proper design of the unit. IF the .user complies with the installation and operation
instructions" furnished by the manufacturer, direct radiation from the welder will be relatively
low. a | -
. -. A a .. Hd = ьощелл ый E - mr
Che pe ae emt yk - ra. . yr = —
mid m+ ry dm Lamb
DIRECT RADIATION FROM WELDING CABLES - The initial radiation, due almost entirely
to the welding cables acting as an antenna, decreases rapidly with the distance from the cables.
This radiation can be kept to a minimum by making the welding cables as short as possible.
Mar 24/76 Page 3
HOBART
i
TM-462
The frequency spectrum emitted by a particular unit can be altered substantially by changing о ‘
the length or position of the welding cables and By differences in loading caused by operation = :
with the electrode arcing to the work. o o
RADIATION FROM POWER LINES - High frequency voltage which is conducted from the
we Ider 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.
In a welder that has been certified by the manufacturer, the radiation from the power line &
generally small when compared to the direct radiation from the welding cables. |
RE-RADIATION - Radiation from the welding cables can be readily picked up by ungrounded
metallic objects or unshielded wiring in the immediate vicinity, conducted some distance,
then re radiated. Usually this is the most troublesome source of interference.
This type of radiation can be kept to a minimum by installing the welder in accordance with
the installation procedures outlined in this instruction manual.
WIRING IN THE WELDING AREAVICINITY = The term "welding area" refers to the area
in which the welding machine , the welding cables, and the weld work are located.
Ungrounded metallic objects in close proximity to the welding area can act as antennae which
will pick up, conduct, and re-radiate the high frequency generated by the welder. Therefore,
no unshielded conductors shall be located within 50 feet (15,250 mm) of the welding area.
This means that all electrical power or lighting wiring within 50 feet of the welding area
shall be enclosed in grounded rigid metallic conduit, copper braid, or some other material
having an equivalent shielding efficiency, or shall consist of lead—covered cable. (Ordinary
flexible helically wrapped metallic conduit i generally not suitable.) The shielding or cable
covering shall be grounded at 50-foot (15,250 mm) intervals. Good electrical bonding shall.
be maintained between 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 of the welder in a vertical or vertical-diagonal direction.)
The foregoing procedure shall apply even if:
1. The welding area i 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 relocation of telephone ar signal wires must be done by the
service company concerned or with their specific permission.
Page 4 a. Mar 24/76
HOBART
i
TM-462
— USE IN METAL BUILDINGS - Where the welding area is enclesed within a metal building,
"proper precautions must be taken to insure that the building is properly grounded. This can
be accomplished by placing several good electrical grounds around the periphery of the .
building. Refer to following grounding procedure.
The installation procedures described in this publication shall be observed even if the we Ider
is operated within a shielded structure, |
GROUNDING - The frame of this welder should be grounded for personnel safety. Where
grounding is mandatory under state or local codes, it is the responsibility of the user to comply
with all applicable rules and regulations. Where no state or local codes exist, it is recom-
mended that the National Electrical Code be followed. Kefer to Table 2 for wire sizes.
The work or work table must also be grounded by using a cable attached to a driven ground
of water pipe as described below. See Figures 1, 2, and 3.
The requirements and recommendations for grounding apply to rubber tire mounted equipment.
In addition to the usual function of protecting personnel against the hazard of electrical
shock due to fault in the equipment, grounding serves to discharge the static electrical charges
which tend to build up on the surfaces of tire mounted equipment. These static charges some-
times cause painful shock to personnel, and in some instances, lead to the erroneous con=
clusion that an electrical fault exists in the equipment.
Use an input-power cable assembly which includes a grounding conductar to connect this
equipment to the input power supply. When included in the cable assembly, the grounding
conductor will be green or green with a yellow stripe, or bare. Connect the grounding соп-
ducto to the equipment grounding terminal, if provided, and if not, to the equipment.
frame , taking care to see that good electrical contact 5 made between conductar 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 & wed,
the equipment may be grounded with a separate conductor if permitted under applicable
code, or by special permission of the jurisdictional body resporsible for enforcement of the
code. Minimum size and colar coding requirements must be in accordance with any appli-
cable state ar local code, ar the National Electrical Code, |
If metallic armored cable or conduit is used, the metal sheathing or conduit must be effec-
tively grounded as required by state ar local code, ar the National Electrical Code.
If a system ground & not available, the welder frame must be connected to a driven ground
rod (see Figures 1 and 2) or to a water pipe that enters the ground not more than 10 feet
(3,048 mm) from the welder. Refer to the WIRE AND FUSE SIZE CHART, Table 2, for
selection of the: proper ground wire. | NA
E E : e ©
A +
NOTE: “The ground wire must be as short as possible in order to produce
the mest efficient installation. UT a
Mar 24/76 Page 5
a
—
1 0
TM-462
20-30 Ibe (9.1—13.6 kg) Soil treating material
{copper sulphate, magnesium sulphate or rock sait) | ВЕ
placed in circular trench and covered Fasten Ground Lead fo
wh Ce Fasten Ground Lead to - the rod with an approved
Ground Lead the rod with an approved ground clamp
ground clamp. Ground Lead
AZ -
ile ; $, UL Removable cover
iS SAN Ted, Sly Floor. " м
С 5b 42246 za bo , 6 45°
в Ne NA AS ARAS o. tas
PENN Not fess than 8 FL.
УЕ: № (2438 mm)
(457 mm)
o
Approx, "ei Z
A N Material A|]:
Ground Rod . Not less than 8 Ft. (2438 mm) N
Approx. { Ft. (305 mm)
Y Soil Treating 7
18 inches
6 Inches {152 mm) Approx.-"
Outside Ground Ins ide Ground
Figure | | | ~ Figure 2
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 à carried into the most useful area of earth surrounding the electrode
(rod). Flood the trench several times when making original installation. See Figure 1.
Treating an Inside Ground - Reduce the diameter of the hole to 6 inches (152 mm), pour soil
freating 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 2,
CONNECTION TO LINE VOLTAGE ~ Refer to Table 2 fa wire sizes required, The power
supply wires serving the welder shall be completely enclesed far a distance of at least 50 feet
(15,250 mm) (in any direction) from the weider in solid metallic conduit or closely braided
copper sheathing. This shielding shall be connected to the ground at the extreme end of
the shielding. (See Figure 3.) The shielding shall be solidly connected to the welder case
so as to make good electrical contact and there shall be no gaps in the shielding run. (Or-
dinary flexible helically wrapped metal conduit is generally not suitable.)
This welder operates on a single-phase , AC input, See nameplate of welder to determine
welding voltage and frequency. Make certain that the welder is connected for the power
supply voltage available. See voltage changeover connection diagram in the back of this
book or inside the welder, 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 on the welder 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 fuse listed ¡ in
Table 2 following. : |
Page 6 Mar 24/76
HOBART
E
TM-462
WARNING - When 3 -conductar, rubber -covered cable & wed, the
grounding wire must be green in colar.
When flexible armared cable ar conduit 5 required by local codes, install
it properly to insure an adequate ground of the equipment. With the machine
frame grounded, the operator is always assured full protection, even in the
unlikely event of insulation failure, or of accidental ground of the power
supply.
CAUTION: The flow of cooling air through the welder & carefully
directed by baffles. Never operate the welder with any panels removed
of open, as serious damage to the components may result.
CAUTION: Make certain that the ground cable attached to the work is
connected securely at both the work and at the machine and that the cable
is in good condition,
À
E Ad 1 Э
2% DS 90
25 0F15250mm)-> | O do Og A a—— 7 Ft(2135mmM)
Minimum He |
° о T]
Power-Line Conduit # = Remote Control
(See first paragraph 00 (Here or on torch Work
under CONNECTION ос handle) or
TO LINE VOLTAGE" Work Tabl
section preceding.) ork Table
=—
"Work" — "Electrode 25 F+(7620 mm) > See
Terminal Terminal Grounding
Inst i
Ground Rod , Ground Rod-——— structions
(See Figures | & 2) See following section (See Figures ! & 2)
on WELDING CABLES
Wiring Precautions
Figure 3
Mar 24/76 Page 7
D |
_ TM-462
e mes = = | Ye воще TO ;
To Fused Disconnect | |
Disconnect Switch Box
Switch and Ground
Black and m)
White O Green
Line
Contac tor—
Single -Phase Input Connections
Figure 4
WARN ING: The fused disconnect switch: Open or place in the OFF posi-
tion and remove the fuses. To avoid an accident, make the eleciric
power connections to the welder first, then to the fused disconnect switch.
