OM-245 020-C

201011

Processes
TIG (GTAW) Welding

Description

230 Volt Arc Welding Power Source

Hobart EZ-TIG 165I

230 Volt 60 Hz TIG Only

File: TIG (GTAW)

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you dont have time to do it any other way. This Owners Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. Weve 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, theres a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part Hobart is registered to the you may need to fix the problem. Warranty and ISO 9001:2000 Quality service information for your particular model System Standard. are also provided.

Working as hard as you do every power source from Hobart is backed by the best warranty in the business.

Protect Your Investment!

Hobart Welders 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 specification sheets. To locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www.HobartWelders.com. For Technical Help call 1-800-332-3281.

Register your product at: HobartWelders.com

Hob_Thank 200909

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . 2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . 9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 4 4 4 5 5 5 7 8 9 9 11 11 11 11 12 12 13 13 13 14 14 15 16 16 17 17 17 18 20 21 21 21 22 23 23 23 24 24 25 25 26

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som _201003
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Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

D D D D D D D D D D D D D D D

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owners 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

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. OM-245 020 Page 1

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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. D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. D Use only correct fuses or circuit breakers. Do not oversize or bypass them. 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 or DIRT 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 even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other Implanted Medical Devices should keep away. D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless 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 frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. OM-245 020 Page 2

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

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.

MOVING PARTS can injure.

D Keep away from moving parts such as fans. D Keep all doors, 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.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94110) when manually lifting heavy parts or equipment.

READ INSTRUCTIONS.
D Read and follow all labels and the Owners Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. D Use only genuine replacement parts from the manufacturer. D Perform maintenance and service according to the Owners Manuals, industry standards, and national, state, and local codes.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. D Sparks can cause fires keep flammables away.

D D D D

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

MOVING PARTS can injure.

D Keep away from moving parts. D Keep away from pinch points such as drive rolls.

D D D D

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

OM-245 020 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and 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 Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: 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 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passersby or individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

OM-245 020 Page 4

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

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7

Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si on lvite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou sont expliqus dans le texte. Indique une situation dangereuse qui si on lvite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou sont expliqus dans le texte. NOTE Indique des dclarations pas en relation avec des blessures personnelles.

. Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y affrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce manuel pour attirer lattention et identifier les dangers possibles. En prsence de lun de ces symboles, prendre garde et suivre les instructions affrentes pour viter tout risque. Les instructions en matire de scurit indiques ci-dessous ne constituent quun sommaire des instructions de scurit plus compltes fournies dans les normes de scurit numres dans la Section 2-5. Lire et observer toutes les normes de scurit. Seul un personnel qualifi est autoris installer, faire fonctionner, entretenir et rparer cet appareil. Pendant le fonctionnement, maintenir distance toutes les personnes, notamment les enfants de lappareil. dans lordre indiqu : 1) un poste souder DC tension constante ( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations, lutilisation dun poste souder DC fil tension constante est recommande. En outre, ne pas travailler seul ! Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de loprateur et les normes nationales, provinciales et locales. Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. En effectuant les raccordements dentre, fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. Les cbles doivent tre exempts dhumidit, dhuile et de graisse; protgezles contre les tincelles et les pices mtalliques chaudes. Vrifier frquemment le cordon dalimentation afin de sassurer quil nest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nu peut entraner la mort. Lquipement doit tre hors tension lorsquil nest pas utilis.

D D

UNE DCHARGE LECTRIQUE peut entraner la mort.

Le contact dorganes lectriques sous tension peut provoquer des accidents mortels ou des brlures graves. Le circuit de llectrode et de la pice est sous tension lorsque le courant est dlivr la sortie. Le circuit dalimentation et les circuits internes de la machine sont galement sous tension lorsque lalimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc de commande du rouleau et toutes les parties mtalliques en contact avec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger. D Ne pas toucher aux pices lectriques sous tension. D Porter des gants isolants et des vtements de protection secs et sans trous. D Sisoler de la pice couper et du sol en utilisant des housses ou des tapis assez grands afin dviter tout contact physique avec la pice couper ou le sol. D Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. D Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. D Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. D Dautres consignes de scurit sont ncessaires dans les conditions suivantes : risques lectriques dans un environnement humide ou si lon porte des vtements mouills ; sur des structures mtalliques telles que sols, grilles ou chafaudages ; en position coince comme assise, genoux ou couche ; ou sil y a un risque lev de contact invitable ou accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser les quipements suivants,

