Hobart Welding Products OM-950 manual

Processes 235 AC And 235/160 AC/DC OM-950 218 245B August 2005 Description Arc Welding Power Source Stick (SMAW ) W elding AC Models: AC/DC Models: STICKMA TE LX R[...]

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[...]

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

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OM-950 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[...]

OM-950 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[...]

OM-950 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[...]

OM-950 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[...]

OM-950 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[...]

OM-950 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. [...]

OM-950 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?[...]

OM-950 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[...]

OM-950 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Single Phase Do Not Switch Under Load Input On Of f Output Hz Hertz Alternating Current Electrode Positive Electrode Negative Direct Current W elding Arc V V olts W ork Electrode 3-2. Manufacturer ’s Rating Labels 217 652-A / 165 371-A Rating Label For EN/FR Machines R[...]

OM-950 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications AC/DC Models Mode Rated W elding Out p ut Amperage Ran g e Maximum Open- Circuit Amperes Input at Rated Load Output 50 Or 60 Hz, Single-Phase W eight Output Range Circuit V oltage 230 V AC 225 A @ 25 V olts AC, 20% Duty Cycle @ 60 Hz; 15% Duty Cycle @ 50 Hz Low: 30 − 150 High: 40 −[...]

OM-950 Page 1 1 4-2. Duty Cycle Charts A. For AC/DC Models 2 Minutes W elding 8 Minutes Resting 086 727 Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 2 0% Duty Cycle at 225 Amperes. Ex- ceeding duty cycle can damage unit and void warranty . *These models have a 15% duty cycle when used with 50 Hz inp[...]

OM-950 Page 12 4-3. V olt-Ampere Curves A. For AC/DC Models 193 509 / 193 510 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 DC Amperes DC V olts 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 30[...]

OM-950 Page 13 B. For AC Models 193 508 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 300 AC Amperes AC V olts A=LOW RANGE B=HIGH RANGE A A BB For 235A Models 4-4. Selecting A Location 804 292-A[...]

OM-950 Page 14 4-5. Installing Electrode Holder And Work Clamp Y T urn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Electrode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through access hole and slide barrel away from electrode holder . Installing Electro[...]

OM-950 Page 15 4-6. W eld Output Cables For weld output cable replacements or ex tensions, contact your Factory Authorized Service Agent. NOTE 4-7. Electrical Service Guide 50/60 Hz Single Phase Input V oltage 230 Input Amperes At Rated Output 47.5 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 50 Normal Operating [...]

OM-950 Page 16 4-8. Connecting Input Power 802 246-A 1 =GND/PE Earth Ground 4 1 3 2 Y Disconnect and lockout/tag- ou t input power before instal- ling receptacle. Y Have only qualified persons make this installation. See rating label in Section 4 - 4, and be sure to supply correct in- put power . 1 Proper Receptacle (NEMA 6-50R) (User-Supplied) Rec[...]

OM-950 Page 17 SECTION 5 − OPERA TION 5-1. Controls A. Controls For AC/DC Models Ref. 190 600-B / 802 105-D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of dc output, Electrode Posi- tive/DCEP (+),or Electrode Nega- tive/DCEN ( − ). For AC Weld Output Use mode switch to select [...]

OM-950 Page 18 B. Controls For AC Models Ref. 190 599-A / 802 105-D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac low range or high range output. 3 1 2[...]

OM-950 Page 19 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. 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 6-2) 6-2. Lubricating Shunt Block [...]

OM-950 Page 20 6-3. Reinstalling Amperage Adjustment Indicator 804 293-A / Ref. 802 248-D / Ref. 190 599-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 Transformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft protruding through front panel a[...]

OM-950 Page 21 6-4. T roubleshooting T rouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 4-8). Check and replace line fuses if open. Reset breakers if necessary (see Section 4-8). Fan does not run; weld output okay . Be sure nothing is blocking movement of fan. If fan does not run freely ,[...]

OM-950 Page 22 SECTION 7 − ELECTRICAL DIAGRAMS 191 364 Figure 7-1. Circuit Diagram For AC/DC (230 V olts) Models 191 362 WORK 230 PRI SEC T1 GRN VOL T ONL Y S2 AC HIGH AC LOW ELECTRODE PLG1 FM S1 Figure 7-2. Circuit Diagram For AC (230 V olts) Models[...]

OM-950 Page 23 SECTION 8 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. W elding Methods 8-1. Shielded Metal Arc Welding (SMA W) Procedure 151 593 1 W orkpiece Make sure workpiece is clean before welding. 2 Work Clamp Place as close to the weld as possible. 3 Electrode A small diameter electrode requires less current than a large one. Fo[...]

OM-950 Page 24 8-2. Electrode And Amperage Selection Chart Ref. 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 ELECTRODE [...]

OM-950 Page 25 8-3. 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[...]

OM-950 Page 26 8-5. 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[...]

OM-950 Page 27 8-7. Electrode Movement During W elding S-0054-A 1 Stringer Bead − Steady Move- ment Along Seam 2 Weave Bead − Side T o Side Movement Along Seam 3 Weave 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 satis[...]

OM-950 Page 28 8-9. Lap Joints S-0063 / S-0064 1 Electrode 2 Single-Layer Fillet W eld Move electrode in circular motion. 3 Multi-Layer Fillet Weld 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 Fille[...]

OM-950 Page 29 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[...]

OM-950 Page 30 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[...]

OM-950 Page 31 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![...]

OM-950 Page 32 SECTION 9 − P ARTS LIST 802 245-F . Hardware is common and not available unless listed. 27 7 6 8 5 4 11 10 23 3 14 18 25 24 22 22 21 20 19 18 17 16 15 13 12 9 2 1 26 Figure 9-1. Main Assembly (AC/DC model illustrated)[...]

OM-950 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 224 794 LABEL, gen precautionary (electrode) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 217 732 LABEL,Warning General Precautionary (En/Fr) V ert 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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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[...]

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 [...]