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SA-191 363-A

SEC

T1

S2

WORK

ELECTRODE

R

Z1

SR1

CONNECTED FOR 230 VOLTS

PRI

GRN

S1

1

2

3

4

CONNECTED FOR 115 VOLTS

PRI

T1

1

2

3

4

PLG1

FM

FM

S1

GRN

S1

PLG1

LINE
(BLK)

NEUTRAL
(WHT)

Figure 6-3. Circuit Diagram For AC/DC (115/230 Volts) Models

SA-191 368

220

PRI

SEC

T1

GRN

VOLT

ONLY

S2

WORK

ELECTRODE

R

Z1

SR1

S.O.P.

POWER

CORD

FM

S1

S.O.P.

Figure 6-4. Circuit Diagram For 300/200 AC/DC (220 Volts) Models

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Summary of Contents for STICKMATE LX

Page 1: ...225 AC DC And 225 AC Processes Description Arc Welding Power Source OM 316 087 083N October 2003 Stick SMAW Welding AC Models AC DC Models STICKMATE LX R Visit our website at www HobartWelders com ...

Page 2: ... 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 parts list will...

Page 3: ... 14 3 7 Electrical Service Guide 15 3 8 Internal Connections For Operating 115 230 Volts 225 Amperes AC And AC DC Models From 115 Volts 16 3 9 Internal Connections For Operating 230 400 Volts 300 200 Amperes AC DC Or 300 Amperes AC Mod els From 230 Volts 17 3 10 Connecting Input Power 18 SECTION 4 OPERATION 19 4 1 Controls 19 SECTION 5 MAINTENANCE TROUBLESHOOTING 21 5 1 Routine Maintenance 21 5 2 ...

Page 4: ......

Page 5: ...nnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cab...

Page 6: ...r or cut off welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can t...

Page 7: ...nsible 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 D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibi...

Page 8: ...02269 9101 phone 617 770 3000 website www nfpa org and www sparky 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 intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 webs...

Page 9: ...ordon d alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D Pour exécuter les branchements d entrée fixer d abord le conducteur de mise à la terre adéquat et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation et s assurer qu il n est ni endommagé ni dénudé le remplacer imméd...

Page 10: ...empts d huile tels que des gants en cuir une chemise en tissu épais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJETÉES peu vent blesser les yeux D Le soudage le burinage le passage de la pièce à la brosse métallique et le meulage provoquent l émission...

Page 11: ...ouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de causer des interférences D Le rayonnement haute fréquence peut causer des interférences avec les équipements de radio navigation et de communication les services de sécurité et les ordinateurs D Ne demander qu à des personnes qualifiées familiarisées avec les équipements électroniques de faire fonctionner l insta...

Page 12: ...ealth Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux Téléphone pour la Région 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs électromagnétiques Données sur le soudage électr...

Page 13: ... 80 VAC 70 67 39 34 134 lbs 61 kg DC 200 A 25 Volts DC 20 Duty Cycle 50 60 Hz 30 200 80 VDC 70 5 4 67 3 6 39 1 8 34 1 3 134 lbs 61 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 Rated Welding Output Range...

Page 14: ...dels 300 200 Amperes A For 115 230 230 And 460 Volt Models 225 150 Amperes These models have a 15 duty cycle when used with 50 Hz input power 2 Minutes Welding 8 Minutes Resting B For AC Models ST 001 836 A SB 099 603 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 B...

Page 15: ... shown A For 115 230 230 And 460 Volt Models 225 150 Amperes B For 220 230 400 And 460 Volt Models 300 200 Amperes 0 10 20 30 40 50 60 70 80 90 100 0 100 200 300 400 DC Amperes DC Volts MIN MAX 0 10 20 30 40 50 60 70 80 90 100 0 50 100 150 200 250 300 350 400 450 AC Amperes A LOW RANGE B HIGH RANGE A A B B 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...

Page 16: ...es shown A For 115 230 And 230 Volt Models 225 Amperes B For 220 Volt Model 300 Amperes C For 230 400 Volt Model 300 Amperes 0 10 20 30 40 50 60 70 80 90 0 100 200 300 400 500 AC Amperes AC Volts 0 10 20 30 40 50 60 70 80 90 100 0 50 100 150 200 250 300 350 400 450 AC Amperes AC Volts A LOW RANGE B HIGH RANGE A A B B 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 300 AC Amperes AC Volts A LOW R...

Page 17: ...electing A Location Ref ST 151 556 ST 802 105 C 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 18: ...it 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 Unit Has Ring Terminal on End 9 Mounting Bolt Rou...

Page 19: ...ircuit Breaker Rating In Amperes 150 110 70 100 60 35 50 Min Input Conductor Size In AWG Kcmil 8 8 12 10 14 14 14 Max Recommended Input Conductor Length In Feet Meters 32 10 75 23 87 26 82 25 101 31 138 42 87 27 Min Grounding Conductor Size In AWG Kcmil 8 8 12 10 14 14 14 Electrical Service Requirements For 300 200 AC DC And 300 AC Models Reference 1997 National Electrical Code NEC Ref S 0092 J ...

Page 20: ...oosen strain relief and remove 230 volt in put power cord Obtain correct size and length 115 volt input power cord see Section 3 7 Install correct size ring terminals to cord leads Route cord through strain relief and connect green lead to ground terminal To install large power cords remove knock out located on lower rear panel of unit insert power cord and install plug into original power cord ho...

