Hobart STICKMATE LX Owner's Manual
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Hobart STICKMATE LX Owner's Manual

225 ac/dc and 225 ac
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STICKMATE LX
OM-316
October 2003
Processes
Stick (SMAW) Welding
Description
AC/DC Models:
AC Models:
Arc Welding Power Source
R
225 AC/DC And 225 AC
087 083N

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Summary of Contents for Hobart STICKMATE LX

  • Page 1 OM-316 087 083N October 2003 Processes Stick (SMAW) Welding Description AC/DC Models: AC Models: Arc Welding Power Source STICKMATE LX 225 AC/DC And 225 AC Visit our website at www.HobartWelders.com...
  • Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications AC/DC Models Maximum Amperes Input at Rated Load Output Open- 50 Or 60 Hz, Single-Phase Rated Welding Amperage Mode Mode Weight Weight Circuit Circuit Output Output Range Range 115 V 220 V 230 V 400 V 460 V Voltage...

  • Page 14: Duty Cycle Charts

    3-2. Duty Cycle Charts A. For AC/DC Models Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 20% Duty Cycle at 225 Amperes. Ex- ceeding duty cycle can damage unit and void warranty. 2 Minutes Welding 8 Minutes Resting A.

  • Page 15: Volt-Ampere Curves

    3-3. Volt-Ampere Curves A. For AC/DC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 115/230, 230 And 460 Volt Models (225/150 Amperes) AC Amperes DC Amperes B.
  • Page 16 B. For AC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 115/230 And 230 Volt Models (225 Amperes) A=LOW RANGE B=HIGH RANGE AC Amperes B.

  • Page 17: Selecting A Location

    3-4. Selecting A Location Rating Label Locate unit near correct input power. Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 18 in (457 mm) for airflow Ref.

  • Page 18: Installing Electrode Holder And Work Clamp

    3-5. Installing Electrode Holder And Work Clamp Y Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder Electrode Holder Barrel Access Hole Set Screw Loosen set screw through access hole and slide barrel away from electrode holder.

  • Page 19: Electrical Service Guide

    3-7. Electrical Service Guide Input Voltage 47.5 23.7 Input Amperes At Rated Output [70] [39] [67] [34] Max Recommended Standard Fuse Or Circuit Breaker Rating [110] [60] In Amperes [100] [50] Min Input Conductor Size In AWG/Kcmil [14] [10] [14] 87 (26) [101 138 (42)

  • Page 20: Internal Connections For Operating 115/230 Volts, 225 Amperes Ac And Ac/Dc Models From 115 Volts

    3-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 3-7. Power Switch S1 Terminals 230V Connection 115V Connection...

  • Page 21: Internal Connections For Operating 230/400 Volts, 300/200 Amperes Ac/Dc Or 300 Amperes Ac Models From 230 Volts

    3-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300 Amperes AC Models From 230 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 3-7. Y Turn Off unit and disconnect input power.

  • Page 22: Connecting Input Power

    3-10. Connecting Input Power Y Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Y Have only qualified persons make this installation. See rating label in Section 3-4, and be sure to supply correct in- put power. Line Disconnect Device Input And Grounding Conductors For Models Not...

  • Page 23: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls A. Controls For AC/DC Models Amperage Adjustment Control Power Switch 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 ac low range or high range output.
  • Page 24 B. Controls For AC Models Amperage Adjustment Control Power Switch Mode Switch Use mode switch to select ac low range or high range output. Ref. ST-190 599-A / ST-802 105-C OM-316 Page 20 Return To Table Of Contents...

  • Page 25: Section 5 − Maintenance & Troubleshooting

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

  • Page 26: Reinstalling Amperage Adjustment Indicator

    5-3. Reinstalling Amperage Adjustment Indicator Y Turn Off welding power source and disconnect input power. Wrapper Remove wrapper from unit. Crank Handle Shunt Shaft Transformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft protruding through front panel and turn crank handle to adjust shunt to the proper vale of “X”, de- pending on model (see detail of...

  • Page 27: Troubleshooting

    5-4. Troubleshooting Trouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 3-10). Check and replace line fuses if open. Reset breakers if necessary (see Section 3-10). Fan does not run; weld output okay. Be sure nothing is blocking movement of fan.

