HobartWelders CYBERTIG 250 Owner Manual

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www.HobartWelders.com

OM-359

March 2001

Processes

TIG (GTAW) Welding

196 831A

Stick (SMAW) Welding

Description

Arc Welding Power Source

R

CYBERTIG 250

And Non-CE Models

From Hobart to You

Thank you and congratulations on choosing Hobart.

Now you can get the job done and get it done right.

We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation

Hobart is registered to the

ISO 9001 Quality System

Standard.

quick and easy. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical

Manual which provides more detailed service and parts information for your unit. To obtain a Technical

Manual, contact your local distributor. Your distributor can also supply you with

Welding Process Manuals such as SMAW, GTAW,

GMAW, and GMAW-P.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the

State of California to cause birth defects and, in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

The following terms are used interchangeably throughout this manual:

TIG = GTAW

Stick = SMAW

TABLE OF CONTENTS

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

1-1.

Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2.

Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3.

Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . .

1-4.

Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5.

EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .

1-1.

Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2.

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

1-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4.

Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5.

Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1.

Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2.

Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

9

10

1

1

1

3

5

5

5

3

4

7

8

8

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

3-1.

Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2.

Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4.

Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5.

Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6.

Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7.

Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8.

Automation 10-Pin Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9.

Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . .

3-10. TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)

3-12. Front Panel Display For TIG AC

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

3-15. Front Panel Display For Stick AC

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17. Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

20

23

16

17

17

12

14

14

11

11

12

15

15

24

26

28

29

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

4-1.

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2.

Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3.

Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4.

Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5.

Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6.

4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional

. . . . Sequence Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7.

Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8.

Selecting TIG Starting Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9.

Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Balance/DIG Control

4-13. Preflow Time Control

4-14. Postflow Time Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Pulse Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. High Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-18. Initial Time Control And Initial Amperage Control

4-19. Final Slope Control And Final Amperage Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

30

32

32

32

34

44

46

48

42

43

43

36

38

40

49

50

50

51

52

(Continued)

TABLE OF CONTENTS

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

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

4-22. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

53

54

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

5-1.

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2.

Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3.

Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4.

Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

56

56

57

58

59

SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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

7-1.

Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2.

Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3.

Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

62

62

63

SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR

AC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

8-1.

Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 64

8-2.

Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1.

Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2.

Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3.

Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

66

67

68

SECTION 10 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

OPTIONS AND ACCESSORIES

WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_4/98

1-1.

Symbol Usage

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

Y

Marks a special safety message.

.

Means “Note”; not safety related.

1-2.

Arc Welding Hazards

Y

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

Safety Standards.

Y

Only qualified persons should install, operate, maintain, and repair this unit.

Y

During operation, keep everybody, especially children, away.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

D

If earth grounding of the workpiece is required, ground it directly with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

D

Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

D

Do not connect more than one electrode or work cable to any single weld output terminal.

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

D

Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

D

Do not touch live electrical parts.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

D

Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on unit.

D

Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install and ground this equipment according to its

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

D

Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D

When making input connections, attach proper grounding conductor first – double-check connections.

D

Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or poorly spliced cables.

D

Do not drape cables over your body.

FUMES AND GASES can be hazardous.

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

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

D

If ventilation is poor, use an approved air-supplied respirator.

D

Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D

Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D

Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D

Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-359 Page 1

ARC RAYS can burn eyes and skin.

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

D

Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D

Wear approved safety glasses with side shields under your helmet.

D

Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

D

Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D

Protect yourself and others from flying sparks and hot metal.

D

Do not weld where flying sparks can strike flammable material.

D

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

D

Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

D

Watch for fire, and keep a fire extinguisher nearby.

D

Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

D

Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D

Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

D

Do not use welder to thaw frozen pipes.

D

Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

D

Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

D

Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

FLYING METAL can injure eyes.

D

Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

D

Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D

Shut off shielding gas supply when not in use.

D

Always ventilate confined spaces or use approved air-supplied respirator.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on gun or torch.

MAGNETIC FIELDS can affect pacemakers.

D

Pacemaker wearers keep away.

D

Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D

Wear approved ear protection if noise level is high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D

Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.

D

Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

D

Keep cylinders away from any welding or other electrical circuits.

D

Never drape a welding torch over a gas cylinder.

D

Never allow a welding electrode to touch any cylinder.

D

Never weld on a pressurized cylinder – explosion will result.

D

Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve.

D

Keep protective cap in place over valve except when cylinder is in use or connected for use.

D

Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-359 Page 2

1-3.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D

Do not install or place unit on, over, or near combustible surfaces.

D

Do not install unit near flammables.

D

Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.

MOVING PARTS can cause injury.

D

Keep away from moving parts such as fans.

D

Keep all doors, panels, covers, and guards closed and securely in place.

FALLING UNIT can cause injury.

D

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

D

Use equipment of adequate capacity to lift and support unit.

D

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D

Allow cooling period; follow rated duty cycle.

D

Reduce current or reduce duty cycle before starting to weld again.

D

Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D

Put on grounded wrist strap BEFORE handling boards or parts.

D

Use proper static-proof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can cause injury.

D

Keep away from moving parts.

D

Keep away from pinch points such as drive rolls.

H.F. RADIATION can cause interference.

D

High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

D

Have only qualified persons familiar with electronic equipment perform this installation.

D

The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

D

If notified by the FCC about interference, stop using the equipment at once.

D

Have the installation regularly checked and maintained.

D

Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

D

Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D

Be sure all equipment in the welding area is electromagnetically compatible.

D

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

D

Locate welding operation 100 meters from any sensitive electronic equipment.

D

Be sure this welding machine is installed and grounded according to this manual.

D

If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

WELDING WIRE can cause injury.

D

Do not press gun trigger until instructed to do so.

D

Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

1-4.

Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

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

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

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

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-359 Page 3

1-5.

EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1.

Keep cables close together by twisting or taping them.

2.

Arrange cables to one side and away from the operator.

3.

Do not coil or drape cables around your body.

4.

Keep welding power source and cables as far away from operator as practical.

5.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-359 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1.

Signification des symboles

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

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN

MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour

éviter tout danger.

Y

Identifie un message de sécurité particulier.

.

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

1-2.

Dangers relatifs au soudage à l’arc

Y

Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées

à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

Y

L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.

Y

Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

D

Ne jamais toucher les pièces électriques sous tension.

D

Porter des gants et des vêtements de protection secs ne comportant pas de trous.

D

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

D

Ne pas se servir de source électrique àcourant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.

D

Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande.

D

Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

D

Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D

Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D

Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée

à une prise correctement mise à la terre.

D

En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.

D

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

D

Mettre l’appareil hors tension quand on ne l’utilise pas.

D

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.

D

Ne pas enrouler les câbles autour du corps.

D

Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.

D

Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

D

N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément

à ce manuel.

D

Porter un harnais de sécurité quand on travaille en hauteur.

D

Maintenir solidement en place tous les panneaux et capots.

D

Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D

Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

D

Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

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

D

Eloigner votre tête des fumées. Ne pas respirer les fumées.

D

A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

D

Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.

D

Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D

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

D

Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D

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

OM-359 Page 5

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

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

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau.

Des étincelles sont projetées pendant le soudage.

D

Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D

Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé.

D

Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

D

Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D

Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.

D

Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

D

Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D

Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

D

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

D

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

D

Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

D

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

D

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

électrode ou couper le fil à la pointe de contact.

D

Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

D

Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.

DES PARTICULES VOLANTES peuvent blesser les yeux.

D

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

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

D

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

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

D

Fermer l’alimentation du gaz protecteur en cas de non utilisation.

D

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D

Ne pas toucher des parties chaudes à mains nues

D

Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D

Porteurs de stimulateur cardiaque, restez à distance.

D

Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

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

D

Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

D

Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

D

Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

D

Ne jamais placer une torche de soudage sur une bouteille à gaz.

D

Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.

D

Ne jamais souder une bouteille pressurisée – risque d’explosion.

D

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.

D

Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.

D

Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

OM-359 Page 6

1-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

D

Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.

D

Ne pas installer l’appareil à proximité de produits inflammables

D

Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D

Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.

D

Utiliser un engin d’une capacité appropriée pour soulever l’appareil.

D

En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D

Prévoir une période de refroidissement, respecter le cycle opératoire nominal.

D

Réduire le courant ou le cycle opératoire avant de recommancer le soudage.

D

Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

D

Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.

D

Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

D

Ne pas s’approcher des organes mobiles.

D

Ne pas s’approcher des points de coincement tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D

Ne pas appuyer sur la gachette avant d’en avoir reçu l’instruction.

D

Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

D

Rester à l’écart des organes mobiles comme le ventilateur.

D

Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer des interférences.

D

Le rayonnement haute frequence peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs.

D

Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

D

L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.

D

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

D

Effectuer régulièrement le contrôle et l’entretien de l’installation.

D

Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

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

D

L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

D

Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.

D

Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

D

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

électronique sensible.

D

Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

D

En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D

Porteurs de stimulateur cardiaque, restez à distance.

D

Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

OM-359 Page 7

1-4.

Principales normes de sécurité

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

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

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

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

33126

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

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5.

Information sur les champs électromagnétiques

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

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.

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

1 Garder les câbles ensembles en les torsadant ou en les attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

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

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

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

Consignes relatives aux stimulateurs cardiaques :

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

OM-359 Page 8

SECTION 2 – DEFINITIONS

2-1.

Warning Label Definitions

1

2

3

4

1.1

2.1

3.1

4.1

+

2.2

1.2

3.2

+

2.3

+

1.3

3.3

Warning! Watch Out! There are possible hazards as shown by the symbols.

1 Electric shock from welding electrode or wiring can kill.

1.1 Wear dry insulating gloves.

Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion or fire.

3.1 Keep flammables away from welding. Don’t weld near flammables.

3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it.