D D D D

D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. D Ne pas enrouler les cbles autour du corps. D Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct. D Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. D Ne pas toucher des porte lectrodes connects deux machines en mme temps cause de la prsence dune tension vide double. D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-lechamp les pices endommages. Entretenir lappareil conformment ce manuel. D Porter un harnais de scurit si lon doit travailler au-dessus du sol. D Sassurer que tous les panneaux et couvercles sont correctement en place. D Fixer le cble de retour de faon obtenir un bon contact mtalmtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. D Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique. D Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage. OM-245 020 Page 5

Il reste une TENSION DC NON NGLIGEABLE dans les sources de soudage onduleur UNE FOIS lalimentation coupe.
D Arrter les convertisseurs, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions indiques dans la partie Entretien avant de toucher les pices.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectu sur des conteneurs ferms tels que des rservoirs, tambours ou des conduites peut provoquer leur clatement. Des tincelles peuvent tre projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peut provoquer des incendies et des brlures. Le contact accidentel de llectrode avec des objets mtalliques peut provoquer des tincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vrifier et sassurer que lendroit ne prsente pas de danger. D Dplacer toutes les substances inflammables une distance de 10,7 m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus. D Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables. D Se protger et dautres personnes de la projection dtincelles et de mtal chaud. D Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et des ouvertures. D Surveiller tout dclenchement dincendie et tenir un extincteur proximit. D Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct. D Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de scurit). D Ne soudez pas si lair ambiant est charg de particules, gaz, ou vapeurs inflammables (vapeur dessence, par exemple). D Brancher le cble de masse sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution, dtincelles et dincendie. D Ne pas utiliser le poste de soudage pour dgeler des conduites geles. D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact. D Porter des vtements de protection dpourvus dhuile tels que des gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. D Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes. D Une fois le travail achev, assurezvous quil ne reste aucune trace dtincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupecircuits appropris. Ne pas augmenter leur puissance; ne pas les ponter. D Une fois le travail achev, assurezvous quil ne reste aucune trace dtincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupecircuits appropris. Ne pas augmenter leur puissance; ne pas les ponter. D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit.

LES PICES CHAUDES peuvent provoquer des brlures.

D Ne pas toucher mains nues les parties chaudes. D Prvoir une priode de refroidissement avant de travailler lquipement. D Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour viter les brlures.

LES FUMES ET LES GAZ peuvent tre dangereux.

Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereux pour votre sant. D Eloigner votre tte des fumes. Ne pas respirer les fumes. D lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de larc pour lvacuation des fumes et des gaz de soudage. D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approuv. D Lire et comprendre les spcifications de scurit des matriaux (MSDS) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. D Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger. D Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien ventil, et en portant un respirateur alimentation dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intense (ultraviolets et infrarouges) susceptibles de provoquer des brlure dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage. D Porter un casque de soudage approuv muni de verres filtrants appropri pour protger visage et yeux pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). D Porter des lunettes de scurit avec crans latraux mme sous votre casque. D Avoir recours des crans protecteurs ou des rideaux pour protger les autres contre les rayonnements les blouissements et les tincelles ; prvenir toute personne sur les lieux de ne pas regarder larc. D Porter des vtements confectionns avec des matires rsistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. OM-245 020 Page 6

DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrent des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.

D Fermer lalimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

LES BOUTEILLES peuvent exploser si elles sont endommages.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec prcaution. D Protger les bouteilles de gaz comprim dune chaleur excessive, des chocs mcaniques, des dommages physiques, du laitier, des flammes ouvertes, des tincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de se renverser. D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. D Ne jamais placer une torche de soudage sur une bouteille gaz. D Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurise risque dexplosion. D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords convenables pour cette application spcifique ; les maintenir ainsi que les lments associs en bon tat. D Dtourner votre visage du dtendeur-rgulateur lorsque vous ouvrez la soupape de la bouteille.

Les CHAMPS LECTROMAGNTIQUES (CEM) peuvent affecter les implants mdicaux.

