HobartWelders STICKMATE LX Owner's manual

STICKMATE

225 AC/DC And 225 AC

Processes

Description

Arc Welding Power Source

OM-316G July 1997

Eff. w/Serial Number KH461314

Stick (SMAW) Welding

AC Models:

AC/DC Models:

The following terms are

used interchangeably

throughout this manual:

MIG = GMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Installation, Operation, And Maintenance Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle Charts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Selecting A Location And Installing Handle 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Weld Output Cables 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Electrical Service Guide 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Internal Connections For Operating 115/230 Volts, 225 Amperes AC

And AC/DC Models From 115 Volts 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or

300 Amperes AC Models From 230 Volts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Connecting Input Power 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Lubricating Shunt Block And Anti-Noise Adjustment 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Troubleshooting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – WELDING METHODS & TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Shielded Metal Arc Welding (SMAW) Procedure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Electrode And Amperage Selection Chart 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Striking An Arc 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Positioning The Electrode Holder 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Weld Bead Characteristics 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Conditions That Affect Weld Bead Shape 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Electrode Movement During Welding 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Butt Joints 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Lap Joints 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Tee Joints 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

OM-316 Page 1

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING

safety_stickom1 6/95OM-316G – 7/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this

procedure! The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,

and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to

avoid the hazards.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. Arc Welding Hazards

WARNING

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 1-4. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

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. Incorrectly installed or

improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the

work or ground.

4. Disconnect input power before installing or servicing this

equipment. Lockout/tagout input power according to OSHA 29

CFR 1910.147 (see Safety Standards).

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal

in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

7. When making input connections, attach proper grounding

conductor first – double-check connections.

8. Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

9. Turn off all equipment when not in use.

10. Do not use worn, damaged, undersized, or poorly spliced cables.

11. Do not drape cables over your body.

12. If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.

13. Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

14. Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

15. Wear a safety harness if working above floor level.

16. Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing; FLYING

SLAG OR SPARKS can injure eyes.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Noise from some

processes can damage hearing. Chipping, grinding,

and welds cooling throw off pieces of metal or slag.

NOISE

1. Use approved ear plugs or ear muffs if noise level is high.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.

4. Use protective screens or barriers to protect others from flash

and glare; warn others not to watch the arc.

5. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

FUMES AND GASES can be

hazardous to your health.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,

cleaners, and degreasers.

5. 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.

6. 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.

7. 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 if necessary, while

wearing an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if welded.

OM-316 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.

1. Protect compressed gas cylinders from excessive heat,

mechanical shocks, slag, open flames, sparks, and arcs.

2. Keep cylinders away from any welding or other electrical circuits.

3. Never drape an electrode holder over a gas cylinder.

4. Never allow a welding electrode to touch any cylinder.

5. Never weld on a pressurized cylinder – explosion will result.

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.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition

can cause fire on the hidden side.

7. 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).

8. 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 and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

12. Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

1-3. Additional Installation, Operation, And Maintenance Hazards

FIRE OR EXPLOSION can result from

placing unit on, over, or near

combustible surfaces.

1. Do not install unit on, over, or near combustible

surfaces or flammables.

HOT PARTS can cause severe burns.

1. Do not touch hot parts bare handed. Allow cooling

period before beginning.

MAGNETIC FIELDS FROM HIGH

CURRENTS can affect pacemaker

operation.

1. Wearers should consult their doctor before going

near arc welding, gouging, or spot welding

operations.

FLYING PIECES OF METAL or DIRT can

injure eyes.

1. Wear safety glasses with side shields or face

shield.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from

Superintendent of Documents, U.S. Government Printing Office,

Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields – Background

Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing

Office, May 1989): “. . . there is now a very large volume of scientific

findings based on experiments at the cellular level and from studies

with animals and people which clearly establish that low frequency

magnetic fields can interact with, and produce changes in, biological

systems. While most of this work is of very high quality, the results are

complex. Current scientific understanding does not yet allow us to

interpret the evidence in a single coherent framework. Even more

frustrating, it does not yet allow us to draw definite conclusions about

questions of possible risk or to offer clear science-based advice on

strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as

practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

The above procedures are also recommended for pacemaker

wearers. Consult your doctor for complete information.