This will prevent an accidental application of power while the welder is
being connected.
1. Remove the top cover from the welder.
2. The line contactor for input power connections is mounted on the back of the vertical
panel ar chassis. See Figure 4. vase
3. The welder electric ground terminal is on another smaller vertical panel parallel to and
mounted on the main vertical panel. The ground terminal E about three inches (76 mm)
from the line contacter,
4. Run the power cable through the hole at the rear of the welder. Loosen the cable clamp
as required to accommodate the cable.
- a Na = я mil a ca * —
Page 8 Mar 24/76
HOBART
Ш
TM-462
5. Remove about 10 inches (254 mm) of the outer insulation that holds the wires of the
cable together.
6. Strip approximately 2 inch (12.7 mm) of insulation from the end of each wire.
7. Install the green wire secure ly to the grounding terminal.
8. Install the other wires to the line contactar as illustrated in Figure 4.
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 with 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. Replace welder top cover and securely fasten in place.
— FC A A .
a A fo. 0. - - PE ==
een - TENA e ‚= E
1 м
3 Wires in Conduit 3 Wires in Air
Line Line Line Wire Ground Wire Line Wire Ground Wire Fuse
Voltage Current | Size Size Size Size Size
208 110 #2 #6 4 78 150
220-230 100 #3 #6 6 8
x # # #8 #8 80
380 58 6 8 ; Ad 20
440-460 50 “#8 #8 10 и 0
500 44 #8 #8 10 8 60
575 40 #9 #8 10 8
Input Wiring and Fuse Size Chart
Table 2
Connections to the Fused Disconnect Switch
1. Connect the black welder cable wire to the terminal in the fused disconnect switch that
leads through the fuse and the switch to the black input power wire.
2. Connect the white welder cable wire to the terminal in the fused disconnect switch that
leads through fuse and switch to the white input power wire.
Mar 24/76 Раде 9
HOBART
E
3. Connect the green welder cable wire to the fused disconnect switch ground and to an
external ground.
NOTE: If the ground E properly installed, the power wiring to the fused
disconnect switch can be wired without regard to color; that is, white to
black to white, ete. However, fo avoid confusion or errar in the future,
adherence to the standard colar code is recommended.
WE LDER ADJUSTMENTS - Keep spark gaps set at 0,008 inch (0.203 mm). Set high frequency
control to lowest possible setting cons ktent with good welding.
WE LDER PANELS - When the equipment is in operation, all access doors and covers shall be
closed and properly fastened. Except far those changes and adjustments covered in the manu= |
facturer's instructions, the equipment: must not be modified in any way. Modification may
affect radiation and thus void the manufacturers certification.
WELDING CABILES
1. The torch cable and the work cable ust each be 25 feet (7620 am) oF less
in length and run together at floor level wherever possible except the lost 7 feet (2, 140 mm
at the torch or "whip" end. (See Figure 3.) Use No. 1 gauge copper cables.
+
2. The leads for the remote switch or gun trigger must ako be 25 feet (7,620 mm) in length
or less and must be brought out close to and parallel to welding cables.
CERTIFICATION NOTICE - In order to comply with F.C.C. regulations after the unit has - Lil
been installed in accordance with the preceding instructions, the user must post the certi-
fication notice at the location of the welder. A convenient form is enclosed in the front
of this book which may be wed for this purpose after it has been properly filled out.
INDIVIDUAL INSTALLATION CERTIFICATION
1. The user may waive any of the requirements outlined in these special installation require=
ments if he desires to exercise the option of having an installation test survey made. This
survey shall be made by a competent engineer in accordance with the test procedure require-
ments set forth in Part 18 of the Federal Communications’ Rules and Regulations.
2. Certification may cover a unit installation ar may be included in the certification of a
complete plant,
RESPONSIBILITY FOR INTERFERENCE = In the event thi equipment causes interference, #
5 5 the user's Fespons ibility to take steps ir in n eliminating the interference.
AU] A —
Page 10 - | _ | Mar 24/76
A "y : tour 2 NC 1
PT I TRE EE A TE EST A
a e
The Lo RTA An
“er +
HOBART
E
TM-462
INPUT VOLTAGE CHANGE OVER - Refer to the voltage changeover diagram of back of the
manual, Closely follow accompanying instructions. :
WARNING: Before proceeding, place fused disconnect switch in
"OFF" position ond remove the fuses.
Remove the top from the welder to gain access to the phase sensing transfarmer for is voltage
- changeover. Be sure pone a are > securely refastened ¡ in n place after the changeover | is occom=
plished. o hen Pa CY Raat
PROGRAMMER AND REMOTE CONTROL CONNECTIONS =~ Refer to Figure 3 as a rough
guide line , but be sure to use the programmer instruction manual to determine the exact
connection procedure.
DESCRIPTION OF EQUIPMENT - (See Figure 5.) The single-phase AC/DC welder requires
a single-phase power input. If has a duty cycle of 60%. The output current of the welder
can be either AC, straight polarity DC, or reverse polarity DC. The maximum no-load
voltage rating is 80 volts. Refer to the nameplate on the front panel far the power input
; open, voltage , and current.
The optional meter panel has four meters - for monitoring AC o DC welding voltage or current.
+ Other components of this circuitry are access ible through a small door on the left side of
‘console. For greater detail on the high frequency circuit, refer to the programmer instruc-
“tion manual.
“The programmer is a self-contained unit which slides in or out of the console like a drawer,
for easy adjustment ar service of internal components, or for changing types of programmers.
Any remote controls in use connect to plugs on the front control panel. The programmer
controk we lding current parameters, plus water and gas flow as described in greater detail
in the programmer instruction manual.
Théiwe Iding current supply, located in the bottom half of corsole, serves as connection
¡point for the welding cables, plus water and gas hoses when used. It also serves to limit
maximum current output, to select welding mode (AC or DC), to reverse DC polarity,
to provide fuses to protect programmer , and to provide 115-V AC auxiliar y power out lets.
See Figure 6.
Mar 24/76 | Page 11
—
—
TM-462
High Frequency
Control
Programmer
di We lding Current Supply
` (See Figure 6) |
Cyber -Tig Console
Figure 5
CONTROLS AND CONNECTORS
Welding Current Supply 3 |
4
2
| ta
| Ne
- Control Panel
Figure 6
Page 12 Mar 24/76
HOBART
E
TM-462
We lding Current Supply (Continued) (Refer to Figure 6) | |
1, AC-DC Polarity Switch = Three -position rotary switch that selects polarity and mode of
operation (AC or DC),
2. Fuse ~ 5 Ampere - Provides overload protection for the programmer.
3. Fuse ~ 15 Ampere ~ Provides overload protection for the programmer.
4. Fuse = 5 Ampere - Provides overload protection for the programmer.
>. Range Switch - Three -pasition rotary switch that selects maximum current for AC or DC
welding: 50 Amps, 100 Amps, or 300 Amps.
6. Gos~from-Cylinder Connector ~ Provides connection for input ges from the gas cylinder.
7. Elecirode" Terminal - Provides electric connection between welder power supply and the
torch electrode,
8. Water-from-Supply Connector - Provides connection for input water from the water
supply.
7. Water-to-Torch Connector = Provides connection for feeding water to the torch,
10, "Work" Terminal = Provides electric connection to the work.
11. Gas-to-Torch Connector - Provides connection for feeding inert gas to the torch.
12. 115-V AC Convenience Outlets - Provides 115-V AC output for auxiliary equipment.
