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Hobart OM-353 manual

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Table of contents for the manual

  • Page 1

    Cybertig Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding Arc Welding Power Source OM-353 122200U November 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 T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-353 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 O[...]

  • Page 6

    OM-353 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-353 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-353 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects 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-353 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-353 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-353 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-353 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 the[...]

  • Page 13

    OM-353 Page 9 SECTION 2 – DEFINITIONS 2-1. W arning Label Definitions S-176 254-A 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 5 6 + 2.3 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 Wear dry insulating gloves. Do not touch electrode with bare hand. Do[...]

  • Page 14

    OM-353 Page 10 2-2. Rating Label For CE Products S-178 813-A ISO/IEC 974-1 X 25% 60% 100% 7A/10.2V 310A/22.4V U 0 = 80V I 2 310A 200A 155A U 2 22.4V 18V 16.2V X 25% 60% 100% 5A/20.2V 310A/32.4V U 0 = 80V I 2 310A 200A 155A U 2 32.4V 28V 26.2V IP 21S U 1 = 220 I 1max = 1 17.2A I 1Eff = 59A 1 1 1 50 Hz U 1 = 380 I 1max = 72.2A I 1E ff = 36A U 1 = 415[...]

  • Page 15

    OM-353 Page 1 1 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Panel – Local Gas Tungsten Arc W elding (GT A W) Shielded Metal Arc W elding (SMA W) V V olts Do Not Switch While W elding Arc Force (DIG) Spot T imer Output Circuit Breaker Remote T emperature Protective Earth (Ground) Alternating Current High[...]

  • Page 16

    OM-353 Page 12 SECTION 3 – INST ALLA TION 3-1. Specifications Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase Rated W elding Output PFC** 200 V 230 V 460 V 575 V KV A KW Amp Range Max OCV IP Rating NEMA Class II (40) – 250 No PFC 106 (4.6*) 92 (4*) 46 (2*) 37 (1.6*) 21 (0.89*) 1 1.4 (0.68*) Amperes, 30 V olts AC, 40% Duty[...]

  • Page 17

    OM-353 Page 13 3-3. Duty Cycle And Overheating 4 Minutes W elding 6 Minutes Resting 6 Minutes W elding 4 Minutes Resting Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating. If unit overheats, thermostat opens, output stops, light goes on (CE models only), and cooling fan runs. Wait fifteen minutes for uni[...]

  • Page 18

    OM-353 Page 14 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) 4 Rating Label (CE Models Only , See Section 2-2) Use rating label to determine input power needs. CE label located on rear panel[...]

  • Page 19

    OM-353 Page 15 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 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 operati[...]

  • Page 20

    OM-353 Page 16 3-8. Remote 14 Receptacle Socket* Socket Information A 24 volts ac. B Contact closure to A completes 24 volts ac contactor control circuit. C Command reference; 0 to +10 volts dc output to remote control. AJ B K I D Remote control circuit common. C L NH D M G F A E 0 to +10 volts dc input command signal from remote control. E F ST-15[...]

  • Page 21

    OM-353 Page 17 3-10. Electrical Service Guide All values calculated at 60% duty cycle. NOTE 60 Hertz Models Without Power Factor Correction With Power Factor Correction Input V oltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 85 74 37 30 55 48 24 19 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 125 11 0 60 4[...]

  • Page 22

    OM-353 Page 18 1 3-1 1. Placing Jumper Links And Connecting Input Power ST-1 17 263-K Check input voltage available at site. 1 Jumper Link Label Check label inside your unit – only one label is on unit. Y Only make connections for th e voltages shown on the la - bel inside your unit. Do not make connections for any other voltages. If jumper link [...]

  • Page 23

    OM-353 Page 19 SECTION 4 – OPERA TION 4-1. Controls Ref. ST-1 17 264-F / Ref. ST-154 795-C 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 Ammeter See Section 4-3. 2 V oltmeter See Section 4-3. 3 High Frequency Switch See Section 4-1 1. 4 Output (Contactor) Switch See Section 4-8. 5 Spot Time Switch And Control (Optional) See Section 4-5. 6 Preflow Time Co[...]

  • Page 24

    OM-353 Page 20 4-2. Output Selector Switch Ref. ST-181 675-A 1 Output Selector Switch Y Do not use AC output in damp areas, if movement is confined, or if there is dan- ger of falling. Use AC output ONL Y if required for the welding process, and then use a remote control. Y Do not change position of switch while welding or while under load. Us e sw[...]

  • Page 25

    OM-353 Page 21 4-4. Crater Time Controls 1 Crater T ime Control Us e control to reduce current over a set period of time (0 – 15 seconds) at the end of the weld cycle when NOT using a remote current control. 2 Crater Time Switch ON – provides crater time. OFF – provides no crater time. Place switch in the OFF position for Shielded Metal Arc W[...]

  • Page 26

    OM-353 Page 22 4-6. AC Balance Control Ref. S-0795-A 1 AC Balance Control Balance Control (AC GT A W): Control changes the AC output square wave. Rotating the control towards 10 provides deeper pene- tration. Rotating the control towards 0 provides more cleaning action of the workpiece. When the control is in the Balanced position, the wave shape p[...]