D Les porteurs de stimulateurs cardiaques et autres implants mdicaux doivent rester distance. D Les porteurs dimplants mdicaux doivent consulter leur mdecin et le fabricant du dispositif avant de sapprocher de la zone o se droule du soudage larc, du soudage par points, du gougeage, de la dcoupe plasma ou une opration de chauffage par induction.

LE BRUIT peut endommager loue.

Le bruit des processus et des quipements peut affecter loue. D Porter des protections approuves pour les oreilles si le niveau sonore est trop lev.

D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque la bouteille est utilise ou quelle est relie pour usage ultrieur. D Utiliser les quipements corrects, les bonnes procdures et suffisamment de personnes pour soulever et dplacer les bouteilles. D Lire et suivre les instructions sur les bouteilles de gaz comprim, lquipement connexe et le dpliant P-1 de la CGA (Compressed Gas Association) mentionn dans les principales normes de scurit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLOSION.
D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables. D Ne pas installer lappareil proximit de produits inflammables. D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionne et protge avant de mettre lappareil en service.

LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.

D Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal. D Rduire le courant ou le facteur de marche avant de poursuivre le soudage. D Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETES peuvent provoquer des blessures.

D Porter un cran facial pour protger le visage et les yeux. D Affter llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. D Les tincelles risquent de causer un incendie loigner toute substance inflammable.

LA CHUTE DE LQUIPEMENT peut provoquer des blessures.

D Utiliser lanneau de levage uniquement pour soulever lappareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. D Utiliser un quipement de levage de capacit suffisante pour lever lappareil. D En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil. D Tenir lquipement (cbles et cordons) distance des vhicules mobiles lors de toute opration en hauteur. D Suivre les consignes du Manuel des applications pour lquation de levage NIOSH rvise (Publication N94110) lors du levage manuelle de pices ou quipements lourds.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pices. D Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprimes. OM-245 020 Page 7

Les PICES MOBILES peuvent causer des blessures.

D Ne pas sapprocher des organes mobiles. D Ne pas sapprocher des points de coincement tels que des rouleaux de commande.

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer des interfrences.

D Le rayonnement haute frquence (H.F.) peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs. D Demander seulement des personnes qualifies familiarises avec des quipements lectroniques de faire fonctionner linstallation. D Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de linstallation. D Si le FCC signale des interfrences, arrter immdiatement lappareil. D Effectuer rgulirement le contrle et lentretien de linstallation. D Maintenir soigneusement ferms les portes et les panneaux des sources de haute frquence, maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour rduire les interfrences ventuelles.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gchette avant den avoir reu linstruction. D Ne pas diriger le pistolet vers soi, dautres personnes ou toute pice mcanique en engageant le fil de soudage.

Les PICES MOBILES peuvent causer des blessures.

D Sabstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir ferms et verrouills les portes, panneaux, recouvrements et dispositifs de protection. D Lorsque cela est ncessaire pour des travaux dentretien et de dpannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifi. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand lentretien est termin et avant de rebrancher lalimentation lectrique.

LE SOUDAGE LARC risque de provoquer des interfrences.

D Lnergie lectromagntique risque de provoquer des interfrences pour lquipement lectronique sensible tel que les ordinateurs et lquipement command par ordinateur tel que les robots. Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement. Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller souder une distance de 100 mtres de tout quipement lectronique sensible. Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi. En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

D D D D D

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les tiquettes et le Mode demploi avant linstallation, lutilisation ou lentretien de lappareil. Lire les informations de scurit au dbut du manuel et dans chaque section. D Nutiliser que les pices de rechange recommandes par le constructeur. D Effectuer lentretien en respectant les manuels dutilisation, les normes industrielles et les codes nationaux, dtat et locaux.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent des fumes et des gaz qui contiennent des produits chimiques dont ltat de Californie reconnat quils provoquent des malformations congnitales et, dans certains cas, des cancers. (Code de sant et de scurit de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composs base de plomb, produits chimiques dont ltat de Californie reconnat quils provoquent des cancers et des malformations congnitales ou autres problmes de procration. Se laver les mains aprs manipulation. Ce produit contient des produits chimiques, notamment du plomb, dont ltat de Californie reconnat quils provoquent des cancers, des malformations congnitales ou dautres problmes de procration. Se laver les mains aprs utilisation. Pour les moteurs essence : Les gaz dchappement des moteurs contiennent des produits chimiques dont ltat de Californie reconnat quils provoquent des cancers et des malformations congnitales ou autres problmes de procration. Pour les moteurs diesel : Les gaz dchappement des moteurs diesel et certains de leurs composants sont reconnus par ltat de Californie comme provoquant des cancers et des malformations congnitales ou autres problmes de procration.

