Instruction/ maintenance manual of the product OM-949 Hobart Welding Products
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Processes OM-949 215 271B August 2005 Description Arc Welding Power Source Stick (SMAW ) W elding STICKMA TE 205 AC 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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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.
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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-.
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.
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.
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 .
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 .
OM-949 Page 18 SECTION 6 − ELECTRICAL DIAGRAMS 215 254-A Figure 6-1. Circuit Diagram.
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.
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.
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.
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.
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.
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.
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.
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.
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!.
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.
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 .
Notes.
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.
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.
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If you have not bought Hobart Welding Products OM-949 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-949 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-949 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-949 will certainly help you make a decision on the purchase.
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However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-949. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-949 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
