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Hobart Welders EZ-TIG 165I, Owner'S Manual

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Hobart Welders EZ-TIG 165I Owner'S Manual Download Page 36

ORIGINAL INSTRUCTIONS 

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 PRINTED IN USA

©

 2009 Hobart Welding Products. 2009

−

01

Hobart Welding Products

An Illinois Tool Works Company

600 West Main Street

Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281

For Literature Or Nearest Dealer:

Call 1-877-Hobart1

Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor

Address

City

State

Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

To locate a Distributor,

retail or service location:

Call 1-877-Hobart1 or visit our website at

www.HobartWelders.com

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

Resources Available

Owner’s Record

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.

For technical assistance:

Call 1-800-332-3281

Register your product at:

HobartWelders.com

Protect Your Investment!

Summary of Contents for EZ-TIG 165I

Page 1: ...Processes 230 Volt 60 Hz TIG Only OM 245 020 A 2009 09 Hobart EZ TIG 165I Processes TIG GTAW Welding Description 230 Volt Arc Welding Power Source File TIG GTAW ...

Page 2: ...ucts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The part...

Page 3: ...LATION 13 4 1 Selecting A Location 13 4 2 Remote Control Receptacle 13 4 3 Shielding Gas Connections 14 4 4 Electrical Service Guide 14 4 5 Connecting Input Power 15 SECTION 5 OPERATION 16 5 1 Controls 16 SECTION 6 MAINTENANCE AND TROUBLESHOOTING 17 6 1 Routine Maintenance 17 6 2 Circuit Breaker CB1 17 6 3 Troubleshooting 18 SECTION 7 ELECTRICAL DIAGRAM 20 SECTION 8 HIGH FREQUENCY 21 8 1 Welding P...

Page 4: ......

Page 5: ...olds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant vo...

Page 6: ...nless they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw ...

Page 7: ... panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing u...

Page 8: ...Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 86...

Page 9: ...urant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou ...

Page 10: ... ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le co...

Page 11: ...ur D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonction...

Page 12: ...sement fermés les portes et les panneaux des sources de haute fréquence maintenir les éclateurs à une distan ce correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipe...

Page 13: ...n 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov N...

Page 14: ...OM 245 020 Page 10 ...

Page 15: ...05 158 A 1 2 3 4 5 6 7 3 2 Specifications Mode Rated Output at 20 Duty Cycle Rated Input 60 HZ Single Phase KVA KW Welding Amperage Range Max OCV AC 150 Amps at 16 Volts 230 V 21 A 64 4 9 04 3 6 02 10 165 80 DC 150 Amps at 16 Volts 230 V 23 A 50 5 3 04 3 9 02 10 165 80 While idling 3 3 Serial Number And Rating Label Location The serial number and rating information for the power source is located ...

Page 16: ... 16 in 608 mm w handles 19 1 4 in 489 mm w o handles Weight 50 lbs 23 kg 3 5 Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 20 Duty Cycle at 150 A AC DC 232 918 B 2 Minutes Welding 8 Minutes Resting 0 50 100 150 200 10 100 Duty Cycle Output Amperes A ...

Page 17: ...e 511 or CEC Section 20 2 Movement 3 18 in 460 mm Location And Airflow 18 in 460 mm 18 in 460 mm 18 in 460 mm 1 Do not move or operate unit where it could tip 805 468 A 4 2 Remote Control Receptacle NOTICE Use this receptacle to connect the dedicated remote control only Connecting other types of equipment to this receptacle may damage your machine 1 8 Socket Socket Information A 1 Command referenc...

Page 18: ...urce 60 Hz Single Phase Input Voltage V 230 Volts VAC 230 Volts VAC Process AC TIG DC TIG Input Amperes A At Rated Output 21 23 Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1 Time Delay Fuse 2 25 30 Normal Operating Fuse 3 30 35 Min Input Conductor Size In AWG 4 14 14 Max Recommended Input Conductor Length In Feet Meters 70 21 64 20 Min Grounding Conductor Size In AWG 4 14 14...

Page 19: ...ect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protection using Section 4 4 fused disconnect switch shown Close and secure door on disconnect device Rem...