OM-245 020 Page 8

2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (tlphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (tlphone : 1-877-413-5184, site internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (tlphone : 800-344-3555, site Internet : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (tlphone : 703-788-2700, site Internet : www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone : 800-463-6727, site internet : www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (tlphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlphone de la rgion 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 (tlphone : 301-504-7923, site internet : 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 (tl[hone : 1-800-232-4636, site internet: www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champs lectromagntiques (CEM) certains endroits. Le courant de soudage cre un CEM autour du circuit et du matriel de soudage. Les CEM peuvent crer des interfrences avec certains implants mdicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs dimplants mdicaux doivent tre prises: par exemple, des restrictions daccs pour les passants ou une valuation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procdures suivantes pour minimiser lexposition aux CEM provenant du circuit de soudage: 1. Rassembler les cbles en les torsadant ou en les attachant avec du ruban adhsif ou avec une housse. 2. Ne pas se tenir au milieu des cbles de soudage. Disposer les cbles dun ct et distance de loprateur. 3. Ne pas courber et ne pas entourer les cbles autour de votre corps. 4. Maintenir la tte et le torse aussi loin que possible du matriel du circuit de soudage. 5. Connecter la pince sur la pice aussi prs que possible de la soudure. 6. Ne pas travailler proximit dune source de soudage, ni sasseoir ou se pencher dessus. 7. Ne pas souder tout en portant la source de soudage ou le dvidoir. En ce qui concerne les implants mdicaux : Les porteurs dimplants doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le mdecin approuve, il est recommand de suivre les procdures prcdentes.

OM-245 020 Page 9

OM-245 020 Page 10

SECTION 3 SPECIFICATIONS
3-1. Included with Your Unit
1 2 1 7 2 3 4 5 6 7 Welding Power Source 5 ft (1.5 m) Primary Cord With Plug Gas Hose Gas Regulator 12 ft (3.7 m) Work Cable With Clamp Air-Cooled 150 Amp TIG Torch with 12-1/2 ft (3.8 m) Cable RFCSRJ45 Foot Control

. Some assembly is required.

6 3 For options and accessories see back of book or contact your distributor.

5
Ref. 805 467 -A / 805 158-A

3-2. Specifications
Mode AC DC Rated Output at 20% Duty Cycle 150 Amps at 16 Volts 150 Amps at 16 Volts * () While idling. Rated Input, 60 HZ, Single-Phase 230 V - 21 A - (.64)* 230 V - 23 A - (.50)* Welding KVA 4.9 - (.04)* 5.3 - (.04)* KW 3.6 - (.02)* 3.9 - (.02)* Amperage Range 10165 10165 Max. OCV 80 80

3-3. Serial Number And Rating Label Location

The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

OM-245 020 Page 11

3-4. Dimensions And Weights

23-15/16 in. (608 mm)

Dimensions

17 in. (432 mm)

Height

17 in. (433 mm)

Width

9-7/8 in. (251 mm)

9-7/8 in. (251 mm)

Length
Ref. 805 467-A

23-15/16 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.

200

Output Amperes (A)

150

100

50

10

% Duty Cycle
20% Duty Cycle at 150 A AC/DC

100

2 Minutes Welding

8 Minutes Resting
232 918-B

OM-245 020 Page 12

SECTION 4 INSTALLATION
4-1. Selecting A Location
1 2 1 Handles Use Handles to lift welder; get help if necessary. 2 3 Cart Line Disconnect Device Place welder on cart to move unit. Locate unit near correct input power supply. Position unit so air can circulate. For information about sources of high-frequency see Section 8.

Movement

Do not move or operate unit where it could tip. 3

For carts and caster kits see back of book or contact your distributor.

Location And Airflow

Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.

18 in. (460 mm)

18 in. (460 mm)

18 in. (460 mm) 18 in. (460 mm)

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.