Mar 24/76 Page 13
C1
TM-462
ARC BOOSTER
ARC - BOOSTER
9 104
HIGH FREQUENCY CONTROL
ARC - BOOSTER ARC- BOOSTER
TIME - INTENSITY
ARC- BOOSTER .
Un OFF
Arc-Booster (OPTIONAL) on Front Panel
Figure 7
1. Arc-booster ON-OFF Switch - Two-pæition toggle switch that se lects between regular
(OFF) and Arc-Booster operation (ON). For continuous operation of the high frequency cir-
- cuitduring AC welding, this switch should be OFF.
2. Arc-booster Time Control Potentiometer = Single ~turn potentiometer that controls time
duration arc-booster is in the circuit. 0 to 2.5 seconds.
3. Arc-bocster Intensity Conirol Potentiometer = Single-turn potentiometer that controls
arc-booster current as desired for the work involved. 2to 10 amps. This current may be
added to by current from HOT START CONTROL.
4. High Frequency Conirol Potentiometer = Single=turn potentiometer that controls intensity
of high frequency. Operates in same manner os standard high frequency intensity control.
Control Settings - To operate the Arc-Booster, set the front panel controls to the desired
positions.
CAUTION: High voltage is present at welding terminals prior to arc
initiation. Arc booster not recommended for manual welding and is
not to be used for AC welding.
Page 14 Mar 24/76
HOBART
i
PREPARATION FOR USE
COOLING WATER CONNECTIONS ~ Refer to Figure 8 when making connections to a
"Circoolator". Refer to Figure 9 when making connections to the city (factory) water supply.
In both cases, the cooling water exifs the torch through the hollow electric cable.
>
NOTE: Ali water ; fittings have left hand threads.
CAUTION: The use of Teflon thread sealing tape is recommended
on the threaded water fittings, except for the torch cable connec-
tion to the welder electrode terminal. The only thread sealant
allowed on this torch cable connection is elecirical joint compound,
This compound i is available from Hobart Brothers Company in 5 oz.
(147.8 c”) tubes (Hobart part no. 903170),
SHELDING GAS CONNECTIONS - Refer to Figure 8 when making connections fo a
"Circoolator" cooled torch, Refer to Figure 9 when making connections to a city water
cooled torch. Refer to Figure 10 when making connections 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 cables, plus the remote or torch switch cables, must each be 25 feet (7620 mm) in
length or less. All of these cables should be routed together at floor level wherever possible,
except the last 7 feet (2140 mm) at the torch ("whip") end see Figure 3). Use No. 1 gauge
copper wire for the welding power cables. Refer to Figures 8, 9, or 10.
NOTE: Make sure all connections are clean and tight. Thread
sealant may be used as specified in the CAUTION note in the pre-
ceding section entitled: COOLING WATER CONNECTIONS,
Keep both welding cables as short as possible and as far away os -
practical from other power lines and metallic objects.
Mar 24/76 Page 15
—
| 1
HOVAC
POWER SUPPLY
Outlets
GAS
TM-462
Regulator
To From |
Torch Cylinder
ие)
Cae
ELECTRODE
WATER
To
Torch Supply
TORCH
4 CIRCOOLATOR
__— ON-OFF Switch
GAS Requlator
To From :
POWER Torch Cylinder
SUPPLY —- WORK
il
ELECTROD O =
6 WATER
To From Ц
Torch Supply
pr
Y
—
Water
Supply —>
e
ÿ To Water Drain
City (Factory) Water Supply Cooled Torch
~ Figure 9 a `
POWER SUPPLY
GAS |
Regulator
To From ‹
Torch Cylinder
WORK >
il
ELECTROD
WATER Bl
To From
Torch Supply
Page 16
Mar 24/76
HOBART
Ë
TM-462
INSTALL PROGRAMMER = Install in the welder console in accordance with the programmer
instruction manual = if it hasn't been factory installed. Make sure that all fasteners holding
the programmer in place, plus all the fasteners securing the we Ider enclosure panek, are
securely tightened.
OPERATION ~ Refer to programmer instruction manual. Thoroughly read the SAFETY WARN =
INGS at the front of this manual,
NOTE: Set the high frequency control to the lowest possible setting
consistent with good welding.
MAINTENANCE
LUBRICATION - The fan motor is permanently lubricated and will never need oil or grecse.
No other points require lubrication.
INSPECTION AND CIEANING - For uninterrupted, satisfactory service from this welder,
it is necessary to keep the machine clean, dry, and well ventilated. Dirt and dust may be
blown or wiped from the inside of the welding machine.
WARNING: Disconnect line voltage from the unit before attempting any
servicing inside unit. Turn fused disconnect switch to "OFF" and remove
its: fuses.
Be sure to wipe the fan blades clean, All electrical connections should be checked and
tightened at regular intervak to eliminate unnecessary losses and to avoid subsequent trouble
from overheating or open circuits.
CAUTION: The flow of air through the welder is carefully directed by
baffles. Never operate the welder with any of the side or top panels
removed or open, as serious damage to the rectifiers might result.
Mar 24/76 Page 17
May 24/76 Revised
—
—
TM-462
SPARK GAPS ~ Set to 0.008 inches (0.20 mm) or less. Check gap frequently, as gap erc ion
is normal, Resurface gap faces as necessary to permit accurate gap spacing. Gain access
to these gaps by removing a small panel on left side, near the rear of welder console. See
Figure 11.
Ba Spark Gaps
Spark Gaps
: =
EE ew
— ‚= Or ое = ина. = ——.. + —_—
REPLACEMENT OF SILICON RECTIFERS - The silicon rectifier is composed of silicon diodes,
some of which are positive (+) base and some negative (-) base. In general, diodes mounted
on the same plate are of the same polarity. Should it become necessary to replace a diode,
great care must be taken fo replace it with one of like polarity.
An absolutely sure means of identification 5 to note the small arrow on the side of the diode. :
If the arrow points toward the stud, the diode is referred to œ a "positive base", If the arrow
points foward the lead (cable) end of the diode, the diode is referred to as a "negative base“.
When ordering replacement diodes, make certain to indicate whether the diode to be replaced
| № positive ar negative base, Part numbers will indicate this, but for absolute surety, indicate
polarity as well. Consult your Hobart dealer for proper diode tightening torques.
HIGH FREQUENCY OR PULSING CRCUITS TROUBLESHOOTING ~ Refer to programmer in-
sruction manual,
hr ———l]]
Page 18 Mar 24/76
Revised May 74/76.
HOBART
E
TM-462
TROUBLESHOOTING - The following chart contains information which can be used to diagnose
and correct uñsatifactory operation or failure of the-varicus components of the welder. Each
“ _symptom of trouble is followed by a list of possible causes and the procedure n
the trouble.
жанна
TROUBLE
CAUSE
REMEDY
Fan will not start
Contactor will not
close (ako see Fan will
not start)
Power switch OFF
Power lines dead
Broken power lead
Wrong line voltage
Incorrect input power соппес-
tions at welder, linkages or
{jumpers on overload panel
Blown line fuses
Blown fuse on front panel
Fan motor failed
Control transformer failed
Loose connections af contac=
tor, terminal strip, control
transformer, or switch SW-1
Nothing in remote conirol
receptacle
Broken lead at contactor
Mechanical obstruction on
contactor
Failed pre-purge timer (units
with pre-purge timer only)
Loose connections at control
transformer , terminal strip,
remote conirol receptacle,
we ld timer, pre-flow timer,
ar contactar coil
Place power switch in ON position,
Check voltage.
Repair.
Check power supply.
Check connections against wiring
diagrams.
Replace, check for cause.
Replace, check for cause.
Replace.
Replace.
Reconnect.
Plug in remote control or local
operation plug.
Repair,
Remove obstruction.
Replace.
Reconnect.
