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Hobart Welding Products OM-2208 manual

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Table of contents for the manual

  • Page 1

    Stellar A T CC/CV and CC Models Processes Descrip tio n Multiprocess W elding Arc Welding Power Source OM -2208 175 493V May 2002[...]

  • 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 A W Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-2208 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 [...]

  • Page 6

    OM-2208 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 Z8[...]

  • Page 7

    OM-2208 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 [...]

  • Page 8

    OM-2208 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 [...]

  • Page 9

    OM-2208 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-2208 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 l[...]

  • Page 11

    OM-2208 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 [...]

  • Page 12

    OM-2208 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 th[...]

  • Page 13

    OM-2208 Page 9 SECTION 2 – INTRODUCTION 2-1. Specifications V oltage Amperage Max. Open- RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load V oltages and Class I Rating Rated Output at 60% Duty Cycle Range in CV Mode Range in CC Mode Circuit V oltage 230 V 460 V 575 V KV A KW 300 A at 32 VDC, 3-Phase 10 – 35 V 5 – 400 A 90 VDC 30[...]

  • Page 14

    OM-2208 Page 10 2-3. V olt-Ampere Curves va_curve1 4/95 – SA-178 652 / SA-178 653 V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. A. CC Mode B. CV Mode ARC CONTROL[...]

  • Page 15

    OM-2208 Page 1 1 SECTION 3 – INSTALLATION 3-1. Selecting a Location loc_2 3/96 - Ref. ST-151 556 / ST -801 192 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply . Y Spe[...]

  • Page 16

    OM-2208 Page 12 3-2. W eld Output Receptacles 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 weldin[...]

  • Page 17

    OM-2208 Page 13 3-3. Remote 14 Receptacle Information Socket* Socket Information 24 VOL TS AC A 24 volts ac. Protected by circuit breaker CB2. AJ K I 24 VOL TS AC B Contact closure to A completes 24 volts ac contactor control circuit. B K I C L NH 1 15 VOL TS AC I 1 15 volts ac. Protected by circuit breaker CB1. C NH D M G E F 1 15 VOL TS AC J Cont[...]

  • Page 18

    OM-2208 Page 14 3-5. Electrical Service Guide Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow- er source requires a CONTINUOUS supply of 60 Hz ( + 10%) power at + 10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to t[...]

  • Page 19

    OM-2208 Page 15 3-6. Connecting Input Power input_9_99 - Ref. ST-144 221 / Ref. ST -070 399-C / ST-801 192 Check input voltage available at site. . The Auto-Link circuitry in this unit automatically links the power source to the primary voltage being applied. A 230/460 unit can be connected to either 230 or 460 V AC input power . A 460/575 model ca[...]

  • Page 20

    OM-2208 Page 16 SECTION 4 – OPERATION 4-1. Front Panel Controls For CC/CV Model 1 Power Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 4-3) 3 Ammeter (see Section 4-3) 4 V/A (V oltage/Amperage) Adjustment Control 5 Mode Switch Th e Mode switch setting determines both the proce[...]

  • Page 21

    OM-2208 Page 17 4-2. Front Panel Controls For CC Model Ref. ST-175 500 23 4 5 1 7 6 1 Power Switch . The fan motor is thermostatically controlled and only runs when cooling is needed. 2 V oltmeter (see Section 4-5) 3 Ammeter (see Section 4-5) 4 V/A (V oltage/Amperage) Adjustment Control 5 Mode Switch Th e Mode switch setting determines both the pro[...]

  • Page 22

    OM-2208 Page 18 4-3. Meter Functions For CC/CV Model The meters display the actual weld output values for approximately three seconds after the arc is broken. NOTE Mode Meter Reading At Idle Meter Reading While W elding Scratch Start TIG VA Actual V olts (OCV) Preset Amps 80.0 85 Actual V olts Actual Amps VA 10.3 85 Lift-Arc TIG Actual V olts Prese[...]

  • Page 23

    OM-2208 Page 19 4-5. Meter Functions For CC Model The meters display the actual weld output values for approximately three seconds after the arc is broken. NOTE Mode Meter Reading At Idle Meter Reading While W elding Scratch Start TIG VA Actual V olts (OCV) Preset Amps 80.0 85 Actual V olts Actual Amps VA 10.3 85 Lift-Arc TIG Actual V olts Preset A[...]

  • Page 24

    OM-2208 Page 20 4-7. Lift-Arc TIG Procedure With Process Switch in the Lift-Arc TI G position, start an arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , a nd slo wly lif t electrode. An arc will form when electrode is lifted. Normal open-circuit [...]

  • Page 25

    OM-2208 Page 21 5-2. V oltmeter/Ammeter Help Displays . Al l directions are in reference to the front of the unit. All circuitry referred to is lo- cated inside the unit. 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side o f t h e unit. If this display is shown, con- tact a Factory Authorized Service Agent. 2 Help 1 Display Indic[...]

  • Page 26

    OM-2208 Page 22 5-3. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. T o blow out unit, direct airflow through front and back louvers as shown. ST-801 192 5-4. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative. Place line disconnect switch in On position (see Section 3-6). Check and repl[...]

  • Page 27

    OM-2208 Page 23 Notes[...]

  • Page 28

    OM-2208 Page 24 SECTION 6 – ELECTRICAL DIAGRAMS 197 550-A Figure 6-1. Circuit Diagram For 230/460 V olt Models[...]

  • Page 29

    OM-2208 Page 25 197 553 Figure 6-2. Circuit Diagram For 460/575 V olt Models[...]

  • Page 30

    OM – 2208 Page 26 SECTION 7 – P ARTS LIST ST-801 428-F . Hardware is common and not available unless listed. 1 2 3 30 31 32 33 34 12 9 38 39 40 42 49 50 51 52 53 56 57 58 59 60 61 22 62 63 64 4 5 6 65 12 11 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 35 36 37 41 43 44 11 45 46 47 48 54 55 66 67 Figure 7-1. Parts Assembly[...]

  • Page 31

    OM-2208 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Parts Assembly Quantity 1 +175 148 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 551 INSULA TOR, side LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM – 2208 Page 28 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Parts Assembly (Continued) Quantity 36 C3,4 192 935 CAP ACITOR, elctlt 2700uf 450VDC (230/460) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 C3,4 193 738 CAP ACITOR, elctlt 1800uf 500VDV (460/575) 2 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 33

    OM-2208 Page 29 Notes[...]

  • Page 34

    OM – 2208 Page 30 Notes[...]

  • Page 35

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 10/01 Service Y ou 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  2002 Hobart Welding Products. 1/02 Hoba rt W elding Produc ts An I l li noi s T ool Works Com pany 600 West M ain S treet Troy , OH 45373 U SA For Technical Assi stance: Call1-800-332-3281 For Lit erature O r Nearest D ealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o[...]