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Hobart OM-303 manual

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Table of contents for the manual

  • Page 1

    Description Arc Welding Power Source TIGMA TE Processes Gas Tungsten Arc (TIG) W elding Shielded Metal Arc (Stick) W elding OM-303 155795N January 2002 [...]

  • 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: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

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  • Page 5

    OM-303 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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! W atch [...]

  • Page 6

    OM-303 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 of f 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 Z8[...]

  • Page 7

    OM-303 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-303 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields 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 17 years o[...]

  • Page 9

    OM-303 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 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-303 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-303 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-303 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, W ashington, D.C. 20402. Recommended Safe Practice for th[...]

  • Page 13

    OM-303 Page 9 SECTION 2 – DEFINITIONS 2-1. General Precautionary Label[...]

  • Page 14

    OM-303 Page 10 2-2. Symbols And Definitions T ig Welding Remote Foot/Hand Control Stick W elding High T emperature Output Alternating Current Direct Current On Electrode Positive Electrode Negative Do Not Switch Under Load V oltage Input A Amperes Of f Electrode Gas Out Amperage Control/ Panel W ork Remote V V olts U 0 Rated No Load V oltage (A ver[...]

  • Page 15

    OM-303 Page 1 1 3-2. Specifications A. 60 Hertz Models Rated Output at 20% Duty Cycle W elding Amperage Range AC High AC Low DC Max. Open-Circuit V oltage Rated Output KV A Dimensions Net W eight TIG: 150 A at 15 VDC (GT A W ) 150 A at 15 V AC TIG W elding A Range 50 – 165 20 – 50 30 – 160 78 200 V – 60 A (3.6)* 230V – 52 A (3.0)* 12.0 (0[...]

  • Page 16

    OM-303 Page 12 SECTION 4 – INST ALLA TION 4-1. Selecting a Location ST-158 075 Position unit so air can circulate. For information about sources of high-frequency see Section 8. For carts and caster kits see back of book or contact your distributor . 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 4-2. T ypical Stick Connections ST-157 858-A Y T urn[...]

  • Page 17

    OM-303 Page 13 4-3. T ypical TIG Connections Ref. ST-157 858-A Y T urn Off power before mak- ing connections. 1 Remote Control 2 T orch Connect to receptacles as shown. 3 W ork Clamp 4 Cylinder Chain or secure cylinder to running gear , wall, or other stationary support. 5 Cylinder V alve Open valve slightly so gas flow blows dirt from valve. Close[...]

  • Page 18

    OM-303 Page 14 4-4. Electrical Service Guide S-0092J . For 230 V models with wall receptacle, 100% duty cycle used to calculate data below . 20% duty cycle used for all other models. Input V oltage 200 230 380 415 460 Input Amperes at Rated Output 59 52 39 36 33 Standard Fuse or Circuit Breaker Rating (Max. Recommended) 90 Amps 80 Amps 60 Amps 50 A[...]

  • Page 19

    OM-303 Page 15 SECTION 5 – OPERA TION 5-1. Controls Ref. ST-155 790-F 1 Weld Process Switch Use switch to select weld process. In Stick position (down), weld output goes On and Of f with Power switch. In GT A W (TIG) position (up), remote control device turns on and adjusts weld output of unit as limited by Amperage control. Built-in arc starter [...]

  • Page 20

    OM-303 Page 16 5-2. Example of Front Panel Amperage Control In Example: Range = DC Percentage of Range = 50% W eld Amperage = 33 A DC Select percentage. Select weld process. Select range and polarity . 5-3. Example of Remote Amperage Control Connect remote control. GT A W Welding Amperage Range AC Low AC High DC 20-50 A 60-165 A 30-165 A In Example[...]

  • Page 21

    OM-303 Page 17 5-4. Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And 22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 1 1 ga 10 ga 6 ga 2 ga – 0.033 in 0.8 mm 0.036 in 0.9 mm 0.048 in 1.2 mm 0.06 in 1.5 mm 0.07 in 1.8 mm 0.1 in 2.5 mm 0.125 in 3.2 mm 0.14 in 3.6 mm 0.186 in 4.8 mm[...]

  • Page 22

    OM-303 Page 18 SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Repair or replace cracked gas hose. Replace o-ring in Electrode/Gas O[...]

  • Page 23

    OM-303 Page 19 SECTION 7 – ELECTRICAL DIAGRAMS SB-154 141-C Figure 7-1. Circuit Diagram[...]

  • Page 24

    OM-303 Page 20 SECTION 8 – HIGH FREQUENCY 8-1. W elding Processes Requiring High Frequency high_freq1 1 1/96 – S-0693 1 High-Frequency V oltage Helps arc jump air gap between torch and workpiece and/or stabilize the arc. 1 TIG W ork 8-2. Incorrect Installation 50 ft (15 m) S-0694 Sources of Direct High-Frequency Radiation 1 High-Frequency Sourc[...]

  • Page 25

    OM-303 Page 21 8-3. Correct Installation 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply , and worktable. 2 Center Point of Welding Zone Midpoint between high-frequency source a n d welding torch. 3 Welding Zone A circle 50 ft ([...]

  • Page 26

    OM – 303 Page 22 SECTION 9 – P ARTS LIST ST-801 399-C Figure 9-1.Main Assembly . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 7 31 32 33 34 35 34 32 36 37 38 39 40 41 11 42 43 45 44 46 47 48[...]

  • Page 27

    OM-303 Page 23 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 154 335 BEZEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 203 990 LABEL, warning general precautionary 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM – 303 Page 24 Description Part No. Dia. Mkgs. Item No. Figure Figure 9-1. Main Assembly (Continued) Quantity 42 PL1 157 958 LIGHT , ind wht lens 28V 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 155 422 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 29

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  • Page 31

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 10/01 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 distri[...]

  • Page 32

    PRINTED IN USA  2002 Hobart Welding Products. 1/02 Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 W es t Main St reet Troy , OH 45373 USA For T ech nical Assistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to or[...]