3.3 Do not weld on drums or any closed containers.

4 Arc rays can burn eyes and injure skin.

4.1 Wear hat and safety glasses.

Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

5 Become trained and read the instructions before working on the machine or welding.

6 Do not remove or paint over

(cover) the label.

5 6

+

S-176 254-A

OM-359 Page 9

2-2.

Symbols And Definitions

NOTE

Some symbols are found only on CE products.

A

Amperes

V

Volts

Output

Protective Earth

(Ground)

Postflow Timer

Panel–Local

Do Not Switch

While Welding

Circuit Breaker

Gas Tungsten Arc

Welding (GTAW)

Arc Force (DIG)

Shielded Metal Arc

Welding (SMAW)

Background Amps

Gas (Supply)

Alternating Current

Preflow Timer

Gas Input

Remote

High Frequency -

Start

High Frequency -

Continuous

Gas Output

Temperature

Input

High Frequency

Increase/Decrease

Of Quantity

Direct Current On Off Percent

Balance Control Maximum Cleaning

Maximum

Penetration

Electrode Positive

Electrode

Negative

Final Slope Meter Single-Phase

U

0

I

1

IP

Rated No Load

Voltage (Average)

Primary Current

Degree Of

Protection

U

1

I

2

I

1eff

Primary Voltage

Rated Welding

Current

Maximum Effective

Supply Current

I

U

2

X

1max

Conventional Load

Voltage

Duty Cycle

Rated Maximum

Supply Current

1

1

Line Connection

Single-Phase

Combined AC/DC

Power Source

Hz

Hertz

Work Thickness Gauge Spark Gap Electrode

S

Seconds

Pulse Percent On

Time

Trigger Hold

OM-359 Page 10

Final Amperage

Spot Time

Pulser On-Off

Initial Time

Lift-Arc t

4T

Pulse Frequency

Initial Amperage

4 Step Trigger Operation Sequence

SECTION 3 – INSTALLATION

3-1.

Selecting A Location

Movement

1

OR

2

Y

Falling Unit Can Cause

Injury.

S

Use lifting eye to lift unit only,

NOT running gear, gas cylinders, or any other accessories.

S

Use equipment of adequate capacity to lift and support unit.

S

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to move unit.

If using lifting forks, extend forks beyond opposite side of unit.

3 Rating Label

Use rating label to determine input power needs.

4 Line Disconnect Device

Locate unit near correct input power supply.

Y

Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC

Section 20.

Y

Be careful when placing or moving unit over uneven surfaces.

Location And Airflow

4

1

3

18 in (460 mm)

18 in (460 mm)

Ref. ST-117 264-C / ST-802 455-B

OM-359 Page 11

3-2.

Dimensions And Weights

C

H 8 Holes

A

D

C

B

E

F

Ref. ST-196 584-B

D

E

B

C

Height

Width

Length

A

F

G

H

Dimensions

34 in (864 mm)

22-1/2 in (572 mm)

25 in (635 mm)

25 in (635 mm)

1-25/64 in (35 mm)

1-5/8 in (41 mm)

20-5/8 in (524 mm)

19-15/16 (506 mm)

22-1/4 (565 mm)

1-5/32 in (30 mm)

1/2 in (13 mm) Dia

Weight

389 lbs (176 kg)

3-3.

Specifications

Amperes Input at AC Balanced Rated

Load Output, 60 Hz, Single-Phase

Rated

Welding Output

PFC**

NEMA Class I (40) –

200 Amperes, 28

Volts AC, 60% Duty

Cycle

No

PFC


200 Amperes, 28

Volts AC, 60% Duty

Cycle

NEMA Class II (40) –

250 Amperes, 30

Volts AC, 40% Duty

Cycle

With

PFC

No

PFC


250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling

**Power Factor Correction

With

PFC

200V

88

*3.3

60

*55.3

110

*3.3

82

*55.3

230V

77

*2.8

52

*49.5

96

*2.8

71

*49.5

460V

38

*1.5

26

*24.5

48

*1.5

35

*24.5

575V

31

*1.1

21

*19.6

38

*1.1

28

*19.6

KVA

17.6

*.59

12.06

*11.2

21.98

*.59

16.32

*11.2

KW

8.6

*.29

8.11

*.39

11.76

*.29

11.81

*1.93

Amperage

Range

5 – 310A

5 – 310A

5 – 310A

5 – 310A

Max

OCV

80V

80V

80V

80V

OM-359 Page 12

3-5.

Specifications(continued)


Load Output, 50/60 Hz, Single-Phase

Rated

Welding Output PFC**


200 Amperes, 28

Volts AC, 60% Duty

Cycle

No

PFC


200 Amperes, 28

Volts AC, 60% Duty

Cycle


250 Amperes, 30

Volts AC, 40% Duty

Cycle


250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling


With

PFC

No

PFC

With

PFC

220V

82

*3.0

61

*45.9

100

*3.0

81

*45.9

400V

45

*1.6

34

*25.1

55

*1.6

44

*25.1

440V

41

*1.4

31

*22.8

50

*1.4

40

*22.8

520V

35

*1.2

26

*23.2

42

*1.2

34

*23.2

KVA

17.6

*.59

12.06

*11.2

21.98

*.59

16.32

*11.2

KW

8.6

*.29

8.11

*.39

11.76

*.29

11.81

*1.93

Amperage

Range

5 – 310A

5 – 310A

5 – 310A

5 – 310A

Max

OCV

80V

80V

80V

80V


Load Output, 50 Hz, Single-Phase

Rated

Welding Output PFC**


175 Amperes, 27

Volts AC, 60% Duty

Cycle

No

PFC


175 Amperes, 27

Volts AC, 60% Duty

Cycle

With

PFC


225 Amperes, 29

Volts AC, 40% Duty

Cycle


225 Amperes, 29

Volts AC, 40% Duty

Cycle

*While idling


No

PFC

With

PFC

200V

80

*3.3

52

*55.3

101

*3.3

74

*55.3

230V

69

*2.8

45

*49.5

88

*2.8

64

*49.5

460V

35

*1.5

22

*24.5

44

*1.5

32

*24.5

575V

28

*1.1

18

*19.6

35

*1.1

26

*19.6

KVA

15.9

*.59

10.3

*11.2

20.2

*.59

14.7

*11.2

KW

7.4

*.29

7.3

*.39

10.2

*.29

10.1

*1.93

Amperage

Range

5 – 310A

5 – 310A

5 – 310A

5 – 310A

Max

OCV

80V

80V

80V

80V

OM-359 Page 13

3-4.

Duty Cycle And Overheating

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

If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see

Section 5-4), and cooling fans run.

Wait fifteen minutes for unit to cool.

Reduce amperage or duty cycle before welding.

Y

Exceeding duty cycle can damage unit and void warranty.

40% Duty Cycle At 250 Amperes 60% Duty Cycle At 200 Amperes

4 Minutes Welding

Overheating

3-5.

Volt-Ampere Curves

6 Minutes Resting

0

Minutes

15

6 Minutes Welding

OR

A

Reduce Duty Cycle

4 Minutes Resting duty1 4/95 / SB-116 198

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

ssb1.1 10/91 – 194 385-A / 194 384-A

OM-359 Page 14

3-6.

Weld Output Terminals And Selecting Cable Sizes

Y

ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

Welding

Amperes

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle

100 4 4

10 – 100% Duty Cycle

150

200

250

300

3

3

2

1

3

2

1

1/0

4

2

1

1/0

2/0

3

1

1/0

2/0

3/0

2

1/0

2/0

3/0

4/0

1

2/0

3/0

4/0

2-2/0

1/0

3/0

4/0

2-2/0

2-3/0

Work

Electrode

350

400

1/0

1/0

2/0

2/0

3/0

3/0

4/0

4/0

2-2/0

2-2/0

2-3/0

2-3/0

2-3/0

2-4/0

Ref. ST-801 972

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere

*Select weld cable size for pulsing application at peak amperage value..

3-3/0

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

3-3/0

S-0007-D

3-7.

Remote 14 Receptacle Information

B

A

K

C

L

D

M

N

J

I

G

H

ST-801 972

OUTPUT

CONTACTOR

A

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

GND

Socket*

A

B

C

F

H

K

D

E

Socket Information

Contactor control 24 volts dc.

Contact closure to A completes 24 volts dc contactor control circuit and enables output.

Output to remote control; 0 to +10 volts dc output to remote control.

Remote control/feedback circuit common.

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

Current feedback; +1 volt dc per 100 amperes.

Voltage feedback; +1 volt dc per 10 volts output.

Chassis common.

*The remaining sockets are not used.

OM-359 Page 15

3-8.

Automation 10-Pin Connection (Optional)

Socket

A Start/Stop

Socket Information For 10-Pin Receptacle RC2

G

H

F

A

I

J

E

C

B

B Gas

C

D

E

F

G

H

Output disabled

Chassis ground

Final slope – collector

Final slope – emitter

Pulse lockout – collector

Pulse lockout – emitter

Ref. ST-801 972

I

J

Valid arc – collector

Valid arc – emitter

Definitions Of Inputs And Outputs

Inputs

A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, but less than 3/4 seconds) starts and stops weld output.

B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initiation.

C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to time out, and

HELP 13 will be displayed on the meters.

Outputs

Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30

VDC.

Final Slope - output is on when in Final Slope.

Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10

Hz.

Arc On - output is on when the contactor is on and there is less than 50 load volts.

OM-359 Page 16

3-9.

Shielding Gas Connections And 115 Volts AC Duplex Receptacle

Tools Needed:

5/8, 3/4, 1-1/8 in

6

5

2

1

4

3

Y

Turn Off power before connecting to receptacle.

1 Gas Valve In Fitting

Located on rear of unit.

