Hobart Welding Products STICKMATE LX Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Information EMF

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SECTION 3

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DEFINITIONS

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3-1. Symbols And Definitions

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3-2. Manufacturer’s Rating Labels

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SECTION 4

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INSTALLATION

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4-1. Specifications

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4-2. Duty Cycle Charts

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4-3. Volt-Ampere Curves

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4-4. Selecting A Location

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4-5. Installing Electrode Holder And Work Clamp

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4-6. Weld Output Cables

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4-7. Electrical Service Guide

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4-8. Connecting Input Power

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SECTION 5

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OPERATION

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5-1. Controls

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SECTION 6

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MAINTENANCE & TROUBLESHOOTING

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6-1. Routine Maintenance

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6-2. Lubricating Shunt Block And Anti-Noise Adjustment

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6-3. Reinstalling Amperage Adjustment Indicator

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6-4. Troubleshooting

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SECTION 7

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ELECTRICAL DIAGRAMS

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SECTION 8

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WELDING METHODS & TROUBLESHOOTING

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8-1. Shielded Metal Arc Welding (SMAW) Procedure

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8-2. Electrode And Amperage Selection Chart

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8-3. Striking An Arc

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8-4. Positioning The Electrode Holder

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8-5. Weld Bead Characteristics

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8-6. Conditions That Affect Weld Bead Shape

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8-7. Electrode Movement During Welding

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8-8. Butt Joints

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8-9. Lap Joints

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8-10. Tee Joints

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SECTION 9

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PARTS LIST

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OPTIONS AND ACCESSORIES
WARRANTY

Summary of Contents for STICKMATE LX

Page 1: ...Processes 235 AC And 235 160 AC DC OM 950 218 245B August 2005 Description Arc Welding Power Source Stick SMAW Welding AC Models AC DC Models STICKMATE LX 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: ...cations 10 4 2 Duty Cycle Charts 11 4 3 Volt Ampere Curves 12 4 4 Selecting A Location 13 4 5 Installing Electrode Holder And Work Clamp 14 4 6 Weld Output Cables 15 4 7 Electrical Service Guide 15 4 8 Connecting Input Power 16 SECTION 5 OPERATION 17 5 1 Controls 17 SECTION 6 MAINTENANCE TROUBLESHOOTING 19 6 1 Routine Maintenance 19 6 2 Lubricating Shunt Block And Anti Noise Adjustment 19 6 3 Rein...

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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: ...gative Direct Current Welding Arc V Volts Work Electrode 3 2 Manufacturer s Rating Labels 217 652 A 165 371 A Rating Label For EN FR Machines Rating Label For All Other Machines INPUT VOL TS AMPERES KW PHASE HERTZ SERIAL NO ST OCK NO EVIDENCE OFLABELTAMPERING VOIDS WARRANTY LR5071 V A KW Hz LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE ALTÉRATION DE L ÉTIQUETTE ANNULLE LA GARANTIE ...

Page 14: ...ts DC 20 Duty Cycle 60 Hz 15 Duty Cycle 50 Hz 30 160 80 VDC 47 5 2 3 104 lb 47 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 AC Models Rated Welding Output Amperage Range Max Open Circuit Voltage Amperes Input at Rated Load Output 50 Or 60 Hz Single Phase Weight Range Voltage 230 V 225 A 25 Volts AC 20 Duty Cycle 60 Hz 15 Duty Cycle 50 Hz ...

Page 15: ... can damage unit and void warranty These models have a 15 duty cycle when used with 50 Hz input power For 235 160A Models 2 Minutes Welding 8 Minutes Resting B For AC Models 001 836 A Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating Y 20 Duty Cycle at 225 Amperes Ex ceeding duty cycle can damage unit and void warranty These models have a 15 duty cycle whe...

Page 16: ...ves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 DC Amperes DC Volts 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 300 350 AC Amperes AC Volts For 235 160A Models ...

Page 17: ... shown 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 300 AC Amperes AC Volts A LOW RANGE B HIGH RANGE A A B B For 235A Models 4 4 Selecting A Location 804 292 A 1 Rating Label See Section 3 2 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 18: ...Electrode Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from electrode holder Insert electrode cable through barrel into end of electrode holder and tighten ter minal screw securely Move barrel toward electrode holder and tighten set screw to secure barrel in place Installing Work Cable onto Work Clamp 7 Work Clamp 8 Work Cable From Unit Has Ring Terminal on E...

Page 19: ... Grounding Conductor Size In AWG 4 12 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specif...

Page 20: ...t power 1 Proper Receptacle NEMA 6 50R User Supplied Receptacle must comply with appli cable codes 2 Input And Grounding Conductors See size and length using Section 4 7 Conductors must comply with applicable codes 3 Over Current Protection Select type and size of over current protection using Section 4 7 4 Plug NEMA 6 50P Connect plug to properly installed receptacle Close and secure door on disc...

Page 21: ...90 600 B 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of dc output Electrode Posi tive DCEP or Electrode Nega tive DCEN For AC Weld Output Use mode switch to select ac low range or high range output 3 1 2 ...

Page 22: ...OM 950 Page 18 B Controls For AC Models Ref 190 599 A 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac low range or high range output 3 1 2 ...

Page 23: ...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 24: ...nstall pinion 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 130 Amps on ac Low Range scale 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 ...

Page 25: ...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 5 1 Electrode freezing to work Increase amperage setting see Section 5 1 Increase arc length Use dry properly stored electrodes Noise and vibratio...

Page 26: ...TION 7 ELECTRICAL DIAGRAMS 191 364 Figure 7 1 Circuit Diagram For AC DC 230 Volts Models 191 362 WORK 230 PRI SEC T1 GRN VOLT ONLY S2 AC HIGH AC LOW ELECTRODE PLG1 FM S1 Figure 7 2 Circuit Diagram For AC 230 Volts Models ...

Page 27: ... a large one Follow recommendations of electrode manufacturer when setting weld amperage see 8 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 w...

Page 28: ...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 POLAR...

Page 29: ...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 8 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 30: ... 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 8 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 31: ...weave bead works better 1 2 3 8 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 32: ... 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 8 7 Remove slag before mak ing another weld pass 45 Or Less 1 2 2 1 3 B Welding Troubleshooting Table 6 1 Porosity Porosity sm...

Page 33: ...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 34: ...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 35: ...OM 950 Page 31 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 36: ... 32 SECTION 9 PARTS LIST 802 245 F Hardware is common and not available unless listed 27 7 6 8 5 4 11 10 23 3 14 18 25 24 22 22 21 20 19 18 17 16 15 13 12 9 2 1 26 Figure 9 1 Main Assembly AC DC model illustrated ...

Page 37: ... strain relief 1 15 185 759 LABEL warning 1 15 217 733 LABEL Warning Electric Shock Input Power En Fr 1 16 FM 190 234 MOTOR fan 1 17 005 656 BLADE fan 1 18 LABEL Control Output order by model and serial number 1 19 190 296 GEAR pinion 1 20 190 295 GEAR pointer 1 21 190 241 HANDLE control current 1 22 190 538 LEAD LIST 1 23 215 248 KIT electrode holder gnd clamp 1 24 LABEL brand Identity order by m...

Page 38: ...Notes ...

Page 39: ...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 40: ...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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