Mar 24/76
Page 19
ecessary to correct
HOBART
i
TM-462
TROUBLE
CAUSE
REMEDY
Contactor hums
Contactor operates
and blows fuse
Welder delivers
welding current but
| soon shuts down
Dirt on contact faces of line
switch magnet
Improper alignment of
stationary and movable yokes
on starting switch
Broken shading coil
Wrong line voltage
Links on overload panel in-
correctly connected
Fuse too small
Diode failed
Short circuit in primary
connections
Transformer failed
Wrong overload relay
elements
Overload relay elements
set incorrectly
Welder overloaded
Duty cycle too high
Power leads too long or foo
small in cross section
Clean faces of magnet.
Correct alignment.
Replace.
Check nameplate of welder for lire
voltage to use, check line voltage.
Check wiring diagram for link
positions, connect links correctly.
Install proper size fuses. (See wire
and fuse size chart in Installation
Section of this manual.)
Replace diode. See Maintenance
section of this manual
Remove short circuits.
Repair or replace.
Check with renewal part recom-
mendation.
Check with welder distributor.
Reduce load - overload can be
carried only for a short time.
Do not operate continually at over-
load currents.
Replace with larger diameter cable.
See wire and fuse chart in Installa-
tion Section of this manual,
Page 20
Mar 24/76
4
HOBART
E
TM=462
TROUBLE
CAUSE
REMEDY
Welder delivers
welding current but
soon shuts down
(Cont'd.)
Contactor operates
but welder will not
deliver current
Welding arc is loud
and spatters exces-
| sively (stick elec-
trode welding).
Welding arc sluggish
Ambient temperature too
high
Ventilation blocked
Fan not operating
Electrode cable or holder
may be grounded
Range switch or polarity
switch not centered on arrow
Water pipe connected to
TIG torch terminal
Transformer winding cpen
Transformer secondary failed
Diode failed
Current setting too high
Polarity wrong
Incorrect rod used on AC
Filter coil short circuited
Current too low
Operate at reduced loads when
temperature exceeds 1009F (38°C).
Check air intake and exhaust
openings for obstruction and re-
move any found.
Check bearings, disconnect leads
and apply motor namepiate voltage
to check.
Use only cable and holder with
sound insulation.
Set exacily on arrow.
Remove. Run cable from torch iug
to TIG torch terminal.
Have transformer repaired.
Have transformer repaired.
Replace diode. See Maintenance
section of this manual.
Check setting and output with
ammeter, or reduce current.
Check polarity, try reversing
polarity.
Use AC or AC/DC rod for AC
welding.
Replace filter.
Check output and current recom-
mended for electrode being used.
Mar 24/76
Page 21
HOBART
i
TM-462
TROUBLE
CAUSE
REMEDY
Welding arc
sluggish (Cont'd.)
Selector switch does
not control polarity
or permit adjustment
between AC and DC
welding
Welder operates but
welding current falls
off
Arc difficult to
strike
Operator gets shock
when welder case is
touched
Operator gets shock
when ground cable,
or work table is
touched
Poor connections
Cables too long or too small
in diameter
Low line voltage
Loose or broken connection
Electrode or ground cable
connections loose at welder,
ground or work
Also see "welder delivers
welding current but soon
shuts down".
Loose connection
Wrong type electrode
Case of welder not grounded
Work table and werk not
grounded
Check all electrode holders,
electrode cable and work cable
connecfions.
Check cable voltage drop, use
larger cable.
Check power source. Notify power
company if necessary.
. _ aa tw
a
Reconnect, check both ends of each
lead to selector switch.
Clean and tighten ali connections,
check ground refurn circuit.
Check connection.
Use proper electroce.
Ground welder case.
Ground work and work table to
plant ground.
Page 22
Mar 24/76
HOBART
E
TM-462
| TROUBLE
CAUSE
REMEDY
4
Weld metal will not
flow, arc is erratic
on AC-TIG welding
Arc is unstable on
AC-TIG welding
Arc is played on weld puddle
Current too high
Arc length too long
Gas cup on torch too smal!
Insufficient gas flow
Helium inert gas used
Ballast resistor failed
Welding speed too slow
High frequency weak
High frequency rheostat not
set properly
Wrong spark gap setting
High frequency rheostat
set improperly
Spark gaps set incorrectly
Welding cable too long
Ballast resistor shorted or
failed
High frequency too weak
Point torch in direction of weld,
not directly into weld puddle.
Reduce current.
Reduce arc length.
Increase size of gas cup.
Increase gas flow.
Use argon gas if possible.
Replace.
Increase speed of travel with torch.
See high frequency checking pro-
cedure in Programmer Module
Manual.
Adjust for best welding conditions.
Adjust spark gap as recommended
in first part of MAINTENANCE
- section .
Set for stable arc.
Set to recommended spacing.
Move welder closer to work.
Repair or replace.
See high frequency check list.
Also see "Arc is unstable.
Mar 24/ 76
Page 23
‘HOBART
E
TM-462
TROUBLE
CAUSE
REMEDY
Arc is unstable
Torch "spits" tung-
sten into work
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 tungs=
ten into work".
Tungsten is balled for AC-
TIG welding either with
reverse polarity DC or high
AC current
Current too high
Current foo high after arc
is struck on AC-TIG welding
Arc length too long
Tungsten too small
Sharp point ground on
rungsfen
Post purge time too short,
causing air contamination of
tungsten
Degrease and clean to bare metal
by chemical or abrasive means if
necessary.
Increase spacing of work pieces or
shorten arc length. Reduce high
frequency setting.
Use smaller eiectrode or grind
point. A polished electrode some-
times helps.
Shorten arc length
-
ee
Зо.
r TE
,
Bal! by grinding only.
Decrease current.
Use foot rheostat to gradualiy in-
crease current after arc is estab-
lished, or hold 1/2" long a few
seconds after striking.
Shorten arc.
Increase size of tungsten.
As rated current of fungsten is
approached, reduce sharpness of
point.
Increase post purge time until
tungsten stays bright after gas
shuts off.
Page 24
Mar 24/76
HOBART
E
TM-462
TROUBLE
CAUSE
REMEDY
Torch "spits" tung-
sten into work
Tungsten touching work,
causing contamination of
Break off end of tungsten.
| (Cont'd.) tungsten and work
Leaky "O" rings in torch Replace.
or leaky hoses in gas line
Hoses previousiy used to Use new hoses.
carry oil, acetylene or
other gases
Weld is dirty Dirty work metal Clean work metal with degreasing
compound, soap and water com-
pound, or wire brush.
Dirty filler rod Keep filler rod in location where
- it will not become dirty.
High frequency set im- Adjust high frequency rheostai
properly for most favorable operation
conditions.
Hign frequency too weak Increase setting of high frequency
rheostat, see high frequency check
list at end of maintenance section.
Insufficient gas flow Increase gas flow. Check for
pinched hoses.
Leaky gas hoses Replace.
Hoses previously used to Use new hoses.
carry oil, acetylene, or -
other gases, causing scum
on weld
Loose connections in gas Tighten.
system
Mar 24/76 Page 25
HOBART
i
-
TROUBLE
CAUSE
REMEDY
On DC-TIG straight
polarity welding,
high frequency jumps]
gap between elec-
trode and work, but
DC power does not
follow to initiate
the arc
High frequency and
arc extend from side
of tungsten
Arc unstable af low
current welding on |
DC straight polarity
TIG
Use of pure tungsten
Controls set for soft start
Use of helium gas
Electrode held very near
work after high frequency
has begun jumping
Tungsten too large
Torch fuse blown
Tungsten used too long atime
Rough tungsten
High frequency switch set to
START (high frequency cuts
ouf)
Arc extends from side of
tungsten
Arc length too long
Arc wanders
Use thoriated tungsten on DC
straight polarity welding.
Set for normal start. Adjust start
control to prevent burn through.
Use argon gas for best arc initiating
properties.
After high frequency spark jumps,
withdraw torch slightly.
Use smaller tungsten or grind point.
Replace, check to see if water is
flowing. Reduce current if over-
loading torch.
Break off 1/4".
Use ground and polished tungsten.
Set to CONTINUOUS (high fre-
quency is continuous).
Use ground and polished tungsten.
Use shortest arc length possible.