2 Gas Valve Out Fitting

Fittings have 5/8-18 right-hand threads.

3 Cylinder Valve

Open valve slightly so gas flow blows dirt from valve. Close valve.

4 Regulator/Flow Gauge

Connect regulator/flow gauge to gas cylinder.

Connect customer supplied gas hose between regulator/flow gauge and gas in fitting.

5 Flow Adjust

Typical flow rate is 20 cfh (cubic feet per hour).

6 115 V 15 Amp AC Receptacle

Receptacle is protected from overload by circuit breaker CB1 (see

Section 5-2).

Front View Rear View

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

3-10. TIG Connections

3

2

4

Tools Needed:

11/16, (21 mm), 3/4 in

5 6

1

1 Gas In Connection

Connect gas hose from gas supply to gas in fitting.

2 Output Selector Switch (See

Section 4-2)

Switch is shown in DCEN (direct current electrode negative) position for TIG HF Impulse DCEN welding.

For front panel control dispay, see

Section 3-11. For TIG AC welding, place switch in AC position (see

Section 4-2). For TIG AC front panel control dispay, see Section 3-12.

3 Work Weld Output Terminal

Connect work lead to work weld output terminal.

4 Remote 14 Receptacle

Connect desired remote control to

Remote 14 receptacle.

5 Electrode Weld Output

Terminal

Connect TIG torch to electrode weld outout terminal.

6 Gas Out Connection

Connect torch gas hose to gas out fitting.

802 734-B

OM-359 Page 17

3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)

1 Front Panel

Correct front panel display for basic

TIG HF Impulse DCEN welding.

.

For all front panel switch pad controls: press switch pad to turn on light and enable function.

NOTE: Green on nameplate indicates a TIG function (see Section

4-1 for description of controls).

1

OM-359 Page 18

CE Models

1

OM-359 Page 19

3-12. Front Panel Display For TIG AC

1 Front Panel


TIG AC welding.

.


NOTE: Green on nameplate indicates a TIG function (see Section

4-1 for description of controls).

1

OM-359 Page 20

CE Models

1

OM-359 Page 21

Notes

OM-359 Page 22

3-13. Stick Connections

Tools Needed:

11/16, (21 mm), 3/4 in

1

4

3

2

1 Work Weld Output Terminal

Connect work lead to work weld output terminal.

2 Electrode Weld Output

Terminal

Connect electrode holder to electrode weld outout terminal.

3 Remote 14 Receptacle

If desired, connect remote control to Remote 14 receptacle.

4 Output Selector Switch (See

Section 4-2)

Switch is shown in DCEP (direct current electrode positive) position for Stick DCEP welding. For front panel control dispay, see Section

3-14. For Stick AC welding, place switch in AC position (see Section

4-2). For Stick AC front panel control dispay, see Section 3-15.

802 733-B

OM-359 Page 23

3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

1 Front Panel


Stick DCEN welding.

.


NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).

1

OM-359 Page 24

CE Models

1

OM-359 Page 25

3-15. Front Panel Display For Stick AC

1 Front Panel


Stick AC welding.

.


NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).

1

OM-359 Page 26

CE Models

1

OM-359 Page 27

3-16. Electrical Service Guide

NOTE

All values in both tables were calculated at 60% duty cycle.

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output

200

88

220

82

Without Power Factor Correction

230

77

400

45

440

41

460

38

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

Normal Operating (Fast) Fuse

3

Min Input Conductor Size In AWG/Kcmil

125

125

4

125

125

6

125

125

6

70

70

8

60

60

8

60

60

10

Max Recommended Input Conductor Length In

Feet (Meters)

167

(51)

137

(42)

153

(47)

305

(93)

369

(112)

281

(86)

Min Grounding Conductor Size In AWG/Kcmil

6 6 6 8 10 10

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

Y

Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

520

35

50

50

10

352

(107)

10

575

31

45

45

10

439

(134)

10

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output

200

60

220

61

With Power Factor Correction

230

52

400

34

440

31

460

26

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

Normal Operating (Fast) Fuse

3

Min Input Conductor Size In AWG/Kcmil

90

90

8

90

90

8

80

80

8

50

50

10

45

45

10

40

40

10

Max Recommended Input Conductor Length In

Feet (Meters)

87 (26)

102

(31)

115

(35)

226

(69)

274

(84)

308

(94)

Min Grounding Conductor Size In AWG/Kcmil

8 8 8 10 10 10

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

Y

Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

520

26

40

40

10

383

(117)

10

575

21

30

30

12

295

(90)

12

OM-359 Page 28

3-17. Placing Jumper Links And Connecting Input Power

2

200 VOLTS

L L

230 VOLTS

L L

230 VOLTS

L L

460 VOLTS

L L

460 VOLTS

L L

S-083 566-C

575 VOLTS

L L

S-010 587-B

Check input voltage available at site.

1 Jumper Link Label

Check label – only one is on unit.

2 Jumper Links

Move jumper links to match input voltage.

3 Input And Grounding

Conductors

Select size and length using Section 3-16.


Select type and size of overcurrent protection using Section 3-16.

Close and secure primary door.

Y

Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC

Section 20.

Connect GND/PE

Conductor First

GND/PE

Earth Ground

1

4

L1 (U)

L2 (V)

3

Connect GND/PE

Conductor First

3/8 in

Tools Needed:

Ref. ST-801 973-B

OM-359 Page 29

SECTION 4 – OPERATION

4-1.

Controls

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

12

1 2 3 4

5

6

7

11

10

13

9

8

14

.

Top row of lights in upper left corner are On for SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function,

Gray indicates a Stick function.

1 Process Control

See Section 4-3.

2 Amperage Control

See Section 4-4.

3 Output Control

See Section 4-5.

4 Start Mode Control

See Section 4-9.

5 Voltmeter

See Section 4-10

6 Ammeter

See Section 4-10

7 Amperage Adjustment

Control

See Section 4-11.

8 Output Selector Switch

See Section 4-2.

9 Power Switch

Use switch to turn unit Off and On.

OM-359 Page 30

10 Postflow Time Control

See Section 4-14.

11 Balance/DIG Control

See Section 4-12.

12 Pulser Controls (Optional)

See Section 4-15.

13 Sequence Controls (Optional)

See Section 4-17.

14 High Frequency Control

See Section 4-16.

Ref. ST-196 616 / Ref. ST-194 388-B / Ref. ST-801 972

B. For CE Units

1 2 3 4

5

6

7

12

11

10

13

9

8

14

.

Top row of lights in upper left corner are On for SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function,

Gray indicates a Stick function.

1 Process Control

See Section 4-3.

2 Amperage Control

See Section 4-4.

3 Output Control

See Section 4-5.

4 Start Mode Control

See Section 4-9.

5 Voltmeter

See Section 4-10

6 Ammeter

See Section 4-10

7 Amperage Adjustment

Control

See Section 4-11.


See Section 4-2.

9 Power Switch

Use switch to turn unit Off and On.


See Section 4-14.


See Section 4-12.

12 Pulser Controls (Optional)

See Section 4-15.

13 Sequence Controls (Optional)

See Section 4-17.


See Section 4-16.

Ref. ST-196 764 / Ref. ST-196 766 / Ref. ST-801 972

OM-359 Page 31

4-2.

Output Selector Switch

1 1

(CE Nameplate)


Y

Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output

ONLY if required for the welding process, and then use a remote control.

Y

Do not change position of switch while welding or while under load.

Use switch to select (DCEN) Direct

Current Electrode Negative, AC, or

(DCEP) Direct Current Electrode

Positive output.

NOTE: Changing position of Output Selector switch may also change Process control, Current control, Output control, and Start

Mode control settings to properly function with latest Output Selector switch setting.

4-3.

Process Control

4-4.

Amperage Control

1

1

1

(CE Nameplate)

(CE Nameplate)

1

1 Process Control

Use control to select Shielded Metal Arc Welding (SMAW) or Gas

Tungsten Arc Welding (GTAW) process.

For SMAW, press button to toggle

LED to Stick position.

For GTAW, press button to toggle

LED to TIG position.

NOTE: Lit LED indicates selected mode.

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

Ref. ST-196 616 / Ref. ST-196 764

1 Amperage Control

Use control to select front panel or remote amperage control.

For front panel amperage control, press button to toggle LED to Panel position.

For remote amperage control, press button to toggle LED to Remote position (see Section 3-7).



OM-359 Page 32

Notes

OM-359 Page 33

4-5.

Output Control

Remote (Standard)Torch Trigger Operation

2

1

2

1

(CE Nameplate)

Current (A)

Preflow

Initial Amps

Push & Hold

Foot Or Finger

Remote Control

Remote (Standard)Torch Trigger Operation

Weld Amps

Final Slope

Release For

Maintained Switch

Final Amps

Postflow

Release Foot Or

Finger Remote

Control

1 Output Control

Y

Weld output terminals are energized when power is On, and Output On LED is lit.

Use control to select front panel, trigger hold, or remote output control.


For weld output, press button to toggle LED to On position.

2 Remote Trigger (Standard) Operation

For remote output control, press button to toggle LED to Remote position (see Section 3-7).

Torch trigger operation is as shown.

NOTE: Initial weld amperage and final amperage is controlled by the remote device, not by the welding power source.

NOTE: If On/Off only type trigger is used, it must be a maintained switch. All functions become active.

Application: Use Remote Trigger when the operator desires to use a foot pedal or finger amperage control.

When Output Selector switch (see Section

4-2) position changes, Output control LED will always switch to Remote.

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

OM-359 Page 34

Trigger Hold (2T)

3 3

(CE Nameplate)

Current (A)

2T Torch Trigger Operation

Weld Amps

Preflow

Initial Amps

Final Slope

Final Amps

Postflow

Push & Release Trigger

In Less Than 3/4 Sec.

