Hobart 180 SD manual

Cybertig 180 SD OM-355 188 290E August 2001 Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding Arc Welding Power Source[...]

Hobart W elders 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. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

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OM-355 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch 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. This group of symbols means W arning! Watch O[...]

OM-355 Page 2 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. ARC RA YS can burn eyes and skin. 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[...]

OM-355 Page 3 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. F A[...]

OM-355 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 years o[...]

OM-355 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier . [...]

OM-355 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans le[...]

OM-355 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger l[...]

OM-355 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

OM-355 Page 9 SECTION 2 – INST ALLA TION 2-1. Included with Y our Unit 1 12 ft (3.7 m) W ork Cable With Clamp And Quick-Connect 2 150 Amp TIG T orch with 12-1/2 ft (3.8 m) Cable 3 Electrode Holder and Quick-Connect 4 Gas Hose 5 Gas Regulator 6 RFCS-14 Foot Control with 20 ft (6 m) Cable 7 8 ft (2.4 m) Primary Cord . Some assembly is required. Fo [...]

OM-355 Page 10 2-3. Dimensions And Weights Dimensions Height 21 in (533 mm) Width 13-5/8 in (346 mm) Length 22-1/8 in (562 mm) A 21-5/16 in (541 mm) A B 13/16 in (21 mm) C 12-7/16 in (316 mm) D 1 – 1/16 in (27 mm) 4 Holes E E 1/2 (13 mm) Front B W eight ST-802 259 C D 210 lbs (95 kg) 2-4. Specifications Mode Rated Output at 40% Duty Cycle Rated I[...]

OM-355 Page 1 1 2-6. V olt-Ampere Curves ssb1.1 10/91 – ST-188 277 / ST -188 278 V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. AC MODE 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 300 350 AMPERES VOL TS Stick MIN Stick MAX DC[...]

OM-355 Page 12 2-8. Remote 14 Receptacle Remote control device has complete control of amperage at all times when connected to Remote 14 receptacle. NOTE Socket* Socket Information A 24 volts DC. B Contact closure to A completes 24 volts DC contactor control circuit. C Command reference; 0 to +10 volts DC output to remote control. AJ B K I L NH D R[...]

OM-355 Page 13 2-10. Electrical Service Guide All values calculated at 40% duty cycle. NOTE Input V oltage 230 Input Amperes at Rated Output 67 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 100 Min Input Conductor Size In A WG/Kcmil 8 Max Recommended Input Conductor Length In Feet (Meters) 166 (51) Min Grounding Conductor Size [...]

OM-355 Page 14 SECTION 3 – OPERA TION 3-1. Controls Ref. ST-188 714-A 1 Output Selector Switch Y Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONL Y 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[...]

OM-355 Page 15 3-2. Example of Front Panel Amperage Control For Stick (SMA W) Welding Select amperage. Select weld process. Select polarity . In Example: Remote weld amperage = 10 – 180 amps DC NOTE: Remote amperage control is active whenever a remote control is connected. If the remote device does not include a means of controlling amperage thro[...]

OM-355 Page 16 3-4. T ypical TIG Connections ST-802 238 1 Remote Foot Control A customer supplied remote finger- tip control may also be used. 2 T orch 3 W ork Clamp Connect remote control, torch, and work clamp to receptacles as shown. 4 Cylinder Chain or secure cylinder to running gear , wall, or other stationary support. 5 Cylinder V alve Open v[...]

OM-355 Page 17 3-6. Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And 22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 1 1 ga 10 ga 6 ga 2 ga – 0.033 in 0.8 mm 0.036 in 0.9 mm 0.048 in 1.2 mm 0.06 in 1.5 mm 0.07 in 1.8 mm 0.1 in 2.5 mm 0.125 in 3.2 mm 0.14 in 3.6 mm 0.186 in 4.8 mm[...]

OM-355 Page 18 4-2. Adjusting Spark Gaps ST-802 745 Y T urn Off power before ad- justing spark gaps. Remove left side panel. 1 Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. 2 Spark Gap Normal spark gap is 0.012 in (0.305 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screws Loosen [...]

OM-355 Page 19 SECTION 5 – ELECTRICAL DIAGRAM SD-188 274-F Figure 5-1. Circuit Diagram For Welding Power Source[...]

