Related Manuals for Hobart Welding Products STICKMATE LX
Summary of Contents for Hobart Welding Products STICKMATE LX
- Page 1 OM-950 218 245B August 2005 Processes Stick (SMAW) Welding Description AC/DC Models: AC Models: Arc Welding Power Source STICKMATE LX 235 AC And 235/160 AC/DC...
- 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.
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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 _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. - 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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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 Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org). -
Page 13: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Do Not Switch Amperes Single Phase Input Under Load Output Hertz Alternating Electrode Positive Electrode Negative Direct Current Current Welding Arc Volts Work Electrode 3-2. Manufacturer’s Rating Labels Rating Label For EN/FR Machines Rating Label For All Other Machines INPUT SERIAL NO. -
Page 14: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Specifications AC/DC Models Amperes Input at Rated Load Maximum Output 50 Or 60 Hz, Open- Rated Welding Amperage Mode Weight Single-Phase Output Output Range Range Circuit Circuit Voltage 230 V 225 A @ 25 Volts AC, Low: 30 −... -
Page 15: Duty Cycle Charts
4-2. 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 For 235/160A Models*... -
Page 16: Volt-Ampere Curves
4-3. 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. For 235/160A Models AC Amperes DC Amperes 193 509 / 193 510 OM-950 Page 12... -
Page 17: Selecting A Location
B. For AC Models The volt-ampere curves show the For 235A Models minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- A=LOW RANGE tween the curves shown. B=HIGH RANGE AC Amperes 193 508 4-4. Selecting A Location Rating Label (See Section 3-2) Locate unit near correct input... -
Page 18: Installing Electrode Holder And Work Clamp
4-5. Installing Electrode Holder And Work Clamp Y Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Electrode Holder Electrode Holder Barrel Access Hole Set Screw Loosen set screw through access hole and slide barrel away from electrode holder. -
Page 19: Weld Output Cables
4-6. Weld Output Cables NOTE For weld output cable replacements or extensions, contact your Factory Authorized Service Agent. 4-7. Electrical Service Guide 50/60 Hz Single Phase Input Voltage Input Amperes At Rated Output 47.5 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker , Time-Delay Normal Operating... -
Page 20: Connecting Input Power
4-8. Connecting Input Power Y Disconnect and lockout/tag- out 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- =GND/PE Earth Ground put power. Proper Receptacle (NEMA 6-50R) (User-Supplied) -
Page 21: Section 5 − Operation
SECTION 5 − OPERATION 5-1. 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 22 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. 190 599-A / 802 105-D OM-950 Page 18...
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Page 23: Section 6 − Maintenance & Troubleshooting
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. 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 6-2) Clean Monthly 6-2. -
Page 24: Reinstalling Amperage Adjustment Indicator
6-3. 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 25: Troubleshooting
6-4. Troubleshooting Trouble 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. -
Page 26: Section 7 − Electrical Diagrams
SECTION 7 − ELECTRICAL DIAGRAMS 191 364 Figure 7-1. Circuit Diagram For AC/DC (230 Volts) Models VOLT ONLY PLG1 AC HIGH AC LOW WORK ELECTRODE 191 362 Figure 7-2. Circuit Diagram For AC (230 Volts) Models OM-950 Page 22... -
Page 27: Section 8 − Welding Methods & Troubleshooting
SECTION 8 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. Welding Methods 8-1. Shielded Metal Arc Welding (SMAW) Procedure Tools Needed: 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 28: Electrode And Amperage Selection Chart
8-2. 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 7014 5/32 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 29: Striking An Arc
8-3. 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 30: Weld Bead Characteristics
8-5. 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 31: Electrode Movement During Welding
8-7. 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 32: Lap Joints
8-9. Lap Joints Electrode Single-Layer Fillet Weld 30 Or Less 30 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 33 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 34 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 35 Notes Start Your Professional Over 80,000 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! trained since 1930! 1-800-332-9448 www.welding.org OM-950 Page 31...
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Page 36: Section 9 − Parts List
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 245-F Figure 9-1. Main Assembly (AC/DC model illustrated) OM-950 Page 32... - Page 37 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ... 224 794 LABEL, gen precautionary (electrode) ........
- Page 38 Notes...
- Page 39 Effective January 1, 2005 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface LF or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
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Page 40: Options And Accessories
Welding Process Handbooks 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 2005 Hobart Welding Products. 6/05...