Socket*
1
1 8

Socket Information
Command reference; +10 volts DC output to remote control. 0 to +10 volts DC input command signal from remote control. Remote control circuit common. 15 volts DC.

2 3

805 113-A

Contact closure to 4 completes 15 volts DC contactor control circuit. Foot control select; jumper to 7 in foot control. Chassis common. OM-245 020 Page 13

Foot Select

5 7

4-3. Shielding Gas Connections . Use

2 Tools Needed: 5/8, 1-1/8 in. 3 1 1 argon shielding gas for best performance.

Cylinder Valve

Open valve slightly so gas flow blows dirt from valve. Close valve. 2 Regulator/Flow Gauge Connect regulator/flow gauge to gas cylinder. Do not over tighten. Connect gas hose to gas in fitting. 3 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour).

Ref. 805 467-A

4-4. Electrical Service Guide . All values calculated at 20% duty cycle. . Actual input voltage cannot exceed 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage
to unit may occur. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase Input Voltage (V) Process Input Amperes (A) At Rated Output Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1 Time-Delay Fuse 2 Normal Operating Fuse 3 Min Input Conductor Size In AWG 4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4 Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Time-Delay fuses are UL class RK5 . See UL 248. 3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible 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. OM-245 020 Page 14 25 30 14 70 (21) 14 30 35 14 64 (20) 14 230 Volts VAC AC TIG 21 230 Volts VAC DC TIG 23

4-5. Connecting Input Power

!
Installation must meet all National and Local Codes have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. Rating Label

18 in. (457 mm) of space for airflow 6

1
=GND/PE Earth Ground 8

Supply correct input power (see Section 4-4). 2 Black And White Input Conductor (L1 And L2) Green Or Green/Yellow Grounding Conductor Input Power Cord. Disconnect Device (switch shown in the OFF position) Disconnect Device Grounding Terminal Disconnect Device Line Terminals

5 7 L1 L2 2

3 4 5 6 7

4 9

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. Remove lockout/tagout device, and place switch in the On position. 10 L2 L1 9 Plug (NEMA 6-50P) 10 Receptacle (NEMA 6-50R) Connect plug to receptacle.

Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.

230 VAC, 1

Tools Needed:

Ref. 805 467-A

OM-245 020 Page 15

SECTION 5 OPERATION
5-1. Controls
1 Material Switch Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control. Do not change position of switch while welding or while under load.

!
4

Use switch to select DC for steel, stainless steel, and chrome-moly, or AC for aluminum applications. 2 5 1 2 Material Thickness/Amperage Control Use control to select material thickness and corresponding amperage. When Material switch is in the DC position, use the blue scale to select the appropriate material thickness and corresponding amperage from the white scale. When Material switch is in the AC position, use the gray scale to select the appropriate material thickness and corresponding amperage from the white scale. The AC parameters have been optimized and automatically 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 seconds for DC or AC. 3 Power Switch Power On LED Use switch to turn unit On and Off. 4 Power is on when LED is lit. LED flashes when input power is more than 10% of 230 volts. No output available when LED is flashing. 5 Output Indicator LED Output is On when LED is lit. LED flashes when unit is overheated (see Section 3-5). LED stops flashing when unit has cooled. 6 7 8 9 Remote Receptacle Torch (See Section 10) Work Clamp (See Section 10) Remote Control

This is a dedicated remote control. Plug remote control into remote receptacle (see Section 4-2). Depress pedal to start arc and increase amperage from 10 amps to maximum value set on the machines Material Thickness/Amperage control. Release pedal to extinguish arc.

805 469-A / 232 896

OM-245 020 Page 16

SECTION 6 MAINTENANCE AND TROUBLESHOOTING

6-1. Routine Maintenance
!
Disconnect power before maintaining.

. Maintain more often during severe conditions.

n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months = Repair l = Replace

nl Labels Every 3 Months

n l Gas Hoses

n lCables And Cords Every 6 Months ~:Durning heavy service, clean monthly.

6-2. Circuit Breaker CB1

1 Circuit Breaker CB1 If CB1 opens, unit will be completely inoperative. If CB1 opens repeatedly, have a Factory Authorized Service Agent check unit..

805 395-B

OM-245 020 Page 17

6-3. Troubleshooting . The remedies listed below are recommendations only. If these remedies do not fix the
trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit.