See trouble category - "Arc
Wanders". |
Расе 26
Маг 24/76
HOBART
E
TM-462
TROUBLE
CAUSE
REMEDY
Arc crater at end
of weld
Arc wanders
| Tungsten discolors
Torch withdrawn before arc
is extinguished
Tungsten contaminated 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 purge
Snap torch back quickly. An
alternate solution is to cut off the
current with the remote switch be-
fore the torch is withdrawn from
the work. Still another solution is
to use the remote rheostat control
to reduce the current before with-
drewing the electrode 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 grinc
point. À polished electrode some-
times helps. Grind point on
electrode.
Increase spacing of work pieces
or shorten arc length. Reduce
high frequency setting.
Increase setting of post purge time.
after weld
Post purge timer sticks Replace or ciean contacts.
Gas vaive sticks Replace.
Loose connections in gas Tighten.
system
Insufficient gas flow Increase.
Leaky hoses Replace.
Mar 24/76 Page 27
HOBART
E
TM-462
TROUBLE
CAUSE
REMEDY
Water to torch flows
too slowly or not at
|
all
Water or gas will not
shut off
High frequency but no
power
Poor weld on AC-TIG
weld discolored
Porous welds
Porous welds on
aluminum alloys
leaky "0" rings
Insufficient water pressure
Water shut off
Water valve sticks
Water hose pinched
Post purge timer set too high
Post purge timer contacts
stick
Valves stuck open
Work cable hooked to
ELECTRODE terminal
Fuse in torch blown
Water in torch, due to
Post purge too long or cold
water flows continuously;
causes condensation in inert
gas section of torch; will
not happen with Circoolator;
water is af room temperature.
Leaky "0" rings in torch
Hydrogen entrapment
Too high welding temperature
welding speed too slow
Turn on water.
Increase water pressure,
Replace water valve.
Remove object pinching hose.
Decrease post purge timer setting.
Replace timer or clean contacts.
Replace valves.
Connect to WORK terminal.
Replace fuse.
Replace "O" rings.
Shorter post purge or use Circoolator
for cooling water.
Replace "0" rings.
Make certain work and filler metal
are clean and dry. Remove oxide
film before welding. Aveid welding
in a humid place. Increase gas flow.
Reduce current and weld as fast as
possible.
Page 28
Mar 24/76
HOBART
E
TM~462
TROUBLE
CAUSE
REMEDY
i
Porous welds on
aluminum alloys
(Cont'd.)
Weld has low tensile
strength (aluminum)
Weld cracking
(aluminum)
Intermittent timer
and relay operation
Weak high frequency
and no welding power
Magnesium used as alloying
material
Impurities in base metal;
for example, calcium
Weld solidifies rapidly
Metallurgical changes due
to weld heat
Welding speed too slow
Current too high
Skip welding
Welding so that welds
intersect
Cold working
Also see "Porous welds on
aluminum alloys".
5 amp fuse blown
Torch fuse blown
Avoid welding aluminum alloys
with high magnesium content.
Use higher grade material.
Use materials which solidify slowly.
Reduce welding speed.
Heat treat.
Increase speed.
Reduce current.
Use continuous welds on aluminum
and its alloys.
Weld at low current and fast speed,
or redesign piece to avoid inter-
section of welds.
Do not weld cold worked aluminum
alloys and do not cold work after
welding.
Replace fuse.
Replace; check to see if water is
flowing. Reduce current if over-
loading torch.
Mar 24/76
Page 29
HOBART
i
TM-462
CAUSE
REMEDY
TROUBLE
High frequency will
not cut off after arc
is struck and high
frequency switch is
in START position
High frequency does
not come on in
AUTO position
Cutput of machine
is at minimum (3
amps) regardless of
current setting
No open circuit
voltage
Voltage control relay (VCR)
contacts stuck
VCR relay circuit defective
Pins loose on connector at
rear of drawer
Wires loose on connector
at top of high frequency
panel
Pins loose on connectors at
rear of drawer or at SCR
Gater
Feedback resistor open
2CR relay contacts not
operating properly
Amp-traps blown
SCR Gater defective
Line voltage incorrect
Links on overload panel in-
correctly connected
Range and selector switch not
in detent position
Pre-purge timer not working
Free contacts and clean them.
Replace defective part.
Tighten pins.
Tighten loose wires.
Tighten pins.
Replace resistor.
Replace relay.
Replace amp-trays after checking
for shorted SCR's, shorted diode
or shorted reactor control coil.
Replace SCR Gater.
Check nameplate of welder for line
voltage to use, check line voltage.
Check wiring diagram for link
positions, connect links correctly.
Set switch on detent.
Replace timer.
‘Page 30
Mar 24/76
——
HOBART
Ш
TM-462
TROUBLE
CAUSE
REMEDY
No open circuit
voltage (Cont'd.)
Low open circuit
voltage
Qutput of machine
will not reach max-
imum rated load
Qutput of machine
won't reach mini-
mum rated load
Line contactor not ener-
gizing
1CR relay not energizing
Open diodes in output
rectifier
Line voltage incorrect
Links on overload panel
incorrectly connected
Maximum current calibration
control misaligned
Amp-trap failed
SCR failed
SCR Gater failed
Control! coil on reactor has
shorted turns
Wrong size electrode and
ground cable used
Line voltage incorrect
Links on overioad panel in-
correctly connected
Minimum current calibration
control misaligned
|
Repair line contactor or circuit.
Plug in remote control or local
operation plug.
Replace diodes. -— See MAIN-
TENANCE section of this manual.
Check nameplate of welder for
line voltage to use, check line
voltage.
Check wiring diagram for link
positions, connect links correctly.
Realign maximum current.
Replace amp-trap.
Replace SCR.
Replace SCR Gater.
Repair or replace reactor.
Use correct size cables.
Check nameplate of welder for
line voltage to use, check line
voltage.
Check wiring diagram for link
positions, connect links correctly.
Realign minimum current.
Mar 24/76
Page 31
i
HOBART
TM-462
TROUBLE CAUSE REMEDY
Qutput of machine Load turns on reactor shorted | Repair or replace reactor.
won't reach mini-
mum rated load
(Cont'd.)
Output current goes | Open circuit in pick-up Replace defective coil.
to maximum regard= | coils
less of current |
setting Wires loose on pick-up coils | Tighten wires.
Pins loose on connectors to | Tighten pins.
drawer or SCR Gater
SCR Gater defective Replace SCR Gater.
Page 32 Mar 24/76
HOBART
E
PL-462
Parts List
EQUIPMENT IDENTIFICATION - An identification plate on the unit's control panel shows
its model number, serial number, and specification number. Whenever ordering parts or
making inquiries, furnish all these numbers.
NOTE: A "specification number" 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 rela-
tionships as indicated in the following example.
Nomenclature Units
Fig. Нет Pari per Application
No. No. No. 1234567 Assembly Code
I~ 123456 Assembly (not shown) 1
1 234567 . Adetail of assembly ]
2 345678 . A sub-assembly 1
3 456789 . . À detail of sub-assembly
(Item 2) I
4 567891 ; » A sub-assembly of Item 2 | ]
5 678910 . « « Adefail of sub~assembly
(ltem 4) 1
Locate the specification number below that appears on your unit, and note the "APPLICATION
CODE" letter adjacent to it.
Specification No, Application Code Specification No. Application Code
5159D-1 A 5289D-1 J
5159D-2 B 5289D-2 K
5159D-3 C 5289D-3 L
5159D-4 D 5289D-4 M
5283D-1 Е 5301D-1 N
5283D-2 F 5301-2 O
5283D-3 G 5301D-3 P
5283D-4 H 5301D-4 R
After locating the desired part in the following figures and parts lists, if the "Application
Code" column says "Alt", proceed to order the part. If there are several part numbers after
the same "lem No.", order only the part number corresponding to the "Application Code"
letter thai you selected above.
Mar 15/76 | | Page 1
|
Front Bottom Panel |
Figure 1
Page 2 Mar 15/76
Fig. Нет Part.