Page 20: ... corre sponding amperage from the white scale The AC parameters have been optimized and auto matically set Preflow is preset at 2 seconds for DC or AC Postflow is preset for one second for every ten amps of output with a minimum of eight sec onds for DC or AC 3 Power Switch Use switch to turn unit On and Off 4 Power On LED Power is on when LED is lit LED flashes when input power is more than 10 of...

Page 21: ...e Clean Δ Repair l Replace To be done by Factory Authorized Service Agent Every 3 Months nl Labels n l Gas Hoses Every 3 Months nΔ lCables And Cords Every 6 Months Durning heavy service clean monthly 6 2 Circuit Breaker CB1 805 395 A 1 Circuit Breaker CB1 If CB1 opens unit will be completely inoperative If CB1 opens repeatedly have a Fact ory Authorized Service Agent check unit 1 ...

Page 22: ...ee Section 9 1 Be sure torch cable is not close to any grounded metal Check cables and torch for cracked insulation or bad connections Repair or replace Wandering arc poor control of direction of arc Reduce gas flow rate see Section 4 3 Select proper size tungsten see Section 9 1 Properly prepare tungsten see Section 9 2 Tungsten electrode oxidizing and not remaining bright after conclusion of wel...

Page 23: ...OM 245 020 Page 19 Notes ...

Page 24: ...OM 245 020 Page 20 SECTION 7 ELECTRICAL DIAGRAM 245 018 A Figure 7 1 Circuit Diagram ...

Page 25: ...f Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conduction of High Frequency 7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring Sources of Reradiation of High Frequency 10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes and Fixture...

Page 26: ...6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Grounding Rod Consult the National Electrical Code for specifications Metal Building Requirements 9 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire acros...

Page 27: ...from American Welding Society AWS and electrode manufacturers 9 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires Use local exhaust forced ventilation at the grinder or wear an approved respirator Read MSDS for safety information Consider u...

Page 28: ...mentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 9 Guidelines The inside diameter of the gas cup should be at least three times the tungsten dia...

Page 29: ... torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool Repeat process Remove rod Welding direction 15 10 3 Positioning Torch Tungsten For Various Weld Joints 162 003 75 70 90 20 20 10 15 75 20 40 30 15 75 90 15 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint ...

Page 30: ...OM 245 020 Page 26 SECTION 11 PARTS LIST 805 466 A 1 2 3 4 5 6 7 8 11 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 11 29 30 31 32 33 34 35 36 37 38 39 40 41 Figure 11 1 Main Assembly ...

Page 31: ... none on Spd Term Blk 1 24 231 238 Nut 468 32 56 Hex 09 H Brs Blk Use w Switches 2 25 217 839 Nut Nylon Strain Rlf Pg13 5 250thk 1 062od 1 26 232 908 Work Cable W Clamp 12 ft 1 27 245 271 Torch Tig 150a 12 5ft Air Cooled 1 28 245 038 Blank Snap in Nyl 500 445 Mtg Hole Black D D 1 29 207 079 Knob Pointer 1 125 Dia 1 30 178 355 Nut 375 32 54 Hex 25 H Nyl Flange 62 D 1 31 Nameplate Hobart EZ TIG 165I...

Page 32: ...90 512 Stand Off 4 4 232 867 Panel Midplane 1 5 T1 237 413 XFMR Main Includes 1 6 RT3 207 890 Thermistor NTC 10K Ohm 25 Deg C 27 50 In Lead 1 7 232 917 Heat Sink Secondary Assy See Figure 11 3 1 8 Z1 237 412 Inductor Output 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only...

Page 33: ...1 396 Diode Ultra Fast Recovery 90 A 600 V Dual SOT 227 2 3 Q2 3 4 5 231 393 Transistor IGBT 100 A 600 V SOT 227 4 4 RT2 213 353 Thermistor NTC 30K Ohm 25 Deg C 8 In Lead 1 5 212 038 Screw M4 7 x 8 5 Pan HD PHL STL PLD Sems Split Fl 15 6 SR1 199 952 Diode Power Module 50 Amp 600 V 1 PH Fast Recovery 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested ...

Page 34: ...Notes ...

Page 35: ... to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items ar...

Page 36: ...utor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier ...

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