Trouble
No weld output; unit completely inoperative.

Remedy
Place machine power switch in On position (see Section 5-1). Place line disconnect switch in On position (see Section 4-5). Check and replace line fuse(s), if necessary (see Section 4-5). Check for proper input power connections (see Section 4-5).

No weld output; unit on.

Check, repair, or replace remote control. Have Factory Authorized Service Agent check unit.

Unit provides only maximum or minimum weld output. Erratic or improper weld output.

Make sure Material Thickness/amperage control is in proper position (see Section 5-1). Have Factory Authorized Service Agent check unit. Lay weld cables out straight, do not leave weld cables coiled. Check position of Material Selector switch (see Section Figure 5-1). Check position of Material Thickness/amperage control (see Section 5-1).

No control of weld output. Lack of high frequency; difficulty in starting GTAW arc.

Make sure Material Thickness/amperage control is in proper position (see Section 5-1). Select proper size tungsten (see 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 weld.

Shield weld zone from drafts. Check and tighten all gas fittings. Properly prepare tungsten (see Section 9-2).

Fan not operating. No weld output; fan does not run.

Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to protect against overheating. Place line disconnect switch in On position (see Section 4-5). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-5). Check for proper input power connections (see Section 4-5).

No weld output; fan on.

Be sure Material Selector switch is set in position (see Section 5-1). Check connection to remote control receptacle (see Section 4-2). Check remote control (see remote control Owners Manual). Unit overheated. Allow unit to cool (see Section 3-5).

Fan not operating; weld output available. Power LED flashes. Output On LED flashes. OM-245 020 Page 18

Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor. Input voltage out of usual range of 230 volts 10%. Unit has overheated. Do not use until LED stops flashing (see Sections 3-5 and 5-1).

Notes

OM-245 020 Page 19

SECTION 7 ELECTRICAL DIAGRAM

245 018-A

Figure 7-1. Circuit Diagram

OM-245 020 Page 20

SECTION 8 HIGH FREQUENCY

8-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage TIG helps arc jump air gap between torch and workpiece and/ or stabilize the arc.

1 Work TIG

high_freq 7/05 S-0693

8-2. Incorrect Installation

Weld Zone 11, 12 50 ft (15 m)

10 9 8 7 3 13 2 14

1 4 5 6

Sources of 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 Fixtures 14 External Phone and Power Lines

OM-245 020 Page 21

8-3. Correct Installation

Weld Zone 3 50 ft (15 m)

50 ft (15 m)

1 2 8 4

8 Ground all metal objects and all wiring in welding zone using #12 AWG wire.

Nonmetal Building

Ground workpiece if required by codes.

Metal Building

8 11

10

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 and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all directions. 4 Weld Output Cables Keep cables short and close together. OM-245 020 Page 22

Conduit Joint Bonding and Grounding

Metal Building Requirements 9 Metal Building Panel Bonding Methods

Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). 6 7 Water Pipes and Fixtures External Power or Telephone Lines Ground water pipes every 50 ft (15 m). 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.

Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. 10 Windows and Doorways Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 11 Overhead Door Track Ground the track.

SECTION 9 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2010-04

Whenever possible and practical, use DC weld output instead of AC weld output.

9-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type - Polarity Electrode Diameter (DCEN) Argon Direct Current Electrode Negative (For Use With Mild Or Stainless Steel) AC Argon Balance Control @ 65% Electrode Negative (For Use With Aluminum)

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens .010 in. (1 mm) .020 in. (1 mm) .040 in. (1 mm) 1/16 in. (1.6 mm) 3/32 in. (2.4 mm) 1/8 in. (3.2 mm) 5/32 in. (4.0 mm) 3/16 in (4.8 mm) 1/4 in. (6.4 mm) Up to 25 15-40 25-85 50-160 130-250 250-400 400-500 500-750 750-1000 Up to 20 15-35 20-80 50-150 135-235 225-360 300-450 400-500 600-800

Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations 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 using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

Radial Grinding Causes Wandering Arc

2-1/2 Times Electrode Diameter 2 3 1

Grinding Wheel

Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2 3 Tungsten Electrode Flat A 2% ceriated tungsten is recommended.

Wrong Tungsten Preparation

4 Ideal Tungsten Preparation Stable Arc

Diameter of this flat determines amperage capacity. 4 Straight Ground Grind lengthwise, not radial.