OM-316 Page 3

SECTION 2 – INSTALLATION

2-1. Specifications

Table 2-1. AC/DC Models

Mode

Rated Welding Amperage

Maximum

Open-

Amperes Input at Rated Load Output

50 Or 60 Hz, Single-Phase

WeightMode

Output Range

Circuit

Voltage

115 V 220 V 230 V 400 V 460 V

Weight

225 A @ 25 Volts AC,

20% Duty Cycle

Low: 30 – 150

High: 40 – 225

80 VAC

Net: 114 lb (52 kg);

150 A @ 25 Volts DC,

20% Duty Cycle

30 – 150 72 VDC

4.6*

47.5

2.3*

23.7

1.2*

Net: 114 lb (52 kg);

Ship: 133 lb (60 kg)

300 A @30 Volts AC,

20% Duty Cycle

Low: 50 – 230

High: 65 – 300

80 VAC

Net: 135 lbs (61 kg);

200 A @ 25 Volts DC,

20% Duty Cycle

25 – 200 72 VDC

5.4*

3.6*

1.8*

1.3*

Net: 135 lbs (61 kg);

Ship: 140 lbs (64 kg)

Overall Dimensions

Height: 21-1/2 in (546 mm); Width: 12-1/2 in (318 mm); Depth: 14 in (356 mm)

*While idling

Table 2-2. AC Models

Rated

Welding

Amperage

Max Open-

Circuit

Amperes Input at Rated Load

Output 50 Or 60 Hz, Single-Phase

Weight

Welding

Output

Range

Circuit

Voltage

115 V 220 V 230 V 400 V KW

Weight

225 A @ 25

Volts AC, 20%

Duty Cycle

Low: 30 – 150A

High: 40 – 225A

80 VAC

4.6*

47.5

2.3*

7.2

0.22*

Net: 100 lb (45 kg)

Ship: 105 lb (48 kg)

300 A @ 30

Volts AC, 20%

Duty Cycle

Low: 35 – 230

High: 65 – 300

80 VAC

5.4*

3.6*

1.8*

11.5

0.22*

Net: 107 lb (49 kg)

Ship: 112 lb (51 kg)

Overall Dimensions

Height: 21-1/2 in (546 mm); Width: 12-1/2 in (318 mm); Depth: 14 in (356 mm)

*While idling

OM-316 Page 4

2-2. Duty Cycle Charts

A. For AC/DC Models

2 Minutes Welding 8 Minutes Resting

SB-086 727 / SB-099 602-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. For 220, 230/400, And 460 Volt Models

(300/200 Amperes)

A. For 115/230, 230, And 460 Volt Models

(225/150 Amperes)

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. For 220, And 230/400 Volt Models

(300 Amperes)

A. For 115/230 And 230 Volt Models

(225 Amperes )

OM-316 Page 5

2-3. Volt-Ampere Curves

A. For AC/DC Models

SB-001 844-B / SB-086 728-B / SB-099 689-A / SB-099 702-A

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities.

Curves of other settings fall be-

tween the curves 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)

A = LOW RANGE

B = HIGH RANGE

OM-316 Page 6

B. For AC Models

SB-001 844-B / SB-099 701-A / SB-099 689-A

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities.

Curves of other settings fall be-

tween the curves shown.

A. For 115/230 And 230 Volt Models

(225 Amperes)

B. For 220 Volt Model

(300 Amperes)

A = Low Range

B = High Range

C. For 230/400 Volt Model

(300 Amperes)

OM-316 Page 7

2-4. Selecting A Location And Installing Handle

ST-087 026-B / Ref. ST-151 556 / ST-155 573-A

1 Lifting Area

Place hands where shown to move

unit. Get help when moving unit.

