Hobart Welding Products Stickmate 205 AC Owner'S Manual Download Page 32 | Manualshive

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OM-949 Page 28

SECTION 8

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PARTS LIST

Figure 8.1. Main Assembly

803 565-B

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Hardware is common and
not available unless listed.

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3

8

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11

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Summary of Contents for Stickmate 205 AC

Page 1: ...Processes OM 949 215 271B August 2005 Description Arc Welding Power Source Stick SMAW Welding STICKMATE 205 AC R ...

Page 2: ...ducts 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 par...

Page 3: ...e Curves 10 3 4 Selecting A Location 10 3 5 Installing Electrode Holder And Work Clamp 11 3 6 Weld Output Cables 12 3 7 Electrical Service Guide 13 3 8 Connecting Input Power 13 SECTION 4 OPERATION 14 4 1 Controls 14 SECTION 5 MAINTENANCE TROUBLESHOOTING 15 5 1 Routine Maintenance 15 5 2 Lubricating Shunt Block And Anti Noise Adjustment 15 5 3 Reinstalling Amperage Adjustment Indicator 16 5 4 Trou...

Page 4: ......

Page 5: ... 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper...

Page 6: ...bustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shields ...

Page 7: ... computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintained ...

Page 8: ...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 intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The E...

Page 9: ...n selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du sectionne...

Page 10: ...e de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules mé...

Page 11: ...interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC signa...

Page 12: ...art 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans les ...

Page 13: ...le 30 205A 80 VAC 47 5 7 6 47 5 2 3 83 lb 38 kg Overall Dimensions Height 18 3 4 in 476 mm Width 12 3 4 in 323 mm Depth 17 1 2 in 445 mm While idling 2 Minutes Welding 8 Minutes Resting 215 256 A Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating Y 20 Duty Cycle at 165 Amperes Ex ceeding duty cycle can damage unit and void warranty 3 2 Duty Cycle Charts 200...

Page 14: ...shown 3 3 Volt Ampere Curves Max Rated Load Min Amps Volts 80 70 60 50 40 30 20 10 0 25 50 75 100 125 150 175 200 225 230 Volt Model 3 4 Selecting A Location 804 294 A 1 Rating Label Locate unit near correct input power Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 457 mm for airflow 1 ...

Page 15: ...onto Electrode Holder 5 Electrode Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from elec trode holder Insert electrode cable through barrel into end of electrode holder and tighten terminal screw securely Move barrel toward electrode hold er and tighten set screw to secure barrel in place Installing Work Cable onto Work Clamp 7 Work Clamp 8 Work Cable From Un...

Page 16: ...orly spliced cables Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 i...

Page 17: ...e cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements 3 8 Connecting Input Power Ref 802 246 A 1 GND PE Earth Ground 4 1 3 2 Y Disconnect and lockout tag out input power before instal ling receptacle Y Have only qualified persons make this i...

Page 18: ...OM 949 Page 14 SECTION 4 OPERATION Ref 215 247 A 803 583 B 1 Amperage Adjustment Control 2 Power Switch 1 2 4 1 Controls ...

Page 19: ...isconnect input power 1 Wrapper Remove wrapper 2 Shunt Block Do not grease screw threads on shunt block Apply light coating of high tempera ture grease to shaded areas of both shunt blocks Turn amperage con trol handle to spread grease evenly 3 Noise Adjustment Screws If shunt block vibrates and becomes noisy tighten adjustment screws 1 4 turn Install wrapper turn On unit and check for shunt noise...

Page 20: ...on gear onto front panel making sure anti rotation pins are in holes on front panel 6 Pointer Gear Install pointer gear overtop of pinion gear and rotate so pointer is indicat ing 140 Amps see example Install crank handle overtop the sta tor pinion gear assembly with the handle straight down It may be necessary to turn the handle slight ly so vertical alignment is possible 7 Securing Screw Install...

Page 21: ...g movement of fan If fan does not run freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry properly stored electrodes Shorten arc length Reduce amperage setting see Section 4 1 Electrode freezing to work Increase amperage setting see Section 4 1 Increase arc length Use dry properly stored electrodes Noise and vibratio...

Page 22: ...OM 949 Page 18 SECTION 6 ELECTRICAL DIAGRAMS 215 254 A Figure 6 1 Circuit Diagram ...

Page 23: ...an a large one Follow recommendations of electrode manufacturer when setting weld amperage see 7 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound Y Welding current starts as soon as electrode touches the workpiece 7 Slag Use a chipping hammer and...

Page 24: ... 7018 7024 Ni Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRODE DC AC POSITION PENETRATION USAGE MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY FAST LOW HYDROGEN STRONG SMOOTH EASY FASTER CAST IRON STAINLESS DEEP DEEP LOW MED LOW LOW LOW LOW ALL ALL ALL ALL ALL FLAT HORIZ FILLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLA...

Page 25: ...a quick twist to free it Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it 1 2 3 1 2 3 Scratch Start Technique Tap Start Technique 7 4 Positioning The Electrode Holder S 0660 90 90 10 30 45 45 10 30 Groove Welds End View Of Work Angle Side View Of Electrode Angle Fil...

Page 26: ... Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration Into Base Metal 5 4 2 3 1 4 1 5 Good Weld Bead 2 3 Poor Weld Bead S 0053 A 7 6 Conditions That Affect Weld Bead Shape S 0061 Angle Too Small 10 30 Angle Too Large Correct Angle Drag Electrode Angle Too Short Normal Too Long Arc Length Slow Normal Fast Spatter Trav...

Page 27: ...weave bead works better 1 2 3 7 8 Butt Joints S 0662 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 through 3 4 in 5 19 mm thick Cut bevel with oxyacetylene or plasma cutting equipment Remove scale...

Page 28: ...electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer or more when a larger fillet is needed Use any of the weaving patterns shown in Sec tion 7 7 Remove slag before mak ing another weld pass 45 Or Less 1 2 2 1 3 7 11 Welding Troubleshooting Table 6 1 Porosity Porosity ...

Page 29: ...ringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Table 6 4 Lack Of Penetration Lack Of Penetration sh...

Page 30: ...Use smaller electrode with lower amperage Increase and or maintain steady travel speed Table 6 7 Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique Table 6 8 Distortion Distortion contraction of weld metal dur ing welding that forces base metal to move Base...

Page 31: ...OM 949 Page 27 Notes 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Over 80 000 trained since 1930 Start Your Professional Welding Career Now ...

Page 32: ...OM 949 Page 28 SECTION 8 PARTS 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 ...

Page 33: ...OR fan 1 14 005 656 BLADE fan 1 15 LABEL control output order by model and serial number 1 16 190 296 GEAR pinion 1 17 190 295 GEAR pointer 1 18 190 241 HANDLE control current 1 19 494 907 SCREW K50 x 20 pan hd trx stl pld thread forming 1 20 190 538 CABLE ASSY 1 21 215 248 KIT electrode holder gnd clamp 1 22 111 644 BUSHING strain relief 370 430 ID X 875 mtg hole 2 When ordering a component origi...

Page 34: ...Notes ...

Page 35: ...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 are covered by the manufacturer s warranty if ...

Page 36: ...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...

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