Push & Release Trigger

In Less Than 3/4 Sec.

NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page).

If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-4).

3 Trigger Hold

For trigger hold operation, press button to toggle LED to Trigger Hold position.


NOTE: When a foot or finger remote control is connected to the welding power source, only trigger input is functional.

NOTE: Amperage is controlled by the welding power source.

Application: Use Trigger Hold (2T) when long extended welds are made.

Trigger Hold (2T) can help to reduce operator fatigue.

OM-359 Page 35

4-6.

4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional Sequence

Controls)

4T Torch Trigger Operation

If unit is equipped with optional Sequence

Controls (see Section 4-17), 4T trigger method is available.

4T torch trigger operation is as shown.

While in 4T mode, there is a feature available during the main weld sequence that allows the operator to toggle between weld current and final current without breaking the arc.

NOTE: When a remote switch is connected to the welding power source, only trigger input is functional. Amperage is controlled by the welding power source.

Application:

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

Select 4T trigger method according to Section 4-7.

Current (A)

Weld Amps

Final Slope

Initial Amps

Preflow

Final Amps

Postflow

Push & Hold

Trigger

Release

Trigger

Push & Release

Trigger In Less

Than 3/4 Sec.

Push & Release

Trigger In Less

Than 3/4 Sec.

Push & Hold

Trigger

Release

Trigger


Controls (see Section 4-17), 4T Momentary trigger method is available.

4T Momentary torch trigger operation is as shown.

While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break the arc and go to postflow.

4T Momentary Torch Trigger Operation


Application:

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

Select 4T Momentary trigger method according to Section 4-7.

Current (A)

Weld Amps

Preflow

Initial Amps

Final Slope

Final Amps

Postflow

Push & Release

Trigger

Push & Release

Trigger

Push & Release

Trigger

Push & Release

Trigger

OM-359 Page 36


Controls (see Section 4-17), Mini Logic operation is available.


During Mini Logic welding operation, the weld amperage can be manually changed

Mini Logic Operation

from the initial amps level to the main weld amps level by pressing and releasing the torch trigger in less than 3/4 seconds.


Application: This ability to change amperage levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.

Select Mini Logic according to Section 4-7.

Weld Amps

Final Slope

Preflow

Initial Amps

Final Slope

Rate

Push & Hold

Trigger

Push & Hold

Trigger For More

Than 3/4 Sec.

Release Trigger

Push & Release

Trigger In Less

Than 3/4 Sec.

Initial Amps

Push & Release

Trigger In Less

Than 3/4 Sec.

Push & Release

Trigger In Less

Than 3/4 Sec.

Push & Hold

Trigger For More

Than 3/4 Sec.

Postflow

OM-359 Page 37

4-7.

Reconfiguring Trigger Hold For 4T And Mini Logic Control

1 Output Control

2 Power Switch

To reconfigure Trigger Hold, turn Off power, push and hold Output control button and turn On power switch.

Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters display [

SEL

] [

H

–

2

].

Press Output control button to change functions. Active function will be displayed on amperage (bottom) meter.

3 Meter Displays

Meter displays for the different functions will be as shown.

Press torch trigger or turn power Off to save setting.

Proceed to Section 4-6 for 4T Operation.

Proceed to Section 4-6 for Mini Logic operation.

Proceed to Section 4-6 for 4T Momentary operation.

NOTE: These features are only available when optional Sequencer is installed.

1

Front Panel

SEL

H-2

2

SEL

HĆ4E

=

4T Momentary

(See Section 4-6)

SEL

H-4

= 4T

(See Section 4-6)

SEL

H4L

= Mini Logic

(See Section 4-6)

3

OM-359 Page 38

1

(CE Nameplate)

Front Panel

SEL

H-2

2

SEL

HĆ4E

=

4T Momentary

(See Section 4-6)

SEL

H-4

= 4T

(See Section 4-6)

SEL

H4L

= Mini Logic

(See Section 4-6)

3

OM-359 Page 39

4-8.

Selecting TIG Starting Characteristics

1

SEL

-2-

4

2

3

Use this function to select desired TIG starting characteristics.

1 Start Mode

2 Power Switch


4 Meters

To select or change TIG starting characteristics, proceed as follows: turn Off power.

Place Output Selector switch in desired position (each position, DCEN, AC, or DCEP has three applicable start characteristics options). Push and hold Start Mode button and turn On power. Hold button for approximately

7 seconds (or until software version number_

_ _ _ _ _-_ clears meters).

The TIG LED and all four Start LEDs will light, and the meters will display [

SEL

] [

-2-

].

Press Start Mode button again to step through the three start characteristics choices.

Amperage (bottom) meter displays active choice

1

= light start,

2

=medium/normal start,

3

=high/hot start.

Press torch trigger or turn Off power to save setting.

Application:

Select

1

(light/soft start) – when welding at low amperages on thin gauge material.

Select

2

(medium/normal start) – factory default setting used for most welding applications.

Select

3

(high/hot start) – when welding at high amperages on thick materials with a large diameter tungsten.

OM-359 Page 40

(CE Nameplate)

1

SEL

-2-

4

2

3

OM-359 Page 41

4-9.

Start Mode

(CE Nameplate)

1

Lift-Arc t

Start Method

2 3

“Touch”

1 – 2

Seconds

1

Do NOT Strike Like A Match!

1 Start Mode

For SMAW welding, press button to toggle

LED to Off position.

For GTAW welding, use control to select

Off for no HF, Lift-Arc t

, HF for arc starting only, or continuous HF. See Section 4-16 for adjusting high frequency intensity.

Application:

When Off is selected, use the scratch method to start an arc for both the SMAW and GTAW processes.

When Lift-Arc is selected, start arc as follows:

2 TIG Electrode

3 Workpiece

Touch tungsten electrode to workpiece at weld start point, enable output with torch trigger, foot control, or hand control. Hold

electrode to workpiece for 1-2 sec-

onds, and slowly lift electrode. An arc will form when electrode is lifted.

Shielding gas begins to flow when electrode touches work piece.

Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.

The solid state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Application:

Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.

When HF Start is selected, start arc as follows:

High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAW process is required.

When HF Continuous is selected, start arc as follows:

High frequency turns on when output is energized and remains on for duration of weld.

Application:

HF Continuous is used when the AC

GTAW process is required.



NOTE: Some start methods may not be available for all processes.

OM-359 Page 42

4-10. Meters

1

2

1 Voltmeter

Voltmeter displays average voltage

(to the nearest 0.1 V) at the weld output terminals.

2 Ammeter

Use meter to preset amperage. Meter displays average weld amperage output of unit to nearest ampere when welding.

NOTE: Meters are self-calibrating.

No adjustment available.

4-11. Amperage Adjustment Control

1

(CE Nameplate)

1

1 Amperage Adjustment Control

Use control to adjust amperage, and preset amperage on ammeter

(see Section 4-10). This control may be adjusted while welding.

For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.

For pulse welding, use Amperage

Adjust control to select from 5–300 amps of peak amperage (see Section 4-15).

For spot welding, use Amperage

Adjust control to select from 5–300 amps of peak amperage (see Section 4-20).

OM-359 Page 43

4-12. Balance/DIG Control

1

3

Setting

Balanced

More Penetration

10

More Cleaning

0

Balance Control Examples

Output Waveforms

50% Electrode

Positive

50% Electrode

Negative

32% Electrode

Positive

68% Electrode

Negative

55% Electrode

Positive

45% Electrode

Negative

(CE Nameplate)

1

Arc


Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control towards 10 provides deeper penetration. Rotating the control towards

0 provides more cleaning action of the workpiece.

When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.

Application:

When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a

0.10 in (2.5mm) of etched zone along the weld toes is required.

Set control to 7 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting.

NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc.

DIG Control (AC And DC SMAW):

When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage.

When setting is increased, shortcircuit amperage at low arc voltage increases.

Application:

Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding.

Ref. S-0795-A

OM-359 Page 44

Notes

OM-359 Page 45

4-13. Preflow Time Control

1

00.2

SEL

3

2

Use control to set length of time (0.2, 0.4, 0.6,

0.8, 1.0, 2.0 or 4.0 seconds) gas flows before welding starts.

1 Process Control

2 Power Switch

3 Meters

To change preflow time, proceed as follows:

OM-359 Page 46

Turn power off. Push and hold Process Control button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).

The TIG LED will light and the meters will display [ o.2

] [

SEL

]. The factory preflow default setting is 0.2 seconds. To change preflow time, press and release Process Control button until desired time is displayed on meters.

Application:

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

2

1

(CE Nameplate)

00.2

SEL

3

OM-359 Page 47

4-14. Postflow Time Control

1

(CE Nameplate)

1


Use control to set length of time

(0–50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance

(approximately 1 second per 10 ampere of welding current).

OM-359 Page 48

4-15. Pulse Controls (Optional)

1

1

More Time

At Peak

Amperage

More Time At

Background

Amperage

(20%)

(80%)

2

(CE Nameplate)

2

3

3

5

Percent (%) Peak

Time Control Setting

(50%)

Balanced

Pulsed Output Waveforms

PPS

Bkg Amp

Peak Amp

4

4

1 On/Off Control

Use control to turn pulse function

On and Off.

2 Background Amps

Use Background Amps control to set the low pulse of the weld amperage, which cools the weld puddle and affects overall heat input. Background Amps is set as a percentage of peak amperage.

3 Pulse Frequency

Ranges from 0.25–10.0 pps

(pulses per second). Control is used to determine appearance of weld bead.

4 Peak Time

A range of 5–95% of each pulse cycle can be spent at the peak amperage level.