Page 21: ...r 1 Primary Coil Lead 4 2 Lead 4 Insulation Sleeving 3 Power Switch Lead 4 4 Lead Connection Hardware Slide Sleeving down and discon nect one lead 4 from the other Re move sleeving 5 Fan Motor FM Lead 2 6 Lead 2 Insulation Sleeving Disconnect fan motor lead 2 at fan motor and remove sleeving Take lead 2 sleeving and secure it over the end of primary coil lead 4 Replace lead 2 sleeving with lead 4 ...

Page 22: ...ting label in Section 3 4 and be sure to supply correct in put power 1 Line Disconnect Device 2 Input And Grounding Conductors For Models Not Supplied With Plug See Section 3 7 for conductor and fuse size and ratings Size and ratings must comply with applicable codes 3 Plug 4 Proper Receptacle User Supplied GND PE L1 2 3 Install conductors into a deenergized line disconnect device Y Always connect...

Page 23: ...odels Ref ST 190 600 B ST 802 105 C 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 24: ...e 20 Return To Table Of Contents B Controls For AC Models Ref ST 190 599 A ST 802 105 C 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 25: ...ower source and disconnect 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 chec...

Page 26: ...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 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 possible 7 ...

Page 27: ...hing is blocking 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 Noi...

Page 28: ...OM 316 Page 24 Return To Table Of Contents SECTION 6 ELECTRICAL DIAGRAMS SA 191 364 Figure 6 1 Circuit Diagram For AC DC 230 Volts Models SA 191 365 Figure 6 2 Circuit Diagram For AC DC 460 Volts Models ...

Page 29: ...I GRN S1 1 2 3 4 CONNECTED FOR 115 VOLTS PRI T1 1 2 3 4 PLG1 FM FM S1 GRN S1 PLG1 LINE BLK NEUTRAL WHT Figure 6 3 Circuit Diagram For AC DC 115 230 Volts Models SA 191 368 220 PRI SEC T1 GRN VOLT ONLY S2 WORK ELECTRODE R Z1 SR1 S O P POWER CORD FM S1 S O P Figure 6 4 Circuit Diagram For 300 200 AC DC 220 Volts Models ...

Page 30: ...PRI T1 GRN S1 230V 1 2 3 4 4 CONNECTED FOR 230 VOLTS PRI T1 1 3 2 POWER CORD FM FM Figure 6 5 Circuit Diagram For 300 200 AC DC 230 400 Volts Models SA 191 370 SEC T1 S O P S2 WORK ELECTRODE R Z1 SR1 S O P 460 PRI GRN VOLT ONLY 230V POWER CORD FM S1 Figure 6 6 Circuit Diagram For 300 200 AC DC 460 Volts Model ...

Page 31: ...C LOW ELECTRODE PLG1 FM S1 Figure 6 7 Circuit Diagram For 225 230 Volts Models SA 191 361 A WORK CONNECTED FOR 230 VOLTS PRI SEC T1 GRN S2 ELECTRODE S1 1 2 3 4 CONNECTED FOR 115 VOLTS PRI T1 1 2 3 4 PLG1 FM FM GRN S1 PLG1 LINE BLK NEUTRAL WHT S1 Figure 6 8 Circuit Diagram For 225 115 230 Volts Models ...

Page 32: ... AC LOW ELECTRODE POWER CORD FM S1 SA 191 366 Figure 6 9 Circuit Diagram For 300 220 Volts Models SA 191 367 WORK CONNECTED FOR 400 VOLTS PRI SEC T1 GRN S2 ELECTRODE S1 230V 1 2 3 4 4 CONNECTED FOR 230 VOLTS PRI T1 1 3 2 POWER CORD FM FM Figure 6 10 Circuit Diagram For 300 230 400 Volts Models ...

Page 33: ...ess current than 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 chipp...

Page 34: ...6011 6013 7014 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 POSITIV...

Page 35: ...ork piece use 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 Elect...

Page 36: ...ead 3 Moderate 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 Fas...

Page 37: ...across gaps a 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 equipmen...

Page 38: ... of speed Hold 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 B Welding Troubleshooting Table 6 1 Porosi...

Page 39: ...nique Place stringer 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 ...

Page 40: ...ower amperage 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 meta...

Page 41: ...OM 316 Page 37 Return To Table Of Contents Notes ...

Page 42: ...OM 316 Page 38 Return To Table Of Contents SECTION 8 PARTS LIST SA 802 245 E Hardware is common and not available unless listed 31 Figure 8 1 Main Assembly AC DC model illustrated ...

Page 43: ...R AC DC 225A model 1 13 SR1 190 965 RECTIFIER AC DC 300A model 1 14 S1 124 511 SWITCH all 225A models 1 14 S1 045 834 SWITCH all 300A models 1 15 190 086 CASE SECTION 1 16 PLG1 088 297 CORD SET 230V 225A model 1 16 071 906 CABLE 460V 225A model 115 230V 225A model 1 16 204 141 CABLE all 300A models 1 17 111 443 BUSHING strain relief 230V 225A model 1 17 604 102 CONNECTOR all 300A models 460V 225A ...

Page 44: ...OM 316 Page 40 Return To Table Of Contents Notes ...

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Page 47: ...3 1 Limited Warranty shall not apply 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...

Page 48: ...r 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 th...

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