OM-355 Page 20 SECTION 6 – HIGH FREQUENCY (HF) 6-1. W elding Processes Using HF high_freq1 7/95 – S-0693 1 HF V oltage GT A W – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SA W – helps arc reach workpiece through flux granules. 2 Flux 1 2 1 Gas Tungsten Arc W elding (GT A W) Submerged Arc W elding (SA W) W [...]

OM-355 Page 21 6-3. Correct Installation 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case, work output terminal, line disconnect device, input supply , and worktable. 2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions. 3 W eld Output Cables K[...]

OM-355 Page 22 SECTION 7 – SELECTING AND PREP ARING TUNGSTEN ELECTRODE gtaw2 7/97 For additional information, see your distributor for a handbook on the Gas T ungsten Arc Welding (GT AW) process . Wear clean glov es to prevent contamination of tungsten electrode. NOTE 7-1. Selecting T ungsten Electrode Amperage Range - Gas T ype ♦ - Polarity El[...]

OM-355 Page 23 7-3. Preparing T ungsten For DC Electrode Negative (DCEN) Welding Ref. S-0161 / Ref. S-0162 1 T ungsten Electrode 2 T apered End Grind end of tungsten on fine grit, hard abrasive wheel before weld- ing. D o not use wheel for other jobs or tungsten can become contami- nated causing lower weld quality . 3 Ideal Tungsten Preparation –[...]

OM-355 Page 24 SECTION 8 – GUIDELINES FOR TIG WELDING (GT A W) 8-1. Positioning The T orch Ref. ST-161 892 Y Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) a t the grinder or wear an approved respirator . Read MSDS for safety information. Consi[...]

OM-355 Page 25 8-2. T orch Movement During Welding ST-162 002-B T ungsten Without Filler Rod T ungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° W elding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove rod W elding direction 15 °[...]

OM-355 Page 26 8-3. Positioning T orch T ungsten For V arious W eld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “ T ” Joint Lap Joint Corner Joint[...]

OM-355 Page 27 Notes[...]

OM-355 Page 28 SECTION 9 – STICK WELDING (SMA W) GUIDELINES 9-1. Stick Welding Procedure stick 12/96 – ST-151 593 Y W eld current starts when electrode touches work- piece. Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp as close t o the weld as possible. 1 W[...]

OM-355 Page 29 9-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTROD[...]

OM-355 Page 30 9-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End View of W ork Angle Side V iew of Electrode Angle End View of W ork Angle Side V iew of Electrode Angle 10 ° -30 ° 9-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater Du[...]

OM-355 Page 31 9-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo S mall Angle T oo Large Correc t Angle 9-9. Electrod[...]

OM-355 Page 32 9-10. Butt Joints S-0662 1 T ack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore 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 oxy- acety[...]

OM-355 Page 33 9-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 9-14. T roubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets i n weld metal. Possible[...]

OM-355 Page 34 9-16. T roubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper[...]

OM-355 Page 35 9-19. T roubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 9-20. T roubleshooting – W aviness [...]

OM-355 Page 36 SECTION 10 – P ARTS LIST Figure 10-1. Main Assembly ST-802 252-D . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 30 31 32 33 34 35 36 37 38 39 40 24 25 41 42 43 29[...]

OM-355 Page 37 Figure 10-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. + 1 188 270 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T4 190 332 COIL, coupling 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-355 Page 38 Figure 10-1. Main Assembly (continued) Description Quantity Part No. Dia. Mkgs. Item No. 188 859 ACCESSORY KIT (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 043 554 RFCS-14, foot control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-355 Page 39 ST-802 254-A . Hardware is common and not available unless listed. 1 2 3 4 6 7 8 9 10 11 4 13 5 12 14 Figure 10-2. Panel, Front w/Components Figure 10-2. Panel, Front w/Components (Figure 10-1 Item 39) Description Quantity Part No. Dia. Mkgs. Item No. 1 174 991 KNOB, pointer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u 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 distrib[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Company 600 West M ain S treet Troy , O H 45373 USA For Technical Assi stance: Call1-800-332-3281 For Lit erat ure Or Nearest Deal er: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to or[...]