OM-245 020 Page 23

SECTION 10 GUIDELINES FOR TIG WELDING (GTAW)

10-1. Positioning The Torch
!
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 using cerium or lanthanum based tungsten instead of thoriated. Thorium dust contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. Workpiece

3 2

90 1

Make sure workpiece is clean before welding. 2 3 4 5 6 5 6 Work Clamp Torch Filler Rod (If Applicable) Gas Cup Tungsten Electrode Place as close to the weld as possible.

1015 4

Select and prepare tungsten according to Section 9. Guidelines: The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in. diameter, gas cup should be a minimum of 3/16 in. diameter. Tungsten extension is the distance the tungsten extends out gas cup of torch.

1025

1/16 in. 3/16 in. Bottom View Of Gas Cup

The tungsten extension should be no greater than the inside diameter of the gas cup. Arc length is the distance from the tungsten to the workpiece.

Ref. ST-161 892

OM-245 020 Page 24

10-2. Torch Movement During Welding

Tungsten Without Filler Rod Welding direction 75

Form pool

Tilt torch

Move torch to front of pool. Repeat process.

Tungsten With Filler Rod Welding direction 75 15

Form pool

Tilt torch

Add filler metal

Remove rod

Move torch to front of pool. Repeat process.

ST-162 002-B

10-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead T Joint

20 90 70 75

20 10

15

Lap Joint 20-40

Corner Joint

90 75 75

15 30

15

ST-162 003 / S-0792

OM-245 020 Page 25

SECTION 11 PARTS LIST

3 2 1 8 9 7 6

11

10

4 40 39 38

12

15 16 17 14 13

36 34 32 31 11 29 27 30 25 24 23 28 33 35

37

22

19 18

20 21

41 26

805 466-B

Figure 11-1. Main Assembly

OM245 020 Page 26

Item No.

Dia. Mkgs.

Part No.

Description Figure 11-1. Main Assembly

Quantity

. . . 1 . . . . . . . . . . . . +245 015 . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 230 366 . . Label, Warning General Precautionary Static . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 232 915 . . Cord Set, 250v 650p 12ga 3/C 7ft Spt3 Jkt . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . 188 048 . . Hose, Nprn Brd No 1 X .250 Id X 18.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . GS1 . . . 216 607 . . Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . 111 443 . . Bushing, Strain Relief .240/.510 Id X .875 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 7 . . . . CB1 . . . 233 184 . . Supplementary Protector, Man Reset 1p 35a 250vac . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . 246 515 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . 137 761 . . Nut, 750 NPT 1.31 Hex .27 H Nyl Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . 232 940 . . Ftg, Hose Brs Barbed M 3/16 Tbg X 5/818 Thrd . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . 232 901 . . Handle, Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 232 939 . . Hose, Sae .187id X .410od X 12 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . 234 898 . . Regulator/Flowmeter, 050 CFH Argon/CO2 Kit . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . L1 . . . . 250 734 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . 232 922 . . Windtunnel, Assembly (see Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . 083 147 . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . . . . . 17 . . . . PC1 . . . 230 058 . . Circuit Card Assy, Control & Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . FM1 . . . 232 923 . . Fan, Muffin 24vdc 4500 Rpm 240 Cfm 4.125 Mtg Holes . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . 232 866 . . Plenum, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . 232 863 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . 239 388 . . Bumper, RBR .875 OD X .188 ID X .39 High Recessed . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . 233 200 . . Cable Assy, RJ45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . S2 . . . . 134 847 . . Switch, Tgl Spdt 15a 125vac Onnoneon Spd Term Blk . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . 231 238 . . Nut, 46832 .56 Hex .09 H Brs Blk Use w/Switches . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . 217 839 . . Nut, Nylon Strain Rlf Pg13.5 .250thk 1.062od . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . 232 908 . . Work Cable, W/Clamp (12 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . 245 271 . . Torch, Tig 150a 12.5ft Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . 245 038 . . Blank, Snapin Nyl .500.445 Mtg Hole Black D/D . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . 207 079 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . 178 355 . . Nut, 37532 .54 Hex .25 H Nyl Flange .62 D . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Hobart EZTIG 165I (Order By Model And Serial No.) . . . . . . . . 32 . . . . . . . . . . . . . 232 864 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . 232 320 . . Nut, Nylon Thd Pg 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . S1 . . . . . 124 511 . . Switch, Tgl Dpst 40a 600vac Scr Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . P1 . . . . 233 165 . . Pot Assy, W/Leads & Connector & Leds Cp Flat 1t 2. . . . . . . . . . . . . . . . . . . . 36 . . . . . T2 . . . . 232 909 . . Inductor, Arc Starter/Output 150 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . PC3 . . . 228 593 . . Circuit Card Assy, Arc Starter CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . . . L2 . . . . 208 066 . . Inductor, Toroid 5 Amp 180 Uh, 12 Leads W/Quick Con . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . 210 323 . . Insulator, Washer Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . 185 835 . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . 245 589 . . RFCSRJ45 Foot Control (Includes) . . . . . . . . . . . . . . . . . . . 245 044 . . . . RFCSRJ45 Foot Control (Pedal Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 676 . . . . CABLE, w/Connectors 14 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 493 . . . . Clamp, Stl Cush .187 Dia X .281 Mtg Hole Zinc Pld . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 4 1 1 1 1 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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 Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-245 020 Page 27

