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Hobart Welding Products 500 manual

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Table of contents for the manual

  • Page 1

    Betastick 500 Processes Description Stick (SMA W) W elding OM-201 444 August 2000 Air Plasma Cutting and Gouging Air Carbon Arc (CAC-A) Cutting and Gouging Arc Welding Power Source Submerged (SAW) W elding Visit our website at www.HobartWelders.com[...]

  • 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: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-201 444 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! [...]

  • Page 6

    OM-201 444 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[...]

  • Page 7

    OM-201 444 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.[...]

  • Page 8

    OM-201 444 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 yea[...]

  • Page 9

    OM-201 444 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 particulie[...]

  • Page 10

    OM-201 444 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 dan[...]

  • Page 11

    OM-201 444 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 surcharg[...]

  • Page 12

    OM-201 444 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 [...]

  • Page 13

    OM-201 444 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 electri[...]

  • Page 14

    OM-201 444 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 powe[...]

  • Page 15

    OM-201 444 Page 1 1 2-5. Manufacturer ’ s Rating Labels For CE Products . Match label to one on unit. See Section 3-4. 2-6. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V oltage Control/ Panel Percent Protective Earth (Ground) Output Circuit Breaker Remote On A 45-250A A Negative ( – ) W eld Output T ermi -[...]

  • Page 16

    OM-201 444 Page 12 SECTION 3 – INST ALLA TION 3-1. Specifications Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model Rated W elding Output Amp Range DC Max OCV DC IP Rating 220 V 380 V 440 V KV A KW SRH-500 500 A @ 40 V olts DC, 50 Or 60 Hz, 35% Duty Cycle A (Low) (45 – 250) B (High) (60 – 500) 75 23M 103 5.5* 60 3.2* 51 2.7* [...]

  • Page 17

    OM-201 444 Page 13 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. va_curve1 – 4/95 – 201 172 3-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting fork[...]

  • Page 18

    OM-201 444 Page 14 3-5. Dimensions And Weights ST-800 039 B A C Inches Millimeters A 30-1/4 768 B 22-1/2 571 C 35-3/4 908 D 20 508 E 1-1/4 32 F 1-1/2 38 G 4-1/2 1 14 H 29-3/4 755 J 1/2 Dia 13 Dia 6 Holes 6 Holes D E F G H J W eight 755 lb (342 Kg) 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces.[...]

  • Page 19

    OM-201 444 Page 15 3-7. Selecting And Preparing Weld Output Cables 10 ft (3 m) 1 T otal Cable Length In Weld Circuit = 20 ft (6 m) 10 ft (3 m) For Example, 2 4 3 2 T ools Needed: sb6.1 1 1/92 – S-0653 1 W eld Output Cable Determine to t a l c a b l e l e ngth in weld circuit and maximum welding am- peres. See Section 3-8 to select proper cable si[...]

  • Page 20

    OM-201 444 Page 16 3-8. W eld Cable Sizes T otal 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) W elding Amperes 10 T o 60% Duty Cycle 60 Thru 100% Duty Cycle 10 Thru 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 20[...]

  • Page 21

    OM-201 444 Page 17 3-10. Remote Amperage Control Receptacle 1 2 1 Remote Amperage Control Receptacle RC1 2 Keyway T o connect remote amperage con- trol to receptacle, insert plug and turn clockwise until tight. Ref. ST-800 040 3-1 1. Electrical Service Guide 50 Hertz Models 500 Amp Model Input V oltage 220 380 440 Input Amperes At Rated Output 103 [...]

  • Page 22

    OM-201 444 Page 18 3-12. Connecting Input Power A. Placing Jumper Links T ools Needed: 3/8 in ssb5.1 2/92 – Ref. ST-800 042 1 2 Jumper links allow operation on dif- ferent input voltages and are facto- ry set for the highest input voltage. Check input voltage available at site. Open rear panel access door to check jumper links. 1 Input V oltage L[...]

  • Page 23

    OM-201 444 Page 19 B. Connecting Input Power Have only qualified persons make this installation. Open rear panel access door . 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using 3-1 1. Conductor rating must comply with national, state, and local electrical codes. Use lugs of proper amper-[...]

  • Page 24

    OM-201 444 Page 20 SECTION 4 – OPERA TION 4-1. Controls 1 Power Switch 2 Amperage Adjustment Control (see Section 4-2) 3 Remote Amperage Control Receptacle (See Section 3-10) 4 Circuit Breaker CB1 (See Section 5-2) 5 Remote Amperage Switch (See Section 4-3) 122 043 2 1 3 4 5 4-2. Amperage Adjustment Control 1 1 Amperage Adjustment Control Use con[...]

  • Page 25

    OM-201 444 Page 21 4-3. Remote Amperage Switch 1 Y Arcing can damage switch. Do not change Remote Am- perage switch position while power is on. Arcing inside switch can damage con- tacts, causing switch to fail. 1 Remote Amperage Switch 2 Remote Amperage Control Us e switch to select way of control- ling amperage adjustment. Fo r front panel contro[...]

  • Page 26

    OM-201 444 Page 22 4-5. Ammeter And V oltmeter (Optional) 1 2 1 V oltmeter V oltmeter displays voltage at the weld output terminals, but not nec- essarily the welding arc due to cable resistance, poor connec- tions, etc. 2 Ammeter Ammeter displays weld amperage output of unit. SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance[...]

  • Page 27

    OM-201 444 Page 23 5-2. Overload Protection Ref. ST-800 040 1 Circuit Breaker CB1 CB1 protects the welding power source control circuit from over- load. If CB1 opens, weld output drops to the minimum of the range selected. Press button to reset circuit break- er . 1 5-3. T roubleshooting T able T rouble Remedy No weld output; unit completely inoper[...]

  • Page 28

    OM-201 444 Page 24 SECTION 6 – ELECTRICAL DIAGRAM 086 018-D Figure 6-1. Circuit Diagram[...]

  • Page 29

    OM-201 444 Page 25 Notes[...]

  • Page 30

    OM-201 444 Page 26 SECTION 7 – PARTS LIST . Hardware is common and not available unless listed. Ref. ST-139 447-F 1 2 3 6 Fig 7-4 8 Fig 7-3 9 10 11 Fig 7-2 12 5 7 4 Figure 7-1 Main Assembly[...]

  • Page 31

    OM-201 444 Page 27 Description Part No. Dia. Mkgs. Item No. Quantity Figure 7-1 Main Assembly 1 006 016 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 006 890 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-201 444 Page 28 Figure 7-2 Panel, Front w/Components (Fig 7-1 Item 13) Description Part No. Dia. Mkgs. Item No. 1 +017 287 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CB1 083 432 CIRCUIT BREAKER, man reset 10A 250VDC 1 . . . . . . . [...]

  • Page 33

    OM-201 444 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 7-3 Panel, Rear w/Components (Fig 7-1 Item 10) Quantity 1 FM 1 16 190 MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 124 274 BRACKET , mtg fan motor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-201 444 Page 30 Replace Coils At Factory Or Authorized Service Stations/Service Distributors Description Part No. Dia. Mkgs. Item No. Figure 7-4. Transformer & Amplifier , Power Main 50 Hz) (Fig 7-1 Item 7) (Listed below as Amplifier) 50 Hz Models Quantity 093 931 TRANSFORMER AND AMPLIFIER, (consisting of) 1 . . . . . . . . . . . . . . . . .[...]

  • Page 35

    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 36

    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 [...]