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Hobart Welding Products 302 manual

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Table of contents for the manual

  • Page 1

    302, And 252TS Models Cyber Pro Pro cesses Descrip ti on MIG (GMA W) W elding Flux Cored (FCA W) W elding Arc Welding Power Source OM -259 177 743K September 2000[...]

  • 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 W ARNING T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-259 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-259 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[...]

  • Page 7

    OM-259 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-259 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-259 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-259 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-259 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-259 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- 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 [...]

  • Page 13

    OM-259 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Rated Open- Circuit Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model Rated W elding Output Circuit V oltage Range DC 200 V 220 V 230 V 380 V 400 V 440 V 460 V 520 V 575 V KV A KW 250 Amp 250 A @ 35 V olts DC, 100% Duty Cycle 14 – 44 34.5 1.7* –– 30 1.4* –– ?[...]

  • Page 14

    OM-259 Page 10 2-3. V olt-Ampere Curves va_curve1 4/95 – SA-180 902 / SA-180 901-B 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. A. 250 Ampere Models B. 300 Ampere Models CP302 MAX CP302 MIN[...]

  • Page 15

    OM-259 Page 1 1 2-4. Dimensions And Weights C C Dimensions E D Height 27-1/4 in (692 mm) 4 Holes Width 22-1/4 in (565 mm) Depth 28-1/4 in (717 mm) A 27-1/2 in (698 mm) A B 3/4 in (19 mm) A C 21-1/8 in (537 mm) D 1-1/8 in (29 mm) E 7/16 in (1 1 mm) Dia W eight ST-801 530 B 320 lb (145 kg) 2-5. Selecting A Location 1 Rating Label Use rating label to [...]

  • Page 16

    OM-259 Page 12 2-6. T ypical MIG Process Connections Using A Constant Speed Wire Feeder Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ace work clamp as close t o the weld as possible. Constant speed wire feeders are used with constant voltage (CV) power sources having a 14-pi[...]

  • Page 17

    OM-259 Page 13 2-8. Slope Selection (250 Ampere Model) Ref. ST-801 518-A 1 Slope Connection Label 2 T apped Reactor AC-Z And Slope Coils T apped reactor AC-Z is factory con- nected to slope tap 8 which is suit- able for most GMAW applications. AC-Z controls the inductance applied to the weld current. T o increase inductance and wet out t h e weld p[...]

  • Page 18

    OM-259 Page 14 2-9. Inductance Selection (300 Ampere Models) 1 Stabilizer Z T apped stabilizer Z is factory connected to the stabilizer tap which suits most GMAW applications. Stabilizer Z controls the inductance applied to the weld current. T o in- crease inductance and wet out the weld puddle, connect to stabilizer Z ending. T o change inductance[...]

  • Page 19

    OM-259 Page 15 2-10. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o 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[...]

  • Page 20

    OM-259 Page 16 2-12. Connecting T o 1 15 V olts AC Duplex Receptacle Ref. ST-801 380-B 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9 a n d remote 14 receptacle RC8. 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB 1 protects 1 15 volts ac portion of RC8 and RC9 from overload. CB2 protects 24 volts ac portion of RC8 from overload. Press[...]

  • Page 21

    OM-259 Page 17 4 2-14. Placing Jumper Links And Connecting Input Power ST-801 382 Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Link Move jumper links to match input voltage, and label on unit. 3 Input And Grounding Conductors See Section 2-13. 4 Line Disconnect Device See Section 2-13. Clo[...]

  • Page 22

    OM-259 Page 18 SECTION 3 – OPERA TION 3-1. Controls Ref. ST-801 380-B 1 Power Switch 2 Pilot Light Light is on when power is On. 3 Preset Indicator Light When light is on, the voltmeter displays preset welding voltage as selected by the V oltage Adjustment control. When light is of f, the voltmeter displays actual welding voltage while welding. Y[...]

  • Page 23

    OM-259 Page 19 4-2. T roubleshooting T rouble Remedy Completely inoperative; fan does not run. Place line disconnect switch in the On position. Check and replace open line fuse(s) (see Section 2-13). Check for proper jumper link positions (see Section 2-14). Check for proper input connections (see Section 2-14). No weld output; fan motor FM running[...]

  • Page 24

    OM-259 Page 20 SECTION 5 – ELECTRICAL DIAGRAMS SB-183 958-A Figure 5-1. Circuit Diagram For 250 Ampere Model For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside the wrapper of the welding power source. SB-183 959 Figure 5-2. Circuit Diagram For 300 Ampere Models[...]

  • Page 25

    OM-259 Page 21 Notes[...]

  • Page 26

    OM-259 Page 22 SECTION 6 – P ARTS LIST Figure 6-1. Complete Assembly 801 383-F 1 2 3 4 5 6 7 11 12 13 14 15 16 Fig 6-3 – 17 18 19 1 20 22 23 24 25 26 27 21 Fig 6-2 – 28 30 31 32 29 33 34 35 36 8 10 9 37 38[...]

  • Page 27

    OM-259 Page 23 Quantity Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly 1 134 464 LABEL, warning general 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 179 430 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-259 Page 24 Quantity Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly (Continued) 36 180 666 BRACKET , mtg PC board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 891 LABEL, warning electric shock 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 29

    OM-259 Page 25 Figure 6-2. Panel, Front w/Components Ref. 802 497 2 1 3 4 5 5 2 7 9 10 11 12 14 15 16 17 18 19 20 21 6 8 13 22[...]

  • Page 30

    OM-259 Page 26 Figure 6-3. Rectifier Assembly Ref. 802 497 1 3 2 4 9 5 6 8 10 7 Figure 6-3. Panel, Front w/Components (Figure 6-1 Item 17) Description Part No. Dia. Mkgs. Item No. 1 022 285 MOUNTING BOARD, rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 087 461 HEA T SINK 2[...]

  • Page 31

    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[...]

  • Page 32

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]