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Hobart Welding Products 302 manual

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Table of contents for the manual

  • Page 1

    Processes 302, 452, And 652 Models OM-222 164 850T January 2002 Cyber Arc TIG (GT A W ) W elding Stick (SMA W) W elding Air Plasma Cutting and Gouging Air Carbon Arc (CAC-A) Cutting and Gouging Flux Cored (FCA W) W elding Description Arc Welding Power Source[...]

  • Page 2

    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[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-222 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! W atch [...]

  • Page 6

    OM-222 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 of f 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 Z8[...]

  • Page 7

    OM-222 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[...]

  • Page 8

    OM-222 Page 4 1-5. EMF Information Considerations About W elding And The Effects 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[...]

  • Page 9

    OM-222 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 . [...]

  • Page 10

    OM-222 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[...]

  • Page 11

    OM-222 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[...]

  • Page 12

    OM-222 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 e l- 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, W ashington, D.C. 20402. Recommended Safe Practice for t[...]

  • Page 13

    OM-222 Page 9 SECTION 2 – DEFINITIONS 2-1. General Precautionary Label W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric sh[...]

  • Page 14

    OM-222 Page 10 2-2. Input Connection Label 1 W arning! Watch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power av[...]

  • Page 15

    OM-222 Page 1 1 2-5. Manufacturer ’ s Rating Labels For CE Products . Match label to one on unit. See Section 3-4.[...]

  • Page 16

    OM-222 Page 12 2-6. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes Amperage Control/ Panel Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMA W ) T emperature Do Not Switch While W elding Arc Force (DIG) Percent Output Circuit Breaker Remote V V olts Protective Earth (Ground) Positive Negative Inp[...]

  • Page 17

    OM-222 Page 13 SECTION 3 – INST ALLA TION 3-1. Specifications Model Rated W elding Amp Maximum Open- IP Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model W elding Output Range DC Circuit V oltage DC Rating 200 V 230 V 380 V 400 V 440 V 460 V 575 V KV A KW 300 Amp 300 A @ 32 V olts DC, 60% Duty Cycle 15 – 395 72 (70) 21M 70 4.0*[...]

  • Page 18

    OM-222 Page 14 3-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. B. 450 Amp Model C. 650 Amp Model A. 300 Amp Model va_curve1 – 4/95 – SA-171 221 / SA-171 222 / SA-171 223[...]

  • Page 19

    OM-222 Page 15 3-4. Selecting A Location 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 (Non CE Models Only) Use rating label to determine input power needs. Label located under front access door . 4 Plate Label (CE Models Only) Label loc[...]

  • Page 20

    OM-222 Page 16 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 1 15 V AC Receptacle And Circuit Breakers Ref. ST-800 101-D Y T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9 a n d Remote 14 receptacle RC8 (see Section 3-10). 2 Circuit Breaker CB1 3 Circuit[...]

  • Page 21

    OM-222 Page 17 3-8. W eld Output T erminals And Selecting Cable Sizes T otal Cable (Copper) Length In W eld 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) Y T urn Off power before connecting to weld output terminals W elding Amperes 10 – 60% Duty Cycle 60 – 100% [...]

  • Page 22

    OM-222 Page 18 3-10. Connecting Remote Control Ref. ST-800 101-D 1 Remote 14 Receptacle RC8 Connect remote control to RC8. OR OR AJ B K I C L NH D M G E F 1[...]

  • Page 23

    OM-222 Page 19 3-1 1. Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model Input V oltage 200 230 460 575 200 230 460 575 230 460 575 Input Amperes At Rated Output 70 61 31 25 102 89 45 36 124 62 50 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 80 70 35 30 125 11 0 50 45 150 70 60 Normal Operating 3 11[...]

  • Page 24

    OM-222 Page 20 3-12. Placing Jumper Links Ref. ST-800 103-A Y Disconnect and lockout/tag- out input power before installing or moving jumper links. 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. Close access door, or go on to Section 3-13. T oo[...]

  • Page 25

    OM-222 Page 21 3-13. Connecting Input Power ST-800 103-B / Ref. ST -801 1 16 3/8 in 3/8 in T ools Nee d e d : IMPORT ANT GND/ 3 PE Connect Green Or Green/Y ellow GND/PE Conductor First. Input Contactor L1 (U) L2 (V) L3 (W) = GND/PE Earth Ground 1 10 3 When making connections in the line disconnect device, connect the Green Or Green/Y ellow conducto[...]

  • Page 26

    OM-222 Page 22 SECTION 4 – OPERA TION 4-1. Controls (Non CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work and electrode cables at the weld output termi- nals (see Section 3-8). Y T urn Off Power before reversing cables. 2 Arc For c e ( D i g )[...]

  • Page 27

    OM-222 Page 23 4-2. Controls (CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work an d electrode cables at the weld output termi- nals (see Section 3-8). Y T urn Off Power before reversing cables. 2 Arc Force (Dig) Control Control increases SMA W s[...]

  • Page 28

    OM-222 Page 24 5-2. Fuse F1 Ref. ST-800 101-C Y T ur n Off power before open- ing rear access door . 1 Fuse F1 (See Parts List For Rating) Fuse F 1 protects control transform- er from overload. If F1 opens, weld output and fan motor stops. Re- place F1. 1 T ools Needed: 3/8 in 5-3. T roubleshooting T rouble Remedy No weld output; unit completely in[...]

  • Page 29

    OM-222 Page 25 SECTION 6 – ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. SC-203 802 Figure 6-1. Circuit Diagram[...]

  • Page 30

    OM-222 Page 26 SECTION 7 – P ARTS LIST ST-800 875-E . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 14 17 18 (Fig.7 – 5) 19 20 21 22 3 4 23 25 26 24 27 28 (Fig.7 – 2) 29 (Fig.7 – 3 & 4) 22 Figure 7-1. Main Assembly (452 Model Illustrated)[...]

  • Page 31

    OM-222 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity Model 302 452 652 1 +179 430 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 +179 432 P ANEL, side 2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-222 Page 28 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) Quantity Model 302 452 652 24 T1 189 855 TRANSFORMER, pwr main 380/400/440 (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . 25 172 410 COIL, pri/sec (center & RH) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 33

    OM-222 Page 29 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 28) Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 652 1S 5 ♦ 169 331 SWITCH, mode polarity (single deck) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1S 5 ♦ 169 332 SWITCH, mode polarity (double deck) 1 1 . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-222 Page 30 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 28) (Continued) Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 652 9 POS 181 245 TERMINAL, pwr output red 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C4,5 128 750 CAP ACITOR, cer disc .1uf 500VDC 2 2 2 . . .[...]

  • Page 35

    OM-222 Page 31 Description Part No. Dia. Mkgs. SR1 Item No. Figure 7-3. Rectifier , Si Diode (302 Model) (Fig 7-1 Item 29) Quantity 175 070 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 177 316 HEA T SINK, rect 3 . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-222 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 7-5. Panel, Rear w/Components (Fig 7-1 Item 18) Quantity 1 173 283 CHAMBER, plenum 14 in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 180 165 BLADE, fan 14 in 3wg 23deg .375 bore CCW 1 . . . . . . . . . . . . .[...]

  • Page 37

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  • Page 39

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 10/01 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 distri[...]

  • Page 40

    PRINTED IN USA  2002 Hobart Welding Products. 1/02 Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 W es t Main St reet Troy , OH 45373 USA For T ech nical Assistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to or[...]