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Hobart Welding Products OM-949 manual

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Table of contents for the manual

  • Page 1

    Processes OM-949 215 271B August 2005 Description Arc Welding Power Source Stick (SMAW ) W elding STICKMA TE 205 AC R[...]

  • 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 specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

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

  • Page 4

    [...]

  • Page 5

    OM-949 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 messag[...]

  • Page 6

    OM-949 Page 2 Arc rays from the w elding 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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

  • Page 7

    OM-949 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-949 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F4[...]

  • Page 9

    OM-949 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les util isés Sy m bole graphique d’av ertis sement ! Attention ! Cette pro- cédur e c omporte d es risques p os sibl[...]

  • Page 10

    OM-949 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau. [...]

  • Page 11

    OM-949 Page 7 2-3 . Dangers s uppléme nt aire s en r e lation avec l’insta llation, le f onctionneme nt e t la m aintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l?[...]

  • Page 12

    OM-949 Page 8 2-5. Princi pales nor mes de sécu rit é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldi[...]

  • Page 13

    OM-949 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications Rated W eldin g Output Amperage Range Max Open- Circuit Amperes Input at Rated Load Output, Single-Phase We i g ht Rated Welding Output Range Circuit V oltage 220 V (50 Hz) 230 V (60 Hz) W eight 165 A @ 25 V olts AC, 20% Duty Cycle 30 − 205A 80 V A C 47.5 7.6* 47.5 2.3* 83 lb (38 kg) [...]

  • Page 14

    OM-949 Page 10 215 257-A The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. 3-3. V olt-Ampere Curves Max Rated Load Min Amps V olts 80 70 60 50 40 30 20 10 0 25 50 75 100 125 150 175 200 225 230 V olt Model 3-4. Selecting A Location 804 294-A 1 Rati[...]

  • Page 15

    OM-949 Page 1 1 3-5. Installing Electrode Holder And Work Clamp Ref. 802 251-A / 803 583-B Y T urn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through access hole and slide barrel away from electro[...]

  • Page 16

    OM-949 Page 12 3-6. W eld Output Cables W eld Cable Size and 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 eld Output T erminals Y T urn off power before connecting to weld out- put terminals. Y Do not use worn, dam- aged, unde[...]

  • Page 17

    OM-949 Page 13 3-7. Electrical Service Guide Input V oltage 230 V − 60 Hz 220 V − 50 Hz Input Amperes At Rated Output 47.5 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 50 Normal Operating 3 70 Min Input Conductor Size In A WG 4 12 Max Recommended Input Conductor Length In Feet (Meters) 87 (27) Min Grounding C[...]

  • Page 18

    OM-949 Page 14 SECTION 4 − OPERA TION Ref. 215 247-A / 803 583-B 1 Amperage Adjustment Control 2 Power Switch 1 2 4-1. Controls[...]

  • Page 19

    OM-949 Page 15 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Repair Or Replace Cracked Cables 6 Months 12 Months Blow Out Or V acuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block (See Section 5-2) 5-2. Lubricating Shunt Block [...]

  • Page 20

    OM-949 Page 16 5-3. Reinstalling Amperage Adjustment Indicator 804 295-A / 803 564-B / 215 247-A Y T urn Off welding power source and disconnect input power . 1 W rapper Remove wrapper from unit. 2 Crank Handle 3 Shunt Shaft 4 T ransformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft protruding through front panel and turn c[...]

  • Page 21

    OM-949 Page 17 5-4. T roubleshooting T rouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 3-8). Check and replace line fuses if open. Reset breakers if necessary (see Section 3-8). Fan does not run; weld output okay . Be sure nothing is blocking movement of fan. If fan does not run freely ,[...]

  • Page 22

    OM-949 Page 18 SECTION 6 − ELECTRICAL DIAGRAMS 215 254-A Figure 6-1. Circuit Diagram[...]

  • Page 23

    OM-949 Page 19 SECTION 7 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. W elding Methods 7-1. Shielded Metal Arc Welding (SMA W) Procedure ST-151 593 1 W orkpiece Make sure workpiece is clean before welding. 2 W ork Clamp Place as close to the weld as possible. 3 Electrode A small diameter electrode requires less current than a large one[...]

  • Page 24

    OM-949 Page 20 7-2. Electrode And Amperage Selection Chart Ref. ST-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 ELECTRO[...]

  • Page 25

    OM-949 Page 21 7-3. Striking An Arc S-0049 / S-0050 1 Electrode 2 W orkpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to work- piece, use a quick twist to free it. Bring electrode straight down to workpiece; then lift s[...]

  • Page 26

    OM-949 Page 22 7-5. W eld Bead Characteristics Ref. S-0052-B 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During W elding 4 Bad Overlap 5 Poor Penetration 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During W elding W eld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded. 4 No Overlap 5 Good Penetrati[...]

  • Page 27

    OM-949 Page 23 7-7. Electrode Movement During W elding S-0054-A 1 Stringer Bead − Steady Move- ment Along Seam 2 W eave Bead − Side T o Side Movement Along Seam 3 W eave Patterns Us e weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. . A single stringer bead is sat[...]

  • Page 28

    OM-949 Page 24 7-9. Lap Joints S-0063 / S-0064 1 Electrode 2 Single-Layer Fillet W eld Move electrode in circular motion. 3 Multi-Layer Fillet W e ld W eld a second layer when a larger fillet is n eeded. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 30 ° Or Less Single-Layer Fillet Weld Multi-Layer Fil[...]

  • Page 29

    OM-949 Page 25 T able 6-2. Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high Reduce arc length or voltage. T able 6-3. Incomplete[...]

  • Page 30

    OM-949 Page 26 T able 6-5. Excessive Penetration Good Penetration Excessive Penetration − weld metal melt- ing through base metal and hanging un- derneath weld. Excessive Penetration Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. T able 6-6. Burn[...]

  • Page 31

    OM-949 Page 27 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Pr ofessional W elding Car eer Now![...]

  • Page 32

    OM-949 Page 28 SECTION 8 − P ARTS LIST Figure 8.1. Main Assembly 803 565-B . Hardware is common and not available unless listed. 19 6 5 7 4 3 8 21 11 15 20 20 18 17 16 15 14 13 12 10 9 2 1 22[...]

  • Page 33

    OM-949 Page 29 Description Part No. Dia. Mkgs. Item No. 8.1. Main Assembly Quantity 1 224 794 LABEL, gen precautionary (electrode) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +210 309 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 34

    Notes[...]

  • Page 35

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2/05 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 distributor and Hobart is t[...]

  • Page 36

    PRINTED IN USA © 2005 Hobart Welding Products. 6/05 Hoba rt We lding Product s An Illinois T ool W or ks Compa ny 600 W est Main Street Tr oy , OH 45373 USA For T ech nical Assistan ce: Call1-800-332-3281 Fo r Liter a tur e Or Nea rest Dea ler : Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]