1- 364097-1
364097-2
364089
402658
W-11166-2
402151
W-10502-17
402670
370851
370447
W-11100-3
10 W-11242-12
11 362677
12 W-11254-8
13 W-11100-5
“O CO “Y O UN ДБ ©) ВО =
14 W-11278-1
15 50W-974
ló W-9746-8
17 402480-3
18 362862
19 W-2974-C
20 AAW-3981
21 16D A-3493
- 361048
- 363201
22 402882-1
23 402882-2
24 1W-10892-1
362314-1
25 8RI-697A-2
26 W-10931-3
27 8RT-701
28 W-10933-3
29 363986
30 8RT-697A-1
31 A-25
32 362086
33 6FW-5651
362869-3
34 351316
Jan 2078 Revised
HOBART
i
Nomenclature
1234567
Panel = Front Botiom
Panel - Front Bottom
. Panel - Front
. Holder ~ Fuse
. Fuse - 5 Amp.
. Holder = Fuse
. Fuse
. Receptacle
. Adapter = Water, Left Hand
. Adapter - Gas, Right Hand
. Screw = 1/2-13 x 1-1/4 HHC ST.
. Washer = 1/2 FL. ST.
. Board - Terminal
. Washer - 1/2 LK. ST.
. Screw - 1/2-13 x 1-3/4 HHC. ST.
. Nut = 1/2-13 Hex ST.
. Bus = Stud Cable
. Resistor
. Block - Terminal
. Label - Terminal Strip
. Resistor - Variable, Ohmite
. Bracket - Mig.
. Washer = Insulating
. Transformer = Current
. Shunt = Current
. Valve = Solenoid, Wafer
. Valve ~ Solenoid, Gas
. Elbow = Street, 90° Brass
» Rectifier - Output Silicon Assy
. Heat Sink = Rect.
. Diode = Positive
. . Plate - Mig.
. Diode = Negative |
. Suppressor = Surge Assy
. » Heat Sink - Rect.
. « Washer — Rocker Am
Bracket = Mounting
. « Bushing - Insulating
. Switch = Polarity (for Replacement,
Switch only, Less bus bars, Creer
362869-1)
.» Plate - Rear
PL-462
Units
per
Application
Assembly Code
I
]
1
2
2
1
I
1
2
2
2
6
2
4
2
2
2
]
I
1
2
2
]
]
1
1
||
4
1
1
2
2
2
1
1
8
2
4
ACE GJLNP
BD FHKMOR
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
BDFHKMOR
BDFHKMOR
All
All
All
Ali
All
Ali
All
All
All
All
All
All
All
All
All
HOBART
E
PL-462
Page 4 Mar 15/76
E
ПТ
PL-462
Nomenclature Units
Figo Item Part per Application
No. No. No. 1234567 Assembly Code
1- 35 366798 . . Contact Set (2 Contacts and 1 Spring) 6 sets Ali
36 | Deleted
37 3665687 - . . Hub - Driving ] All
38 Sw-215-8 . « Ring = Contact, Rear 1 All
39 SW-215-2 . « Ring = Contact, Front 1 All
40 366588 . . Plate - Front ] AH
41 AW-459 . » Catch = Friction Ball ] All
42 362952 . . Bar - Bus ] Ali
43 361402 . . Bar = Bus ] All
44 361400 . Bar - Bus 2 All
45 362726 Handle - Switch 1 Ali
46 363095-3 . Bar - Bus ] All
47 360255-16 . Sleeving - Fiberglass 2 Ali
- 362868 . Label - Terminal 1 BDFHKMOR
- 402480-1 » Block - feminal 1 BDFHKMOR
364099 » Switch - Range :- 1 All
48 364098 . . Plate = Rear ] All
49 SW-215-2 . . Ring - Contact ] All
50 AW-459 ‚+ Catch = Friction Ball 1 All
51 SW-260 . . Plate - Front 1 Ali
52 366798 . . Contact Set (2 Contacts and 1 Spring) 3 sets All
53 HF-2514 ‚ « Switch - Micro 2 All
54 363676-1 . o Resistor = 75 OHMS, 10 Watt ] All
55 363672 | . + opacer - Switch 4 All
56 363676-2 . Resistor = 50 OHMS, 10 Watt ] All
57 361768 . Bushing — Spacer 1 All
58 403990 . Actuator - Sw. ] All
59 361415 . Shafi - Actuator 1 All
60 362726 . Handle - Sw, ] All
61 Deleted
62 364101 . Bar - Bus ] All
- W-9407-91 . Cable - *2 Assy | All
- W-9760-83 . Cable = 76 Assy 1 All
- . W-9760-84 . Cable - 76 Assy 1 All
- W-9360-221 » Cable - 1/0 Assy 1 ~All
63 362953 . Bar - Bus 1 All
- W-9760-112 . Cable - #6 Assy 1 All
- 364915 . Bar = Bus ] All
- 404040-1 Nameplate - Ident. 1 Ali
64 402128-10 Protector — Plastic 4 All
- 8RT-323 Insert = Barbed 2 NOPR
- BRT-324 Nut - Water ] NO PR
- 8RT~325 Nut - Gas ] NOPR
= Not Illustrated
Jan. n 20/81 . Revised
me AA Page 5
al PN
E
PL-462
Front Meter Panel Group
Figure 2
Page 6 Mar 15/76
Fig + iiem Part
No. No.
=
ТО) —
o “LO сл + со
10
11
12
13
14
15
16
17
18
Mar 15/76
No.
362989
362598
362633
40445 1-1
404449-1
404447-1
404445-1
362600
400382
362758
402219
362685
AAW-835A
363118
400248
AAW-835 A
362630
401428-1
403050-1
16D A-2177-4
W-9712-8
Revised Aug 23/78
HOBART
E
Nomenclature
1234567
Spacer - Front Panel
Panel - Front, Meter
Panel - Front, Meter
. Meter - D.C. Volt, 0-T00V
. Meter - D.C. Ammeter, 0-400 Amp.
. Meter - A.C. Volt, 0-100V
.- Meter - A.C. Ammetier, 0-400 Amp.
. Panel - Meter
. Capacitor
Panel = High Frequency Adj.
. Rheostat
. Panel = Front
. Knob = Rheostat
— Panel - High Frequency Adj.
. Knob
. Knob = Rheostat
. Pane! - Front Arc Booster
. Fotentiometer
. Switch
. Rheostat
. Rheostat
]
1
1
1
]
1
1
]
2
1
I
uu
1
1
2
1
1
1
Î
1
]
PL-462
Units
per
Assembly
Application
Code
All
ACE GJLNP
BDFHKMOR
BD FHKMOR
BDFHKMOR
BDFHKMOR
BDFHKMOR
BDFHKMOR
BDFHKMOR
ABEFJKNO
ABEFJKNO
ABEFJKNO
ABE FJKNO
CD GHLMPR
CD GHLMPR
CD GHLMPR
CDGHLMPR
CD GHLMPR
CD GHLMPR
CD GHLMPR
CD GHLMPR
Page 7
—
нии Loti
Lifting Yoke Assembly
Figure 3
Page 8 Mar 15/76
Fig. -ltem Part.
3- I 365048
2 402037-23
3 404377
| 362907
4 362979
5 400706
6 401943-1
7 STRY-63-2
3 363573
9 402807
1 402799-3
12 402833-3
13 363056
14 363000
15 400891-1
16 400891-2
17 Y-1890-3
18 8IW-130
362608-1
362608-2
362608-3
362608-4
19 362609
- 366046
20 404274-1
21 366041
- 1CZ-188-0
- 363134-2
22 361899
23 402677
24 361897
25 361896
- 363094-1
- 363094-2
26 361900
27 2361895
28 W-11287-2
29 W-11110-5
30 361901
31 405171
- 363161
32 W-9552-14
July 15/91 Revised
HOBART
E
Nomenclature
1
234567
Yoke - Lifting Assy
Grommet - Rubber
Contactor - Line
Heat Sink = Assy
+
Heat Sink
. Lug - Terminal
. Capacitor - .022 MFD 600V
. Strip - Terminal
. Capacitor - 100 WY D.C., .047 MFD
. Label - Terminal Strip
. Strip = Terminal , 5 Station
‚ 5.С.К. = Westinghouse, 25 I|.D.