Peak amperage (5–310 amps), is set with the Amperage Adjustment control (see Section 4-1).

Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage.

5 Pulsed Output Waveforms

Example shows affect changing the Peak Time control has on the pulsed output waveform.

Application:

Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.

Pulsing can also be used for filler material addition technique training.

NOTE: Function is enabled, when LED is lit.

OM-359 Page 49

4-16. High Frequency Control

1

Y

Do not use high frequency while Shielded Metal Arc Welding (SMAW).


For GTAW, use control to set HF intensity. Set as low as possible.

Application:

If HF is present at the tungsten, the control is set high enough.

Ref. ST-801 972

NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the HF Intensity control towards maximum, may help to restabilize the arc.

.

As high frequency intensity is increased, the possibility of interfering with local electronic devices, especially communication equipment, also increases. Set control as low as possible to avoid such interference.

4-17. Sequence Controls (Optional)

1

5

3

1 Initial Time Control

See Section 4-18.

2 Initial Amperage Control

See Section 4-18.

3 Final Slope Control

See Section 4-19.

4 Final Amperage Control

See Section 4-19.

5 Spot Time Control

See Section 4-20.

4

2

1

2

OM-359 Page 50

(CE Nameplate)

5

3

4

Ref. ST-196 616 / Ref. ST-196 764

4-18. Initial Time Control And Initial Amperage Control

(CE Nameplate)

1

1

2

2

1 Initial Time Control

Indicator light is on when Initial

Time control function is active.

NOTE: Initial Sequence control function is inactive when Spot Time function is active.

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

2 Initial Amperage Control

Indicator Light is on when Initial Sequence control function is active.

NOTE: Initial Amperage control function is inactive when Spot Time function is active.

Use control to select a starting amperage (5–310 amps) that is different from the weld amperage. Note:

Initial Amperage can be used with or without a remote control (Initial

Amperage and Initial Time control settings will override a remote control device).

Application:

Initial Amperage can be used while

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

NOTE: Function is enabled, when

LED is lit.

OM-359 Page 51

4-19. Final Slope Control And Final Amperage Control

(CE Nameplate)

1

1

2

4-20. Spot Time Control

1

(CE Nameplate)

2

1 Final Slope Control

Indicator light is on when Final

Slope control function is active.

Note: Final Slope control function is inactive when Spot Time function is active.

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

2 Final Amperage Control

Indicator light is on when Final

Amperage control function is active.

Note: Final Amperage control function is inactive when Spot

Time function is active (see Section 4-20).

Final amperage is the amperage to which weld amperage has sloped down to (0–100% of amperage set on Amperage Adjust control).

Application:

Final Slope should be used while

GTAW welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.

Note: This applies if the operator is using an on/off only type control to start and stop the welding process.

Note: Do not use this function with a foot or finger amperage control.

NOTE: Function is enabled, when

LED is lit.

1

1 Spot Time Control

Indicator light is on when Spot

Time function is active. When

Spot Time function is active, Initial Time, Initial Amperage, Final

Slope, and Final Amperage functions are inactive (see Section 4-17).

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

(DCEN) set-up.

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

Use Amperage Adjust control

(see Section 4-11) to set amperage.

Application:

TIG spot welding is used for joining thinner materials that are in close contact with the fusion method. A good example would be joining coil ends.

NOTE: Function is enabled, when LED is lit.

OM-359 Page 52

4-21. Timer/Cycle Counter

1

(CE Nameplate)

2

1 2 3

4 5 6

3

1 2 3

4 5 6

4

1

2

1 Amperage Control

2 Output Control (Contactor)

To read timer/cycle counter, hold Amperage and Output (contactor) buttons while turning on power.

3 Timer Display

The hours and minutes are displayed on the volt and amp meters for the first five seconds, and are read as 1, 234 hours and 56 minutes.

4 Cycle Display

The cycles are displayed on the volt and amp meters for the next five seconds, and are read as 123, 456 cycles.

OM-359 Page 53

4-22. Resetting Unit To Factory Default Settings (All Models)

1

2 3

4

5

1 Process Control

2 Amperage Control

3 Output Control

4 Start Control

OM-359 Page 54

5 Power Switch

To reset all welding power source functions to original factory settings, turn power off.

Push and hold the Process, Amperage,

Output and Start controls and turn On power. Hold switch pads for approximately 7 seconds (or until software version number

_ _ _ _ _ _-_clears meters).

1 2 3

4

CE Models

5

OM-359 Page 55

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1.

Routine Maintenance

Y

Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Repair Or

Replace

Cracked

Weld

Cables

Adjust Spark

Gaps

14-Pin Cord

6 Months

Gas Hose

OR

Blow Out Or Vacuum

Inside,

During Heavy Service,

Clean Monthly

Torch Cable

Clean And

Tighten

Weld

Terminals

Replace

Cracked

Parts

5-2.

Circuit Breaker CB1

1

1 Circuit Breaker CB1

If CB1 opens, high frequency and output to the 115 volts ac duplex receptacle stop. Press button to reset breaker.

Ref. ST-801 972

OM-359 Page 56

5-3.

Adjusting Spark Gaps

4

3

2

1

Tools Needed:

0.012 in (0.305 mm)

5/32 in

Y

Turn Off power before adjusting spark gaps.

Open access door.

1 Tungsten End Of Point

Replace point if tungsten end disappears; do not clean or dress tungsten.

2 Spark Gap

Normal spark gap is 0.012 in (0.305

mm).

If adjustment is needed, proceed as follows:

3 Adjustment Screws

Loosen screws. Place gauge of proper thickness in spark gap.

4 Pressure Point

Apply slight pressure at point until gauge is held firmly in gap. Tighten screws. Adjust other gap.

Reinstall access door.

Ref. ST-801 972 / Ref. S-0043

OM-359 Page 57

5

0

V

HLP

A

--0

V

HLP

A

--5

10

V

HLP

A

-10

5-4.

Voltmeter/Ammeter Help Displays

.

All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.

0 Help

0

Display

Indicates a short in the thermal protection circuitry located on the transformer of the unit.

If this display is shown, contact a Factory Authorized Service Agent.

1 Help

1

Display

An SCR overcurrent condition has occurred.

Turn power off and back on to correct condition. If problem continues, contact a Factory

Authorized Service Agent.

2 Help

2

Display

Indicates a malfunction in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent.

3 Help

3

Display

Indicates the transformer of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled.

4 Help

4

Display

Indicates a malfunction in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

5 Help

5

Display

Indicates the rectifier assembly of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled.

6 Help

6

Display

Not used.

7 Help

7

Display

Not used.

8 Help

8

Display

Not used.

9 Help

9

Display

Indicates a short in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

10 Help

10

Display

Indicates Remote Output control is activated. Release Remote Output control to clear help message.

11 Help

11

Display

Indicates Output Selector switch is not in correct position (see Section 4-2).

12 Help

12

Display

Indicates a non-allowable set-up on the front panel.

13 Help

13

Display

AIC option, output enable signal broken causing weld output to stop, but gas continues to flow.

6

1

V

HLP

A

--1

11

V

HLP

A

-11

V

HLP

A

--6

7

12

2

V

HLP

A

--2

V

HLP

A

--7

V

HLP

A

-12

3

13

8

V

HLP

A

--8

V

HLP

A

--3

V

HLP

A

-13

9

4

V

HLP

A

--4

V

HLP

A

--9

OM-359 Page 58

5-5.

Troubleshooting

NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.

There are no user serviceable parts inside unit.

Refer to Section 5-4 for any Help (

HLP

) message displayed on voltmeter/ammeter.

Trouble Remedy

No weld output; unit completely inoperative.

No weld output; unit on.

Unit provides only maximum or minimum weld output.

Erratic or improper weld output.

No control of weld output.

No output from duplex receptacle RC2 and no high frequency.

Lack of high frequency; difficulty in starting GTAW arc.

Place line disconnect switch in On position (see Section 3-17).

Check and replace line fuse(s), if necessary (see Section 3-17).

Check for proper input power connections (see Section 3-17).

Check for proper jumper link position (see Section 3-17).

If using remote control, place Output control in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output control in On position

(see Section 4-1).

Check, repair, or replace remote control.

Have Factory Authorized Service Agent check unit.

Make sure Amperage control is in proper position (see Section 4-1).

Have Factory Authorized Service Agent check unit.

Use proper size and type of weld cable (see Section 3-6).

Clean and tighten all weld connections.

Check position of Output Selector control (see Section Figure 4-1).

If using remote control, check position of Amperage Adjustment control (see Section 4-1).

If using remote control, place Output control in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output control in On position

(see Section 4-1).

Make sure Amperage control is in proper position (see Section 4-1).

Reset circuit breaker CB1 (see Section 5-2).

Wandering arc – poor control of direction of arc.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

Fan not operating.

Reset circuit breaker CB1 (see Section 5-2).

Select proper size tungsten.

Check High Frequency Intensity control setting (see Figure 4-1).

Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connections. Repair or replace.

Check spark gaps (see Section 5-3).

Reduce gas flow rate.

Select proper size tungsten.

Properly prepare tungsten.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

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

Unit equipped with Fan-On-Demand t

. Fans run only when necessary. Unit equipped with circuitry to protect against overheating.

OM-359 Page 59

SECTION 6 – ELECTRICAL DIAGRAM

OM-359 Page 60

Figure 6-1. Circuit Diagram For Non-CE Models

202 484-A

Figure 6-2. Circuit Diagram For CE Models

194 381-F

OM-359 Page 61

SECTION 7 – HIGH FREQUENCY

7-1.

Welding Processes Requiring High Frequency

1 High-Frequency Voltage

TIG – helps arc jump air gap between torch and workpiece and/ or stabilize the arc.