  • Page 28: Section 6 − Electrical Diagrams

    SECTION 6 − ELECTRICAL DIAGRAMS SA-191 364 Figure 6-1. Circuit Diagram For AC/DC (230 Volts) Models SA-191 365 Figure 6-2. Circuit Diagram For AC/DC (460 Volts) Models OM-316 Page 24 Return To Table Of Contents...
  • Page 29 NEUTRAL CONNECTED FOR 115 VOLTS (WHT) CONNECTED FOR 230 VOLTS LINE (BLK) PLG1 PLG1 SA-191 363-A WORK ELECTRODE Figure 6-3. Circuit Diagram For AC/DC (115/230 Volts) Models VOLT ONLY POWER CORD S.O.P. S.O.P. WORK ELECTRODE SA-191 368 Figure 6-4. Circuit Diagram For 300/200 AC/DC (220 Volts) Models OM-316 Page 25 Return To Table Of Contents...
  • Page 30 CONNECTED FOR 400 VOLTS CONNECTED FOR 230 VOLTS 230V POWER CORD SA-191 369 WORK ELECTRODE Figure 6-5. Circuit Diagram For 300/200 AC/DC (230/400 Volts) Models 230V VOLT ONLY POWER CORD S.O.P. S.O.P. WORK ELECTRODE SA-191 370 Figure 6-6. Circuit Diagram For 300/200 AC/DC (460 Volts) Model OM-316 Page 26 Return To Table Of Contents...
  • Page 31 VOLT ONLY PLG1 AC HIGH AC LOW WORK ELECTRODE SA-191 362 Figure 6-7. Circuit Diagram For 225 (230 Volts) Models NEUTRAL CONNECTED FOR 230 VOLTS CONNECTED FOR 115 VOLTS (WHT) LINE (BLK) PLG1 PLG1 WORK ELECTRODE SA-191 361-A Figure 6-8. Circuit Diagram For 225 (115/230 Volts) Models OM-316 Page 27 Return To Table Of Contents...
  • Page 32 VOLT ONLY POWER CORD S.O.P. AC HIGH AC LOW WORK ELECTRODE SA-191 366 Figure 6-9. Circuit Diagram For 300 (220 Volts) Models CONNECTED FOR 400 VOLTS CONNECTED FOR 230 VOLTS 230V POWER CORD WORK ELECTRODE SA-191 367 Figure 6-10. Circuit Diagram For 300 (230/400 Volts) Models OM-316 Page 28 Return To Table Of Contents...

  • Page 33: Section 6 − Welding Methods & Troubleshooting

    SECTION 7 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. Welding Methods 7-1. Shielded Metal Arc Welding (SMAW) Procedure Tools Needed: ST-151 593 Workpiece Electrode Holder Position Make sure workpiece is clean before welding. Arc Length Work Clamp Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound.

  • Page 34: Electrode And Amperage Selection Chart

    7-2. Electrode And Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 1/16 5/64 3/32 6013 5/32 3/16 7/32 3/32 5/32 7014 3/16 7/32 3/32 5/32 7018 3/16 7/32 3/32 5/32 7024 3/16 7/32 3/32 Ni-Cl 5/32 3/16 3/32 308L 5/32 6010...

  • Page 35: Striking An Arc

    7-3. Striking An Arc Electrode Scratch Start Technique Workpiece 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 Tap Start Technique workpiece;...

  • Page 36: Weld Bead Characteristics

    7-5. Weld Bead Characteristics Large Spatter Deposits Poor Weld Bead Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A Fine Spatter Uniform Bead Good Weld Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded.

  • Page 37: Electrode Movement During Welding

    7-7. Electrode Movement During Welding Stringer Bead − Steady Move- ment Along Seam Weave Bead − Side To Side Movement Along Seam Weave Patterns Use 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.

  • Page 38: Lap Joints

    7-9. Lap Joints Electrode Single-Layer Fillet Weld ° Or Less ° Or Less Move electrode in circular motion. Multi-Layer Fillet Weld Weld a second layer when a larger fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.
  • Page 39 Table 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.
  • Page 40 Table 6-5. Excessive Penetration Excessive Penetration − weld metal melt- ing through base metal and hanging un- derneath weld. Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. Table 6-6.
  • Page 41 Notes OM-316 Page 37 Return To Table Of Contents...

  • Page 42: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. SA-802 245-E Figure 8-1. Main Assembly (AC/DC model illustrated) OM-316 Page 38 Return To Table Of Contents...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... 134 464 LABEL, gen precautionary ..........
  • Page 44 Notes OM-316 Page 40 Return To Table Of Contents...
  • Page 47 1-877-HOBART1 HSW-25 spot welder models effective with Serial No. KK200262 and newer. for your local This limited warranty supersedes all previous Hobart warranties and is exclusive with Hobart distributor. no other guarantees or warranties expressed or implied. Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

  • Page 48: Options And Accessories

    Call 1-877-Hobart1 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  PRINTED IN USA 2003 Hobart Welding Products. 1/03...

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