» Diode = 410 D.R.
. Heat Sink
. Heat Sink
. Bushing - Nylon
. Bushing = Nylon
C
Amp Trap = 110 Amp.
apacitor - P.F.
Board - Overload, Assy
Board = Overload, Assy
Board = Overload, Assy
Board = Overload, Assy
©
>
o
©
2
Board ~ Terminal
Bracket = Mig. Assy
. Capacitor = Across Line
. Bracket ~ Mig.
. Teminal = Seider
Lead - Connecting
Bracket - Lefi
Switch - Micro
Bar - Actuating
Bracket - Right
Le ad
Lei
. Bracket - Overload Panel
. Insulator
. Nut - 6-32 x 5/8 Rd. Hd. MH. St.
. Screw - F6-32 x 5/8 Rd. Hd. MH. St.
. Block = Drilling
. Block - Terminal , 15 Station
. Bar - Bus
. Rod - Threaded
PL-462
Units
per
Application
Assembly Code
AND e e nl al ей mol ya mad mt met №) e e a o == == == ое № № nd == К) = == № № PY > = == № =!
All
Ali
Ali
All
AH
All
All
Ali
Ali
All
All
All
All
All
Ali
All
All
All
All
ABCD
EFCH
JKLM
NOPR
A
All
All
All
All
All
All
All
АН
All
All
All
All
All
Ali
All
Ali
All
ABCDEFGHJKLM
All
Page 9
HOBART
i
PL-462
Page 10 Mar 15/76
Ш
HOBART
PL-462
Nore nc lature Units
Fig. Item Part | per Application
No, No. No. 1234567 Assembly Code
3- 403019 . Label - Terminal Strip 1 ABCD
403021 . Label - Terminal Strip 1 EFGH
403020 . Label - Terminal Strip 1 JKLM
403078 . Label = Terminal Strip I NOPR
33 W-11281-3 . Nut - Brass 28 ABCD
W-11281-3 . Nut ~ Brass 36 EFGHJKL
MN OPR
- W-9552-1 . Rod - Threaded 4 ABCD
- W=9552-1 . Rod = Threaded 6 EFGHJKL
MN OPR
34 430534 Element - Heat, L, H. 1 All
430535 Element - Heat, R, H. ] All
~ 363161 Link - Change over 2 ABCDE FGH
| J KLM
- 363212 Cable - Change over 2 - NOPR
- Not Illusirated
Mar 15/76 | Page 11
July 14/76 Revised
—
C |
PL-462
High Frequency Panel
Figure 4
Page 12 Mar 15/76
Fig. ltem Part
No. No.
Or AWN —
27
28
29
30
31
No.
362735-1
362735-2
402801
402480-1
400078
W-2974-E
AATW-140-1
AATW-140-5
402802
402879
362909
FTW-328-0
8RT-654
401427-2
W-9026-10
363988
FTW-413
FTW-410-
FTW-411
FIW-412
FIW-415
362703
362734
364899
362742
W-11114-6
W-11280-2
W-11254-4
W-11242-5
W-11160-2
362704
363386
355224-16
362957.
362958
360255-2
12CW-600
- Not Illustrated
Mar 15/76
HOBART
i
Nomenclature
1234567
Panel - High Frequency, Assy
Panel - High Frequency, Assy
, Nameplate - Terminal
. Strip - Terminal
. Bracket - Mig.
. Resistor
. Transformer
. Transformer
. Capacitor
. Clamp ~- Capacitor
. Resistor
. Capacitor
. Washer = Rubber Cushioning
. Capacitor
. Resistor
. Bracket - Mig. Assy
. Spark Gap = Assy
. . Electrode - End
. . Electrode - Center
. . Bose
. . Strap
. Board - Mig. Coil
. Panel = High Freq.
. Resistor = 200 OHM, 10W
. Washer = #8 Flat Brass
. Coil = High Freq.
. Screw ~ 1/4-20 x 1-1/2 RHMS
. . Nut = 1/4-20 Hex Jam Steel
. « Washer = 1/4 lock Steel —
. Washer = 1/4 Flat Steel
. . Washer = 1/4 lock ET
. Board - Insulating Coil
. Coil = High Frequency Sub-Assy: 27°
o. . Insulation = Coil a
. . Coil - High Freq., Qutside-
. « +» Coil = High Freq., Inside
. . . Sleeving = Fiberglass
Spacer
PL-462
Units
per Application
Assembly
Code
ABE FJK
NO
All
Ali
Ali
All
ABEFJK
NO
All
All
All
All
All
All
All
All
Ali
AH
AH
AH
All
All
All
All
All
All
Ali
AH
All
All
Ali
All
All
All
All
All
All
All
Page 13
||
[| PL-462
High Freq uency Panel
Figure 5
Page 14 Mar 15/76
Fig. item
No. No.
5-
SO CO NN O UN 2 CS NS —
29
30
31
32
33
34
35
36
Mar 15/76
Part
No 5
3626411
36264 1-2
362699
W-9026-11
401943-1
W-9026-1
401429-3
W-9714-1
1CZ-938B
TRY-174-3
8TRY-63-7
W-9714-25
362533
402801
402480- 1
16D A-4004 A-8
402480-3
402810-1
TRY-154-1
403006
362636
363113
W-2974-E
AATW-140-1
AATW-140-5
FIW-328=0
404065-1
361374-3
362703
362700
362695
16D A-4052-0
160 А-4052-1
FTW-413
FTW-410
FTW-411
FIW-412
FTW-415
362742
W-11114-6
W-11280-2
W-11254-4
W-11242-5
HOBART
И
Nomenclature
1234567
Panel - High Frequency Assy
Panel = High Frequency Assy
. Panel
. Resistor
. Capacitor
. Resistor
. Zener = 51V, 1 Watt
. Resistor
. Diode
. Clamp = Capacitor
. lerminal = 8 Station
. Resistor
. Timer - Assy )
. Label - Terminal Strip
. Block - Terminal
Relay
. Block - Teminal
e Re lay |
. Capacitor
. Label - Terminal
. Transformer - Assy
. Choke - Filter Assy..
. Resistor = Variable
. Transformer
Transformer
. Capacitor - Mica
. Rectifier = Silicon
. Reactor
. Board = Insulating Coil
. Bracket = Mig. Socket Assy
. . Bracket - Mig.
. . Socket
‚ . Socket
» Spark-Gap - Assy
. « Electrode - End
. Electrode - Center
. . Base
s . Strip
. Coil - High Frequency Assy
. « Screw = 1/4~20 x 1-1/2 RHMS
. o Nut = 1/4-20 Hex Jam Steel
. . Washer = 1/4 LK. St.
- « Washer = 1/4 Flat Steel
PL-462 =
Units
per
Application
Assembly Code
I
Î
I
Î
1
]
Î
I
1
1
3
I
I
I
I
I
1
1
]
]
1
]
1
||
]
1
2
1
1
1
1
2
1
1
2
!
1
I
1
4
8
8
4
CDGHLM
PR
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
CDGHLM
PR.
All
All
All
All
All
Ali
All
All
All
All
All
All
All
All
All
All
All
All
Page 15
HOBART
Ш
РЕ-462
Раде 16 Mar 15/76
Fig. Нет
No. No.
5 -
37
38
39
40
4]
42
43
44
Bart
No.
W-11160-2
362704
363386
355224-16
362937
362958
360255-2
8R1-654
365929
362909
- Nor Illustrated
Mar 15/76
HOBART
E
Nomenclature
1234567
. . Washer - 1/4 Lock ТЕТ.
. . Board - Insulating Coil
o» Coil - High Frequency Sub-Assyr
. . . Insulation - Coil
. . . Coil - High Frequency, Outside
.‚ » « Coil = High Frequency, Inside
. . . Sleeving = Fiberglass
. Washer = Rubber
. Capacitor ~ Assy
. Resistor = Assy
PL-462
Units
per
Assembly
mtd PO NY —= == == == me А.