1

Work

TIG high_freq 12/96 – S-0693

7-2.

Incorrect Installation

13

Weld Zone

11, 12

50 ft

(15 m)

9

8

7

10

2

3

1

4 5 6

14

Sources of Direct High-Frequency

Radiation

1 High-Frequency Source (welding power source with built-in HF or separate HF unit)

2 Weld Cables

3 Torch

4 Work Clamp

5 Workpiece

6 Work Table

OM-359 Page 62

Sources of Conduction of High

Frequency

7 Input Power Cable


9 Input Supply Wiring

Sources of Reradiation of High

Frequency

10 Ungrounded Metal Objects

11 Lighting

12 Wiring

13 Water Pipes and Fixtures

14 External Phone and Power Lines

S-0694

7-3.

Correct Installation

3

50 ft

(15 m)

Weld Zone

7

50 ft

(15 m)

5

1

6

4

2

8

8

Ground all metal objects and all wiring in welding zone using

#12 AWG wire.

Nonmetal

Building

Ground workpiece if required by codes.

9

Metal Building

8

8

11

10

Ref. S-0695 / Ref. S-0695

1 High-Frequency Source (welding power source with built-in HF or separate HF unit)

Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.

2 Center Point of Welding Zone

Midpoint between high-frequency source and welding torch.

3 Welding Zone

A circle 50 ft (15 m) from center point in all directions.

4 Weld Output Cables

Keep cables short and close together.

5 Conduit Joint Bonding and Grounding

Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m).

6 Water Pipes and Fixtures

Ground water pipes every 50 ft (15 m).

7 External Power or Telephone Lines

Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.

8 Grounding Rod

Consult the National Electrical Code for specifications.

Metal Building Requirements

9 Metal Building Panel Bonding Methods

Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame.

10 Windows and Doorways

Cover all windows and doorways with grounded copper screen of not more than

1/4 in (6.4 mm) mesh.

11 Overhead Door Track

Ground the track.

OM-359 Page 63

SECTION 8 – SELECTING AND PREPARING TUNGSTEN

ELECTRODE FOR DC OR AC WELDING

ac/dc_gtaw 2/2000

Y

Whenever possible and practical, use DC weld output instead of AC weld output.

8-1.

Selecting Tungsten Electrode (

Wear Clean gloves To Prevent Contamination Of Tungsten

)

Electrode Diameter DC – Argon – Electrode

Negative/Straight Polarity

Amperage Range - Gas Type

♦

- Polarity

AC – Argon DC – Argon – Electrode Positive/Reverse Polarity

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium

(Red Band) Alloy Tungstens

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

Pure Tungsten

(Green Band)

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

Zirconium Alloyed Tungsten (Brown

Band)

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

Up to 15

5-20

15-80

70-150

125-225

225-360

360-450

450-720

720-950

Up to 25

15-40

25-85

50-160

135-235

250-400

400-500

500-750

750-1000

*

*

*

*

*

*

*

*

*

*

*

*

10-20

15-30

25-40

40-55

55-80

80-125

*

*

*

10-20

15-30

25-40

40-55

55-80

80-125

*

*

*

*

*

*

*

*

*

Up to 20

15-35

20-80

50-150

130-250

225-360

300-450

400-500

600-800

Up to 20

15-35

20-80

50-150

130-250

225-360

300-450

400-550

600-800

♦

Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended.

Up to 15

5-20

10-60

50-100

100-160

150-210

200-275

250-350

325-450

AC – Argon –

Balanced Wave

Up to 15

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Up to 10

10-20

20-30

30-80

60-130

100-180

160-240

190-300

250-400

Up to 15

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

OM-359 Page 64

8-2.

Preparing Tungsten Electrode For Welding

Y

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines

1

2

1 Tungsten Electrode

2 Tapered End

Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

2-1/2 Times

Electrode Diameter

4

Ideal Tungsten Preparation – Stable Arc

1

2

3

1 Stable Arc

2 Flat

Diameter of this flat determines amperage capacity.

3 Grinding Wheel

Grinding wheel should be dedicated to grinding tungsten only.

4 Straight Ground

4

Wrong Tungsten Preparation – Wandering Arc

B. Preparing Tungsten For Conventional AC Welding

1

2

3

1 Arc Wander

2 Point

3 Grinding Wheel

Grinding wheel should be dedicated to grinding tungsten only.

4 Radial Ground

1

1 – 1-1/2 Times

Electrode Diameter


2 Balled End

Y

Understand and follow safety symbols at start of

Section 9-1 before preparing tungsten.

Ball end of tungsten by applying AC amperage recommended for a given electrode diameter (see Section

8-1). Let ball on end of the tungsten take its own shape.

2

OM-359 Page 65

SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)

9-1.

Positioning The Torch

10–25

°

4

1

2

10–15

°

90

°

5

6

3

5

6

4

Y

Weld current can damage electronic parts in vehicles.

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

.

For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.

1 Workpiece

Make sure workpiece is clean before welding.

2 Work Clamp

Place as close to the weld as possible.

3 Torch

4 Filler Rod (If Applicable)

5 Gas Cup


Select and prepare tungsten according to Sections 8-1 and 8-2.

Guidelines:

The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter.

Tungsten extension is the distance the tungsten extends out gas cup of torch.

The tungsten extension should be no greater than the inside diameter of the gas cup.

Arc length is the distance from the tungsten to the workpiece.

1/16 in

3/16 in

Bottom View Of Gas Cup

Ref. ST-161 892

OM-359 Page 66

9-2.

Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool

Tungsten With Filler Rod

Welding direction

Form pool

Tilt torch

Tilt torch

75

°

75

°

15

°

Move torch to front of pool. Repeat process.

Add filler metal

Remove rod Move torch to front of pool. Repeat process.

ST-162 002-B

OM-359 Page 67

9-3.

Positioning Torch Tungsten For Various Weld Joints

90

°

Butt Weld And Stringer Bead

20

°

20

°

“T” Joint

75

°

70

°

10

°

15

°

20-40

°

Lap Joint

75

°

30

°

15

°

90

°

Corner Joint

75

°

15

°

OM-359 Page 68

ST-162 003 / S-0792

SECTION 10 – STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

2

4

5

1 7

6

3

Y

Weld current starts when electrode touches workpiece.

Y

Weld current can damage electronic parts in vehicles.

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

1 Workpiece

Make sure workpiece is clean before welding.

2 Work Clamp

3 Electrode

A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2).

4 Insulated Electrode Holder

5 Electrode Holder Position

6 Arc Length

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound.

7 Slag

Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

Tools Needed: stick 12/96 – ST-151 593

OM-359 Page 69

10-2. Electrode and Amperage Selection Chart

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

3/32

1/8

5/32

3/16

7/32

1/4

1/16

5/64

3/32

1/8

5/32

3/16

7/32

3/32

1/8

5/32

3/16

3/32

1/8

5/32

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

1/4

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

10-3. Striking an Arc – Scratch Start Technique

1

3

10-4. Striking an Arc – Tapping Technique

1

3

2

OM-359 Page 70

2

6010

6011

6013

EP

EP

EP,EN

ALL

ALL

ALL

DEEP

DEEP

LOW

MIN. PREP, ROUGH

HIGH SPATTER

7014

7018

7024

NI-CL

308L

EP,EN

EP

EP,EN

EP

EP

ALL

ALL

FLAT

HORIZ

FILLET

ALL

ALL

MED

LOW

LOW

LOW

LOW

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON

STAINLESS

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

Ref. S-087 985-A

1 Electrode

2 Workpiece

3 Arc

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

S-0049

1 Electrode

2 Workpiece

3 Arc

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

S-0050

10-5. Positioning Electrode Holder

90

°

90

°

10

°

-30

°

End View of Work Angle Side View of Electrode Angle

GROOVE WELDS

45

° 10

°

-30

°

45

°

End View of Work Angle

FILLET WELDS

Side View of Electrode Angle

10-6. Poor Weld Bead Characteristics

S-0060

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

1

2

3 4

10-7. Good Weld Bead Characteristics

2

1

3 4 5

5

S-0053-A

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater During

Welding

Weld a new bead or layer for each

1/8 in. (3.2 mm) thickness in metals being welded.

4 No Overlap

5 Good Penetration into Base

Metal

S-0052-B

OM-359 Page 71

10-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.

Angle Too Small

Correct Angle

10

°

-

30

°

Angle Too Large

Drag

ELECTRODE ANGLE

Too Long

Spatter

Too Short

Normal

ARC LENGTH

Slow

Normal

TRAVEL SPEED

Fast

S-0061

10-9. Electrode Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.

1 2

1 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side to Side

Movement Along Seam

3 Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode.

Do not let weave width exceed

2-1/2 times diameter of electrode.

3

S-0054-A

OM-359 Page 72

10-10. Butt Joints

1

3

1/16 in

(1.6 mm)

30

°

2

4

10-11. Lap Joint

30

°

Or Less

1

30

°

Or Less

1

2

Single-Layer Fillet Weld

10-12. Tee Joint

3

Multi-Layer Fillet Weld

1

2

45

°

Or Less

2

3

1

1 Tack Welds

Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld.

2 Square Groove Weld

Good for materials up to 3/16 in (5 mm) thick.

3 Single V-Groove Weld

Good for materials 3/16 – 3/4 in

(5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

Create 30 degree angle of bevel on materials in V-groove welding.

4 Double V-Groove Weld

Good for materials thicker than 3/16 in (5 mm).

S-0662

1 Electrode

2 Single-Layer Fillet Weld

Move electrode in circular motion.

3 Multi-Layer Fillet Weld

Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.

