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Hobart Welding Products 302 manual

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Table of contents for the manual

  • Page 1

    Cyber Flex Processes 302 and 452 Models Multiprocess W elding Description Arc Welding Power Source OM-277 163 768V June 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: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-277 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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-277 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-277 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-277 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects Of Low Frequency Electric A n d M a g n e t i c F i e l d s 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 [...]

  • Page 9

    OM-277 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_Fre 4/97 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-277 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-277 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-277 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-277 Page 9 SECTION 2 – DEFINITIONS 2-1. General Precautionary Label 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 not wear wet or damaged gloves. 1.2 Protect yourself from electric sho[...]

  • Page 14

    OM-277 Page 10 2-2. Input Connection Label 1 W arning! Watch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power av[...]

  • Page 15

    OM-277 Page 1 1 2-5. Manufacturer ’ s Rating Labels For CE Products Match label to one on unit. See Section 3-4. 2-6. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Amperage/V oltage Control – Panel Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMA W) T emperature Do Not Switch While W elding[...]

  • Page 16

    OM-277 Page 12 SECTION 3 – INST ALLA TION 3-1. Specifications IP Rated Amperage/ Max Amperes Input at Rated Load Output 50 or 60 Hz, Three-Phase Model IP Rating W elding Output V oltage Range Max OCV – DC 200 V 230 V 380 V 400 V 440 V 460 V 520 V 575 V KV A KW 300 A @ 32 15 – 375A In CC Mode 60 VDC In CC Mode 57.5 4.0* 50 3.5* 30 1.5* 28 1.4*[...]

  • Page 17

    OM-277 Page 13 3-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 – 4/95 – ST-168 912 / ST -168 913 / ST-168 914 / ST -168 915 A. CC Mode B. CV Mode 300 Amp A. CC Mode 450 Amp B. CV Mode[...]

  • Page 18

    OM-277 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) Use rating label to determine input power needs. Label located under front access door . 4 Plate Label (CE Models Only) Label loc[...]

  • Page 19

    OM-277 Page 15 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 1 15 V AC Receptacle And Circuit Breakers Ref. ST-800 166-B Y T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9 a n d Remote 14 receptacle RC8 or terminal strip 1T (see Section 3-10). 2 Circuit [...]

  • Page 20

    OM-277 Page 16 3-8. W eld Output T erminals And Selecting Cable Sizes 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) T urn Off power before connecting to weld output terminals. W elding Amperes 10 – 60% Duty Cycle 60 – 100% Du[...]

  • Page 21

    OM-277 Page 17 3-10. Connecting Remote Control Ref. ST-800 170-E / Ref. S-0004-A / S-0750 1 Remote 14 Receptacle RC8 Connect remote control to RC8. If plug does not fit, wire cord to termi- nal strip 1T . Y T urn Off power before opening terminal strip cover . 2 T erminal Strip 1T 3 Remote Control Cord 4 Strain Relief (Customer Supplied) Secure cor[...]

  • Page 22

    OM-277 Page 18 3-1 1. Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model Input V oltage 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 69 60 30 24 104 90 45 36 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 80 70 35 30 125 11 0 50 45 Normal Operating 3 100 90 45 35 150 125 70 50 Min Input Conductor S[...]

  • Page 23

    OM-277 Page 19 3-12. Placing Jumper Links Ref. ST-800 103-A Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input voltage. Close access door , or go on to Section 3-13. T ools Needed: 2 1 Do not overtighten jumper link nuts. 230 VOL TS Ref. S-174 973-A 575 VOL[...]

  • Page 24

    OM-277 Page 20 3-13. Connecting Input Power ST-800 103-B / Ref. ST -801 1 16 1 Input And Grounding Conductors See Section 3-1 1. 2 Line Disconnect Device See Section 3-1 1. 3 Reed Switch (Ground Current Sensor) (Optional) 4 Grounding Conductor If unit is equipped with optional ground current sensor , route grounding conductor through reed switch tw[...]

  • Page 25

    OM-277 Page 21 SECTION 4 – OPERA TION 4-1. Controls (Non CE Models) Ref. ST-184 940 1 Process Selector Switch 2 Arc Force (Dig) Control Control increases SMAW short-circuit amper- age which allows the operator to use a very short arc length without sticking the electrode. Set control at 0 for normal welding amperage. T urn clockwise to increase s[...]

  • Page 26

    OM-277 Page 22 4-2. Controls (CE Models) Ref. ST-184 938 1 Process Selector Switch 2 Arc Force (Dig) Control Control increases SMAW short-circuit amper- age which allows the operator to use a very short arc length without sticking the electrode. Set control at 0 for normal welding amperage. T urn clockwise to increase short-circuit amperage. 3 Hot [...]

  • Page 27

    OM-277 Page 23 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . OR 5-2. Fuse F1 Ref. ST-800 101-C Y T urn[...]

  • Page 28

    OM-277 Page 24 5-3. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative; pilot light PL1 off. Place line disconnect device in On position (see Section 3-13). Check for open line fuse(s), and replace if open (see Section 3-13). Check for proper input power connections (see Section 3-13). Check for proper jumper link positi[...]

  • Page 29

    OM-277 Page 25 SECTION 6 – ELECTRICAL DIAGRAM SC-196 109-A For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. Figure 6-1. Circuit Diagram[...]

  • Page 30

    OM-277 Page 26 SECTION 7 – P ARTS LIST ST-800 704-D . Hardware is common and not available unless listed. Figure 7-1. Main Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 14 17 18 (Fig.7 – 5) 19 20 21 22 3 4 23 25 26 24 27 28 (Fig. 7-2) 29 (Fig. 7-3 & 4) 22[...]

  • Page 31

    OM-277 Page 27 Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 Figure 7-1. Main Assembly 1 +179 430 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 +179 432 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-277 Page 28 Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 Figure 7-1. Main Assembly (Continued) 26 179 213 COIL, pri/sec (LH) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 T1 189 846 TRANSFORMER, pwr main 380/520 (consisting of) 1 . . .[...]

  • Page 33

    OM-277 Page 29 Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 30) 1 S1 1 63 557 SWITCH, mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 S1 1 63 556 SWITCH, mode 1 . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-277 Page 30 Description Part No. Dia. Mkgs. Item No. Quantity Figure 7-3. Rectifier , Si Diode (302 Model) (Fig 7-1 Item 31) 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 177 316 HEA T SINK, rect 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 35

    OM-277 Page 31 Description Part No. Dia. Mkgs. Item No. Quantity Figure 7-4. Rectifier , Si Diode (452 Model) (Fig 7-1 Item 31) 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 191 989 BAR, mtg rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-277 Page 32 Description Part No. Dia. Mkgs. Item No. Quantity Figure 7-5. Panel, Rear w/Components (Fig 7-1 Item 18) 1 173 283 CHAMBER, plenum 14 in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 180 165 BLADE, fan 14 in 3wg 28deg .375 bore CCW 1 . . . . . . . . . . . . .[...]

  • Page 37

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  • Page 39

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y ou 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 distribu[...]

  • Page 40

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Company 600 West Main St reet Troy , OH 45373 U SA 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 or[...]