2 Running Gear Mounting Holes

3 Rating Label

Locate unit near correct input

power.

4 Amperage Adjustment Rod

5 Handle

6 Pin

Install as shown.

Move pin into locked position

shown.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

Locked Pin

18 in (457 mm) for airflow

2-5. Weld Output Cables

For weld output cable replacements or extensions, contact your Factory

Authorized Service Agent.

NOTE

OM-316 Page 8

2-6. Electrical Service Guide

Input Voltage

115 220 230 400 460

Input Amperes At Rated Output

95 [70]

47.5

[67]

[39]

23.7

[34]

Max Recommended Standard Fuse Or Circuit Breaker Rating

In Amperes

150 [110]

[100]

[60]

[50]

Min Input Conductor Size In AWG/Kcmil

8 [8]

[10]

[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]

[ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models

Reference: 1993 National Electrical Code (NEC) Ref. S-0092-J

OM-316 Page 9

2-7. Internal Connections For Operating 115/230 Volts, 225 Amperes AC

And AC/DC Models From 115 Volts

Follow applicable electrical codes and have a competent electrician make internal

connections. Note the input amperes as stated in Section 2-6.

NOTE

Y Turn Off unit and disconnect input

power.

Remove amperage adjustment handle and

wrapper.

1 Wrapper

2 Lead 2

3 Lead 3

Remove insulated sleeving, and disconnect

lead 2 from lead 3.

4 Lead 4

5 Input Power Cable Black Lead

6 Input Power Cable Strain Relief (On

Rear Panel)

Remove insulated sleeving, and disconnect

lead 4 from black lead.

7 Power Switch S1 (As Viewed From

Rear Of Switch)

8 Terminal Screw 1

9 Jumper Lead 1

Remove screw securing jumper lead 1 to ter-

minal on Power switch.

Route lead 3 to switch terminal, and secure

jumper lead 1 and lead 3 to terminal with

screw.

10 Jumper Lead

11 Terminal Screw 2

12 Input Power Cable White Lead

Remove screw securing jumper lead and

white lead to switch terminal.

13 Ground Terminal

14 Input Power Cable Green Lead

Remove green lead from ground terminal,

loosen strain relief, and remove 230 volts in-

put power cable.

Obtain correct size and length 115 volts input

power cable (see Section 2-6). Install correct

size ring terminals to cable leads.

Route cable through strain relief, and connect

green lead to ground terminal.

Connect lead 2, lead 4, and black input power

cable lead together, and secure with existing

hardware.

Route white input power cable lead to termi-

nal on Power switch where original white lead

was disconnected, and secure white lead and

jumper lead to terminal with existing screw.

Tighten strain relief, install wrapper and am-

perage adjustment handle.

Connect input power according to Section

2-9.

3/8 in

(cut tie wraps)

Ref. ST-156 521

34 5

13 14

4513

230V Connection 115V Connection

OM-316 Page 10

2-8. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300

Amperes AC Models From 230 Volts

Follow applicable electrical codes and have a competent electrician make internal

connections. Note the input amperes as stated in Section 2-6.

NOTE

Ref. ST-087 027-C / Ref. ST-156 374

Connected For 400 Volts

Connected For 230 Volts

3/8 in

(cut tie wraps)

Y Turn Off unit and disconnect

input power.

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

sleeving.

7 Primary Coil Lead 2

Slide sleeving out of the way, and

connect power switch Lead 4 to pri-

mary coil lead 2, and secure with

existing hardware. Secure sleeving

over connection.

Connect fan motor lead 2 back onto

fan motor.

Reinstall wrapper and amperage

adjustment handle.

OM-316 Page 11

2-9. Connecting Input Power

ST-801 298

Y Have only qualified persons

make this installation. See

rating label in Section 2-4, and

be sure to supply correct in-

put power.