Weld both sides of joint for maximum strength.

S-0063 / S-0064

1 Electrode

2 Fillet Weld

Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.

For maximum strength weld both sides of upright section.

3 Multi-Layer Deposits

Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section

10-9. Remove slag before making another weld pass.

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

OM-359 Page 73

10-13. Weld Test

3

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2

1

2 To 3 in

(51-76 mm)

2

3

1 Vise

2 Weld Joint

3 Hammer

Strike weld joint in direction shown.

A good weld bends over but does not break.

1

10-14. Troubleshooting – Porosity

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

S-0057-B

Possible Causes

Arc length too long.

Damp electrode.

Workpiece dirty.

Corrective Actions

Reduce arc length.

Use dry electrode.

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

10-15. Troubleshooting – Excessive Spatter

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

Possible Causes

Amperage too high for electrode.

Arc length too long or voltage too high.


Decrease amperage or select larger electrode.

Reduce arc length or voltage.

OM-359 Page 74

10-16. Troubleshooting – Incomplete Fusion

Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes

Insufficient heat input.

Improper welding technique.

Workpiece dirty.


Increase amperage. Select larger electrode and increase amperage.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

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

10-17. Troubleshooting – Lack Of Penetration

Lack of Penetration

Possible Causes

Improper joint preparation.

Improper weld technique.

Insufficient heat input.

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

Good Penetration


Material too thick. Joint preparation and design must provide access to bottom of groove.

Keep arc on leading edge of weld puddle.

Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

10-18. Troubleshooting – Excessive Penetration

Excessive Penetration

Possible Causes

Excessive heat input.

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

Good Penetration


Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

OM-359 Page 75

10-19. Troubleshooting – Burn-Through

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

Possible Causes



Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

10-20. Troubleshooting – Waviness Of Bead

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

Possible Causes

Unsteady hand.

Use two hands. Practice technique.

10-21. Troubleshooting – Distortion


Possible Causes


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

Base metal moves in the direction of the weld bead.


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

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-359 Page 76

Notes

OM-359 Page 77

SECTION 11 – PARTS LIST

.

Hardware is common and not available unless listed.

OM-359 Page 78

Figure 11-1. Main Assembly

802 609-B

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

Quantity

. . . 1 . . . . . PC1 . . . . .

. . . . . . . . . . . . . . . . . . . . . .

203 899

186 914

. . . Circuit Card Assy, Interface (consisting of)

. . . .

. . . . . . . . . . . . . . . . . . . . . . .

Display, LED Numeric 7 Segment 3 Digit (LED’s 18 – 23) . . . . . . . . .

. . . 1 . . . . . PC1 . . . . .

. . . . . . . . . . . . . . . . . . . . . .

203 899

186 914

. . . Circuit Card Assy, Interface (consisting of) (CE Models Only)

. . . . Display, LED Numeric 7 Segment 3 Digit (LED’s 18 – 23)

. . . . . . .

. . . . . . . . .

. . . . . . . . PLG13, 15

. . . . . . . . . . PLG10

. . .

. . . .

131 054

130 203

. . .

. . .

Connector W/Sockets

Connector W/Sockets

. . . . . . . . . .

. . . . . . . . . .

PLG14

PLG4

. . . .

. . . . .

115 092

115 093

. . .

. . .

Connector W/Sockets

Connector W/Sockets

. . . . . . . . . .

. . . . . . . . . .

PLG17

PLG16

. . . .

. . . .

131 052 . . . Connector W/Sockets

115 091 . . . Connector W/Sockets

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2 . . . . . . . . . . . . . . . . 195 778 . . . Actuator Push Button Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 3 . . . . . . . . . . . . . . . .

. . .

. . .

4

5

. . . . .

. . . . .

PC2

PC3

. . .

. . .

♦

190 734 . . . Circuit Card, Pulser

♦

. . . 6 . . . . . . . . . . . . . . . .

190 512 . . . Stand–off, No 6–32 X .6406 Lg

190 738 . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Card, Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 762 . . . Hf Control Box Assy, ( Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 7 . . . . . . . . . . . . . . . . 204 289 . . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 8 . . . . . . . . . . . . . . . .

194 590

204 312

. . .

. . .

Label, Miller 12.563 X 5.376 Horizontal Syncrowav

Top, Cover

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 9 . . . . . . R3 . . . . . .

. . . 10 . . . . . . . . . . . . . .

201 133

+204 291

. . .

. . .

Resistor, WW Fxd 400 W 35 Ohm W/Mtg Bkt

Panel, Rear

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

127 363

168 384

. . .

. . .

Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . .

Label, Warning Electric Shock And Incorrect Input P . . . . . . . . . . . . . . .

. . . 11 . . . . . . . . . . . . . . . . 168 343 . . . Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h . . . . . . . . . . . . . . .

. . . 12 . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

184 057

189 491

. . .

. . .

Door, Primary Board

Spacer, Hinge

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 13 . . . . . . . . . . . . . . . .

. . . 14 . . . . . GS1 . . . . .

605 227

133 873

. . .

. . .

Nut, 750–14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

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

. . . 16 . . . . . . . . . . . . . . . .

. . . 17 . . . . . . . . . . . . . . . .

602 969

010 146

. . .

. . .

Plug, Protective No 6 Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . .

176 272 . . . Conn, Clamp Cable

202 485 . . . Baffle, Rear Panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 18 . . . . . . . . . . . . . . . .

186 162

184 058

. . .

. . .

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 19 . . . . . . 1T . . . . . .

. . . 20 . . . . . . . . . . . . . . . .

. . . 21 . . FM1, FM2 . . .

. . . 22 . . . . . . . . . . . . . . . .

199 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 783 . . . Blade, Fan 9.000 5wg 39deg .312 Bore Cw Plstc . . . . . . . . . . . . . . . . .

188 706

187 807

. . .

. . .

Motor, Fan 230v 50/60hz 1550 Rpm .312 Dia Shaft

Bracket, Mtg Motor Fan

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 23 . . . . . . . . . . . . . . . .

. . . 24 . . . . . . . . . . . . . . . .

192 864

026 627

. . .

. . .

Support, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasket, Lifting Eye Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . .

25

25

. . . .

. . . .

. . . 25 . . . .

T1, Z1

T1, Z1

T1, Z1

. . . . .

. . . . .

. . . . .

194 379

196 715

196 711

. . .

. . .

. . .

Xfmr/Stabilizer Assy, 200/230/460

Xfmr/Stabilizer Assy, 230/460/575

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Xfmr/Stabilizer Assy, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . .

TH1

PLG1

. . . . . . 201 443 . . . Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead

. . . . . 202 119 . . . Connector W/Sockets

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . PLG7 . . . . . 202 116 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

1

1

2

2

2

1

1

. . . . . . . . . .

. . . . . . . . . .

. . .

. . .

26

27

PLG8

PLG11

. . . . .

. . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

202 117

202 118

200 647

192 862

. . .

. . .

. . .

. . .

Connector W/Sockets

Connector W/Sockets

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bracket, Support Switch

Bracket, Mtg Rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

1

1

. . . 28 . . . . . SR1 . . . . .

. . . . . . . . . . . . . . . . . . . . . .

196 485

605 603

. . .

. . .

Rectifier Assy, (Figure 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tubing, Gl Acryl 1.000–1.036 Idxspool Nat Fa1 . . . . . . . . . . . . . . . . .

1

0.875

2

1

1

1

1

1

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

. . . . . . . . . . . . . . . . . . . . . .

184 052

083 426

. . . Baffle, Cap Power Factor

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 30 . . . .

. . . 31 . . . . .

C5, C6

TE1

. . . .

. . . . . .

111 634 . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

034 587 . . . Term Assy, Pri 1ph 3v (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Board, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . 038 618

. . . . . . . . . . . . . . . . . . . . . . 601 835

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

601 836

038 888

. . . .

. . . .

. . . .

. . . .

Link, jumper term bd pri

Nut, brs hex 10-32reg

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nut, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stud, pri board brs .250-20 x 1.500

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

2

12

4

2

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

038 887

010 913

010 915

602 207

175 479

. . . .

. . . .

. . . .

. . . .

. . . .

Stud, pri board brs 10-32 x 1.375

Washer, flat brs .187 ID

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Washer, flat brs .250 ID x .625 OD x .031thk

. . . . . . . . . . . . . . . . . . . .

Washer, lock .255 ID x .489 OD

Link, jumper

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6

4

2

1

1

1

2

4

4

1

1

1

2

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

6

1

6

OM-359 Page 79

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 11-1. Main Assembly (continued)

. . . . . . . . . . . . . . . . . . . . . .

. . . 32 . . . . . . . . . . . . . .

190 161

+196 584

. . .

. . .

Lug, Univ W/Screw 1/O–14 Wire .266std

Base

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 33 . . . . . . . . . . . . . . . .

155 436

189 224

. . .

. . .

Label, Ground/Protectiv

End Cap

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 34 . . . . . . . . . . . . . . . . 197 026 . . . HF Panel Assy, Lower (Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 35 . . . . . . S1 . . . . . .

. . . 36 . . . . . . R5 . . . . . .

128 757

198 547

. . .

. . .

Switch, Tgl Dpst 60a 600vac Scr Term Wide Tgl

Rheostat, Ww 25. W 1.5 Ohm Fric Term

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 37 . . . . . . S5 . . . . . .

. . . 38 . . . . . . . . . . . . . . . .

201 121

204 305

. . .

. . .

Switch Assy, Polarity With Leads And Hardware (Dx)

Panel, Front

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

143 397 . . . Blank, Snap–in Nyl .312 Mtg Hole Black

117 860 . . . Blank, Snap–in Nyl .187 Mtg Hole Black

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 39 . . . . . . . . . . . . . . . .