Application
Code
All
All
All
All
All
All
All
All
All
All
Page 17
—
A
— NN
win.
Frame and Transformer Group
Figure 6
Page 18 Mar 15/76
Fig. Нет
No. No.
Qi AR OO —
00 “1 ©
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Mar 15/76
Part
No.
365050
363690
12TW-5%0
8RT-609
12TW=595-1
8 RT-300
8RT-299
8RT-302
8RT~296
363044
363121
AAW-2628
363112-1
AAW-2212
363361
363112-2
363066
362561
362642
363906
363915
363921
363914
362564
363226
362579
362982
362963
12CW-2170
362814
365042
365043
365046
365051
372100
362725
363504
363502
365056
W-10051-10
W-10051-4
365045
HOBART
i
Nomenclature
1234567
Panel - Rear
Shroud - Fan
Bracket - Mig. Fan
Fan
Motor = Fan
Connector — Strain Relief
. Insulator = Hole
. Clamp
. Bracket
Resistor = Ballast, Assy
. Coil
. Insulaior = Porcelain
. Brace - Mig.
. Support - Center
. Bar - Mounting
. Brace - Mounting
Fransformer - Control
Transformer - Control
Transtormer = Control
Transformer - Control
Transformer = Welding
Transformer - Welding
Transformer = Welding
sransformer - Welding
Reactor - Welding
Reactor = Welding
Choke - Filter
Support - Meter Panel
Support = Panel, Lower Front
Grommet - Lifting Yoke
Cover - Side Panel
Side - Left Assy
Side - Right Assy
Panel - Side, Lefi
Panel - Top
Leg - Handle
Guard - Frame Front
Guide = Drawer
Slide = Drawer
Support = Drawer
Clamp - Cable
Clamp - Cable
Panel - Side Right
per
PL-462
Units
Assembly
Application
Code
wal
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
ABCD
o - ==
DIA
rh is? А; те Гб
NO PR
ABCD"
EFGH
JKLM
NOPR
ABCDEFGHJKLM
NOPR
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
Page 19
HOBART
i
PL-462
Page 20 Mar 15/76
Fig. Item
No. No.
6- 34
35
36
Part
No.
362972
363585
365027
360384
403599
12RT~493
403821-1
40089 1-1
400891-2
- Not ltlustrated
Mar 15/76
E HOBART
i
Nomenclature
1234567
Bracket - Mig. Trans.
Coil - Pickup
Base
Insulator
Label = Cyber Tig
Mount = Clamp
Clamp - Lead
Bushing = Plastic
Bushing = Plastic
PL-462
Units
per
Assembly
PO ВО ВО SY NO ro № =
Application
Code
All
All
All
Ali
All
CA
All
All
All
Page 21
Diagrams
HOBART
i
TM-462
1. Note the model and specification number shown on the equipment nameplate.
2. Locate these numbers in the model and specification number columns below.
3. Use only these diagrams and instructions that are applicable. See following pages.
Arc Booster Voltage Front Panel
Model Spec. Connection Schematic | Changeover | Connection Outline
No. No. Diagram Diagram Diagram Diagram Dimension
CT-300 | 5159D-1 | 364104 366443 364103 366714
AC/DC | 51590-2 | 364104 366443 364103 366714
51590 -3 | 363183 363164 366443 364103 366714
51590 -4 | 363183 363164 366443 364103 366714
5283D-1 364104 366444 364103 366714
5283D-2 | 364104 366444 364103 366714
5283D-3 | 363183 363164 366444 364103 366714
5283D-4 | 363183 363164 366444 364103 366714
5289D-1 | 364104 366445 364103 366714
5289D-2 | 364104 366445 364103 366714
5289D-3 | 363183 363164 366445 364103 366714
5289D 4 | 363183 363164 366445 364103 366714
5301D-1 | 364104 366446 364103 366714
5301D-2 | 364104 366446 364103 366714
5301D-3 | 363183 363164 366446 364103 366714
5301D-4 | 363183 363164 366446 364103 366714
NOTE: See Programmer instruction manual for
the power source schematic diagram.
Mar 24/76
Revised Jan 20/78
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ATTENTION!!!
PLEASE FILL OUT AND RETURN THE
WELDER REGISTRATION CARD BELOW.
Cut Along Dotted Line
PER
|
| / | NO POSTAGE
NECESSARY
IF
BUSINESS REPLY MAIL
E
. I
: | FIRST CLASS MAIL PERMIT NO. 12 TRQY, OHIO ро
IR
I.
POSTAGE WILL BE PAID BY ADDRESSEE
Hobart Brothers Company
600 West Main Street
Troy, Ohio 45373-9933
Dobretelatraoktiton abra rbotertebaoce llo Dorlaoh
HOBART BROTHERS CO, —
WELDER REGISTRATION CARD
Serial No.
Owner's Name
Address
City State
Date Received in Satisfactory Order?
Obtained From:
IMPORTANT!
Factory |
Fill out at once
Dealer or Distributor |
in ink and return to Hobart
Brothers, Immediate return of this card registers warranty date.
425141
®
“POWER PROTECTION”
3 YEAR WARRANTY
1. General: Hobart's products are warranted for three (3) years following date of shipment to the original user with the exceptions of
items listed in paragraphs 2 through 8.
2. Parts and Labor For: Motor driven guns; High frequency/Capacitor Discharge units; Running gears/T railers; Field optons,
are warranted for one (1) year.
3. Expendable tems: Primary and secondary switch contacts, cable connectors, carbon brushes, fuses, bulbs, filters, nozzies,
contact fips, liners, cutting tips and wire feed rolls are worn or consumed in the normal process of welding or cutting and are there-
fore warranted only if found to be detective prior 10 use.
4. Replacement parts: Replacement and exchange parts are warranted for the rernainder of the original equipment warranty or for
a period of ninety (90) days, whichever is greater,
5. Semiautomatic Bems: Mig welding guns and cables and plasma cutting torches, tig torches and cables and remote controls
and accessory Kits are warranted for ninety (90) days.
6. Engines, Tires, and Batteries: Hobart does not wamant items furnished by Hobart but manufactured by otners, including with-
out limitation, gasoline or diesel engines, engine electrical equipment, batteries, and tres. Such items are werranted direciy Dy the
manufacturer, and Hobart may periodically inform customers of such warranty coverage; however, Hobart does not guarantee the
accuracy or completeness of its information regarding such wananties.
7. Exclusive Remedies: In case of Hobart's breach of warranty or any other duty with respect © the quality of any product or serv-
ice, the sole and exclusive remedies therefore shall be:
Asto PRODUCTS, (1) reparr, (2) replacement, or (3) where authorized by Hobart, payment of or credit for the purchase price (less
reasonable depreciation based on its actual use) upon retum of the product, and as to SERVICES (including repair under war-
rary), the sole and exciusive remedies therefore shall be payment or credit for Hobart's actual charge therefore or, in the absence
of any actual charge, the customary of reasonable charge for such services, and if such breach also involves impairment of Hobart
products, the remedies available for breach of warranty with respect to the product.
8. Modification and Misuse: This warranty does not apply to products which have been modified in any way by ary party other
than Hobart: nor fo products which have not been instalied and operated in accordance with applicable industry standards; nor to
products which have been used other than under the usual conditions for which designed; nor to products that have not received
proper care, jubrication, protection, and maintenance under supervision Of competent personnel. Use of a product after discovery of
a defect voids all warranties.
DISCLAIMER OF WARRANTIES
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF, EXCEPT AS SPECIFI-
. CALLY PROVIDED IN THE EXPRESSED WARRANTIES SET FORTH ABOVE, ALL PRODUCTS ARE SOLD “AS IS”. HOBART
MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
WARNING
At all times, safety is an important consideration in the installation, servicing, and operation of the
product, and skilled, qualified technical assistance should be utilized at all times. Specific recom-
mendations are included in “Safety in Welding and Cutting”, American National Standard No. Z-49-1.
Hobart Brothers Company October 1989
Troy, Ohio 45373 U.S.A. 910516
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