  • Page 27

    OM-353 Page 23 4-7. Amperage Adjustment Controls 1 Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter (see S e c t i o n 4 - 3 ) . T h i s c o n t r o l m a y be adjusted while welding. For remote amperage control , front panel control setting is the maximum amperage available. For example: If front panel con[...]

  • Page 28

    OM-353 Page 24 4-9. Arc Controls 1 Arc Control (Dig) For AC And DC SMA W W elding When set at 0, short-circuit amper- age at low arc voltage is the same as normal welding amperage. When setting is increased, short- circuit amperage at low arc voltage increases. Set at 0 for GT AW welding. 2 Arc Control Switch Place switch in the ON position to turn[...]

  • Page 29

    OM-353 Page 25 4-1 1. High Frequency Controls Y Place High Frequency switch in Off position before using the shielded metal arc welding (SMA W) process. 1 High Frequency Switch ST ART – (Up position) provides H F for arc starting only . High frequency turns o n t o help start arc when out- put is enabled. High frequency turns off when arc is star[...]

  • Page 30

    OM-353 Page 26 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And T ighten W eld T erminals Repair Or Replace Cracked W eld Cables Adjust Spark Gaps Replace Cracked Parts 14-Pin Cord Gas Hose T orch Cable 6 Months OR Blow Out Or V acuum Inside,[...]

  • Page 31

    OM-353 Page 27 5-3. Adjusting Spark Gaps Ref. ST-154 795-C T ools Nee d e d : 1 4 3 4 3 2 Y T urn Off power before adjusting spark gaps. Open access door . 1 Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. 2 Spark Gap Normal spark gap is 0.008 in (0.203 mm). If adjustment is needed, proceed as follo[...]

  • Page 32

    OM-353 Page 28 T rouble Remedy Fan not operating. NOTE: fan only Check and remove anything blocking fan movement. runs when cooling is necessary . Have Factory Authorized Service Agent check fan motor . Unit provides only maximum or minimum weld output. Have Factory Authorized Service Agent check control board PC1. W eld output always above or alwa[...]

  • Page 33

    OM-353 Page 29 SC-188 161-A 5-5. Circuit Diagram[...]

  • Page 34

    OM-353 Page 30 SECTION 6 – HIGH FREQUENCY (HF) 6-1. W elding Processes Using HF high_freq1 7/95 – S-0693 1 HF V oltage GT A W – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. SA W – helps arc reach workpiece through flux granules. 2 Flux 1 2 1 Gas Tungsten Arc W elding (GT A W) Submerged Arc W elding (SA W) W [...]

  • Page 35

    OM-353 Page 31 6-3. Correct Installation 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case, work output terminal, line disconnect device, input supply , and worktable. 2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions. 3 W eld Output Cables K[...]

  • Page 36

    OM-353 Page 32 SECTION 7 – P ARTS LIST Figure 7-1. Main Assembly ST-120 135-R . Hardware is common and not available unless listed. 1 2 – Fig.7 – 3 3 4 5 6 7 – Fig.7 – 5 8 9 10 11 12 13 30 31 14 15 16 17 – Fig.7 – 4 18 19 20 21 22 23 24 25 26 27 28 29 – Fig.7 – 2[...]

  • Page 37

    OM-353 Page 33 Replace Coils at Factory or Authorized Factory Service Station Figure 7-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 182 605 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SR1 181 106 RECTIFIER, si diode[...]

  • Page 38

    OM-353 Page 34 1 2 ST-120 088-G 3 4 5 6 7 4 8 9 10 12 13 Includes Item 26 11 14 15 16 17 18 19 23 25 26 27 1 Fig 7-6 21 20 28 29 22 24 . Hardware is common and not available unless listed. Figure 7-2. Panel, Front w/Components[...]

  • Page 39

    OM-353 Page 35 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 29) Description Quantity Part No. Dia. Mkgs. Item No. 1 097 922 KNOB, pointer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . [...]

  • Page 40

    OM-353 Page 36 Figure 7-3. Rectifier , Si Diode (Fig 7-1 Item 2) Description Quantity Part No. Dia. Mkgs. 181 106 Item No. 1 C7-10 031 689 CAP ACITOR, rectifier 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 166 667 CLAMP , spring rectifier 2 . . . . . . . . . . . . . . . . . . . . [...]

  • Page 41

    OM-353 Page 37 Figure 7-5. Panel, Mtg Components (Fig 7-1 Item 7) Description Quantity Part No. Dia. Mkgs. Item No. 1 R7 186 468 RESIST OR, WW fxd 100W50 ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 17 721 P ANEL, mtg relay 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 42

    OM-353 Page 38 ST-120 003-Q . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 Figure 7-6. Control Panel, Lower Front[...]

  • Page 43

    OM-353 Page 39 Figure 7-6. Control Panel, Lower Front (Fig 7-2 Item 18) Description Quantity Part No. Dia. Mkgs. Item No. 1 171 652 P ANEL, front lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R25 137 429 RESISTOR, C2 W 3.3K 1 . . . . . . . . . . . . . . . . [...]

  • Page 44

    OM-353 Page 40 Notes[...]

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  • Page 47

    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 48

    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 [...]