107 983

097 922

. . .

. . .

Blank, Snap–in Nyl .500 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . .

Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 40 . . . . . . . . . . . . . .

174 041

+196 492

. . .

. . .

Label, Indicator Intensity Control

Door, Access Front

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

134 327

127 363

. . .

. . .

Label, Warning General Precautionary Static&wire Fe

Label, Warning Electric Shock Can Kill

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 41 . . . . . . . . . . . . . . . .

. . . 42 . . . . . . . . . . . . . . . .

175 952

194 388

. . .

. . .

Plastic, Handle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplate, Miller Syncrowave 250DX . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 42 . . . . . . . . . . . . . . . .

. . . 43 . . . . . . . . . . . . . . . .

196 766

184 066

. . .

. . .

Nameplate, Miller Syncrowave 250DX (Wordless)

Door Spark Gap Access

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 44 . . . . . . . . . . . . . . . .

. . . 44 . . . . . . . . . . . . . . . .

196 616

196 764

. . .

. . .

Plate, Indicator Syncrowave 250DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plate, Indicator Syncrowave 250DX (Wordless) . . . . . . . . . . . . . . . . . . .

. . . 45 . . . . . . . . . . . . . . . . 183 332 . . . Knob, Pointer .570 Dia X .125 Id W/Spring Clip . . . . . . . . . . . . . . . . . . .

. . . 46 . . . . . . . . . . . . . . . .

. . 47 . . . . . . . . . . . . .

174 991

204 416 . .

. . .

Drawer, Mat

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 48 . . . . . . . . . . . . . 204 313 . . Drawer, Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

. .

. .

. .

. .

49

50

51

52

53

54

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

204 307

204 314

204 389

200 920

200 922

494 907

. .

. .

. .

Slide, Drawer

Drawer

HOLDER, Torch/Cable (consisting of)

. . . .

. . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Door, Torch/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Housing, Torch/Cable Holder

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCREW, k50 x 20 pan hd – trx pld pt thread forming . . . . . . . . . . . . . . . . .

1

1

1

1

1

1

8

1

1

4

1

3

1

1

1

1

1

3

1

1

1

1

1

1

2

2

2

1

2

2

1

1

♦

OPTIONAL

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-359 Page 80

Item

No.

Dia.

Mkgs.

Part

No.

196 762

Description

Figure 11-2. HF Control Box Assembly (Figure 11-1 Item 6)

Quantity

. . . 1 . . . . . . G1 . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

199 854

199 855

. . . Spark Gap Assy, (consisting of)

. . . . Base

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . 199 856 . . . . Holder, Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 2 . . . . . . . . . . . . . . . .

196 455

184 068

. . . .

. . .

Points, Spark Gap

Bracket, Spark Gap

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 3 . . . . . . C3 . . . . . .

. . . 4 . . . . . . R8 . . . . . .

201 197

188 067

. . .

. . .

Capacitor, Polyp Met Film .002uf 4400vacpnlmtg

Resistor, ww fxd 100 w 200 ohm w/clips

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . .

5

6

. . . C11, C19

. . . . . . R2

. . .

. . . . . .

195 552

189 132

. . .

. . .

Capacitor, Polyp Met Film 20. Uf 250 Vac 10%

Resistor Assy,

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 7 . . . . . . R1 . . . . . . 186 468 . . . Resistor, Ww Fxd 100 W 50 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . .

. . . 8 . . . . . . . . . . . . . . . .

. . . 9 . . . . . . . . . . . . . . . .

010 493

196 576

. . .

. . .

Bushing, Snap–in Nyl .625 Id X .875 Mtg Hole

Hf, Control Box

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 10 . . . . . . T3 . . . . . . 074 398 . . . Xfmr, High Voltage 115v Pri 3600v Sec 30 Ma . . . . . . . . . . . . . . . . . . . .

1

1

1

2

1

1

4

4

1

1

1

1

1



.


7

6

5

8

1

2

3

4

5

10

Figure 11-2. HF Control Box Assembly

9

802 756

OM-359 Page 81

Item

No.

Dia.

Mkgs.

Part

No.


197 026

Figure 11-3. HF Panel Assembly, Lower (Figure 11-1 Item 34)

. . . 1 . . . . . . . . . . . . . . . .

. . . 2 . . . . . . . . . . . . . . . .

197 022

193 415

. . .

. . .

Panel, Lower Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector, Faston 1/4 Ring W/75deg Bend . . . . . . . . . . . . . . . . . . . . . .

. . . 3 . RC2/CB1/C12 . 201 153 . . . Receptacle, W/Leads And Circuit Breaker

. . . . . . . . . . . . . . . 143 976 . . . Connector W/Sockets

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 4 . . . . . RC1 . . . . .

156 734

201 127

. . .

. . .

Nut, 010–32 .31hex .13h Stl Pld Sem Cone Wshr.38d

Harness, Assy 14 Pin Recpt

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 5 . . . . . CM1 . . . . .

. . . 6 . . . . . . . . . . . . . . . .

197 220

089 120

. . .

. . .

Module, Filter .1mf 500vdc 8 Ckt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clamp, Hose .375 – .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . .

. . . 7 . . . . . . . . . . . . . . . .

. . . 8 . . . . . . . . . . . . . . . .

155 527

120 854

. . .

. . .

Hose, Nprn Brd No 1 X .250 Id X 28.000

Ftg, Gas

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 9 . . . C13, C14 . . .

. . . 10 . . . . . . . . . . . . . . . .

196 499 . . . Capacitor Assy,

157 317 . . . Holder, Hf Coil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 11 . . . . . . T4 . . . . . . 199 487 . . . Coil, Hf Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . 12 . . . . . . . . . . . . . . . .

203 474

157 318

. . .

. . .

Service Kit, DX Coupling Coil

Holder, Hf Coil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 13 . . . . . . . . . . . . . . . . 097 421 . . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

1

4

1

1

1

2

1

1

2

2

1

1



.


1

2 3

4

6

9

7

5

10

8

11

9

12

802 757

13

Figure 11-3. HF Panel Assembly, Lower

OM-359 Page 82

Item

No.

Dia.

Mkgs.

Part

No.


196 485

Figure 11-4. HF Rectifier Assembly (Figure 11-1 Item 28)

. . .

. . .

1

2

. . . Mod 1, 2 . . . .

. . . . . . . . . . . . . . . .

196 760

196 191

. . .

. . .

Thyristor, SCR Module

Heat Sink, Rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 3 . . . . . HD1 . . . . . 191 941 . . . Transducer, Current Hall

. . . 6 . . C7, 8, 9, 10 . . 190 460 . . . Capacitor Assy

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 4 . . . . . TH2 . . . . . . 188 431 . . . Thermister, NTC

. . . 5 . . . . . . . . . . . . . . . . 196 171 . . . Insulator, Rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

2

2

2

1



.


1

4

2

5

1

3

6

Figure 11-4. Rectifier Assembly

5

Ref. 802 609-A

OM-359 Page 83

Warranty Questions?

Call

1-877-HOBART1 for your local

Hobart distributor.

Service

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

Support

Need fast answers to the tough welding questions?

Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Effective January 1, 2000

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

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

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

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

International distributor.

1.

5 Years Parts – 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Engine Driven Welding Generators

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

3.

1 Year — Parts and Labor

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Maxstar 140

* Spot Welders

* Load Banks

* Hobart Cyclomatic Equipment

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True

Blue

 for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.

6 Months — Batteries

5.

90 Days — Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate 185 & Spoolmate 250

* Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2.

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

3.

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

HOBART PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s option: (1) repair; or

(2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Hobart authorized service facility as determined by

Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE

FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY HOBART IS EXCLUDED

AND DISCLAIMED BY HOBART.

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

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

Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

hobart standard 7/00

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

Zip

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor, retail or service location:

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

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

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

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information and Parts)

Circuit Diagrams

Welding Process Handbooks

File a claim for loss or damage during shipment.



2000 Hobart Welding Products. 1/00 PRINTED IN USA

Hobart Welding Products

An Illinois Tool Works Company

600 West Main Street

Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281

For Literature Or Nearest Dealer:

Call 1-877-Hobart1

HobartWelders CYBERTIG 250 Owner Manual

www.HobartWelders.com

OM-359

Processes

Description

CYBERTIG 250

And Non-CE Models

From Hobart to You

Thank you and congratulations on choosing Hobart.

Now you can get the job done and get it done right.

We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation

Hobart is registered to the

ISO 9001 Quality System

Standard.

Hobart Welders manufactures a full line of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

WARNING

TABLE OF CONTENTS

(Continued)

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1.

Symbol Usage

1-2.

Arc Welding Hazards

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

ELECTRIC SHOCK can kill.

FUMES AND GASES can be hazardous.

ARC RAYS can burn eyes and skin.

WELDING can cause fire or explosion.

FLYING METAL can injure eyes.

BUILDUP OF GAS can injure or kill.

HOT PARTS can cause severe burns.

NOISE can damage hearing.

CYLINDERS can explode if damaged.

1-3.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

MOVING PARTS can cause injury.

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

WELDING WIRE can cause injury.

1-4.

Principal Safety Standards

1-5.

EMF Information

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

1-1.

Signification des symboles

1-2.

Dangers relatifs au soudage à l’arc

UN CHOC ÉLECTRIQUE peut tuer.

Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

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

LE SOUDAGE peut provoquer un incendie ou une explosion.

DES PARTICULES VOLANTES peuvent blesser les yeux.

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

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

LE BRUIT peut affecter l’ouïe.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

1-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

LA CHUTE DE L’APPAREIL peut blesser.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

DES ORGANES MOBILES peuvent provoquer des blessures.