1 Plug

2 Receptacle

3 Input And Grounding

Conductors For Models Not

Supplied With Plug

See Section 2-6 for conductor and

fuse size and ratings. Size and

ratings must comply with applicable

codes.

230 VAC,

GND/PE

Install conductors into a deenergized line

disconnect device.

3/8 in

Y Always connect

grounding

conductor first.

OM-316 Page 12

SECTION 3 – OPERATION

3-1. Controls

A. Controls For AC/DC Models

ST-087 026-B / Ref. ST-086 696-F

1 Amperage Adjustment Control

2 Amperage Range Indicator

3 Power Switch

For DC Weld Output

4 Positive (+) Weld Output

Terminal

5 Negative (–) Weld Output

Terminal

For Electrode Positive (DCEP),

connect work cable to negative (–)

terminal and electrode holder cable

to positive (+) terminal.

For Electrode Negative (DCEN),

reverse cable connections.

For AC Weld Output

6 Low Range Electrode Weld

Output Receptacle

7 High Range Electrode Weld

Output Receptacle

When welding below upper amper-

age limit of low range receptacle,

use low range receptacle.

8 Work Weld Output Receptacle

586

See unit nameplate for specific AC ranges.

OM-316 Page 13

B. Controls For AC Models

Ref. ST-155 574 / Ref. SC-107 516-F

See unit nameplate for specific ranges.

1 Amperage Adjustment Control

2 Amperage Range Indicator

3 Low Range Electrode Weld

Output Receptacle

4 High Range Electrode Weld

Output Receptacle

When welding below upper amper-

age limit of low range receptacle,

use low range receptacle.

5 Work Weld Output Receptacle

6 Power Switch

3 5

OM-316 Page 14

SECTION 4 – MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Repair Or

Replace

Cracked

Cables

Clean And

Tighten Weld

Connections

6 Months

12 Months

Blow Out Or Vacuum

Inside,

During Heavy Service,

Clean Monthly

Lubricate Shunt Block

(See Section 4-2)

4-2. Lubricating Shunt Block And Anti-Noise Adjustment

ST-155 498-A

Y Turn Off welding power

source and disconnect input

power.

1 Shunt Block

Apply light coating of high-tempera-

ture grease to shaded areas of both

shunt blocks.

Install amperage control handle

and locking pin. Turn handle to

spread grease evenly.

2 Noise Adjustment Screws

If shunt block vibrates and

becomes noisy, tighten adjustment

screws 1/4 turn. Install wrapper,

handle, and pin, turn On unit, and

check for shunt noise. Repeat pro-

cedure until noise stops. Do not

overtighten. Call your nearest

Factory Authorized Service Agent if

noise continues.

Reinstall wrapper, handle, and pin.

Y Install wrapper before

turning On power.

3/8 in

OM-316 Page 15

4-3. Troubleshooting

Trouble Remedy

No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 2-9).

Check and replace line fuses if open. Reset breakers if necessary (see Section 2-9).

Fan does not run; weld output okay. Be sure nothing 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 3-1).

Electrode freezing to work. Increase amperage setting (see Section 3-1).

Increase arc length.

Use dry, properly stored electrodes.

Noise and vibration from shunt block. Lubricate shunt block and/or tighten adjustment screws (see Section 4-2).

SECTION 5 – ELECTRICAL DIAGRAMS

SA-183 995-A

Figure 5-1. Circuit Diagram For 115/230 Volts, 225/150 Amperes AC/DC Model

OM-316 Page 16

SA-183 994

Figure 5-2. Circuit Diagram For 230 Volts, 225/150 Amperes AC/DC Model

SA-183 996

Figure 5-3. Circuit Diagram For 460 Volts, 225/150 Amperes AC/DC Model

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HobartWelders STICKMATE LX Owner's manual

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