. Hardware is common and

not available unless listed. 4

3 2

7
805 135-B

Figure 11-2. Windtunnel Assembly

Item No.

Dia. Mkgs.

Part No. 232 922

Description Figure 11-2. Windtunnel Assembly (Figure 11-1, Item 15)

Quantity

. . . 1 . . . PC2 . 230 144 . . Circuit Card Assy, Commutator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 242 084 . . Bushing, Snap-In Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . 3 . . . . . . . . . 190 512 . . 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 Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM245 020 Page 28

. Hardware is common and

not available unless listed. 1

3 5 3 6

3
805 123-A

Figure 11-3. Heat Sink, Secondary Assembly

Item No.

Dia. Mkgs.

Part No. 232 917

Description

Quantity

Figure 11-3. Heat Sink, Secondary Assembly (Figure 11-2, Item 7)

. . . 1 . . . . . . . . . 232 869 . . Heat Sink, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . D9,D12 231 396 . . 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 Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-245 020 Page 29

Notes

Effective January 1, 2010

Warranty Questions?

Call 1-800-332-3281 7 AM 5 PM EST

Service You 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 distributor and Hobart is there to help you, every step of the way. Assistance Visit the Hobart website: www.HobartWelders.com

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MA or newer.
This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied. Hobart products are serviced by Hobart or Miller Authorized Service Agencies.
LIMITED WARRANTY Subject to the terms and conditions below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Hobart/Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart/Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart/Miller will provide instructions on the warranty claim procedures to be followed. Hobart/Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original retail purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. Hobarts 5/3/1 Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.) Items furnished by Hobart/Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Hobart/Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

2.

3.

1.

5 Years Parts and Labor * Original Main Power Rectifiers only to include SCRs, diodes, and discrete rectifier modules * Reactors * * Stabilizers Transformers

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobarts/Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart/Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart/Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Hobarts/Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart/Miller authorized service facility as determined by Hobart/Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART/MILLER IS EXCLUDED AND DISCLAIMED BY Hobart/Miller. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
hobart_warr 201001

2.

3 Years Parts and Labor * Drive Systems * * * * * * Idle Module PC Boards Rotors, Stators and Brushes Solenoid Valves Spot Welder Transformer Switches and Controls

3.

1 Year Parts and Labor Unless Specified (90 days for industrial use) * Accessories * * * Batteries (Trek 180 Only) Contactors Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.) Flowgauge and Flowmeter Regulators (No Labor) HF Units MIG Guns/TIG Torches Motor-Driven Guns Plasma Cutting Torches Regulators Relays Remote Controls Replacement Parts (No labor) 90 days Running Gear/Trailers Water Coolant Systems

* * * * * * * * * * * 4.

Engines, batteries (except Trek 180) and tires are warranted separately by the manufacturer.

Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)

Protect Your Investment!

Register your product at: HobartWelders.com

Resources Available
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 Hobart Welding Products
An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA

For technical assistance:

Call 1-800-332-3281

For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturers Transportation Department.

ORIGINAL INSTRUCTIONS PRINTED IN USA

2010 Hobart Welding Products. 201001