HobartWelders STICKMATE LX Owner's manual
- Category
- Welding System
- Type
- Owner's manual
STICKMATE
R
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
AC
225 A @ 25 Volts AC,
20% Duty Cycle
Low: 30 – 150
High: 40 – 225
80 VAC
Net: 114 lb (52 kg);
DC
150 A @ 25 Volts DC,
20% Duty Cycle
30 – 150 72 VDC
95
4.6*
47.5
2.3*
23.7
1.2*
Net: 114 lb (52 kg);
Ship: 133 lb (60 kg)
AC
300 A @30 Volts AC,
20% Duty Cycle
Low: 50 – 230
High: 65 – 300
80 VAC
Net: 135 lbs (61 kg);
DC
200 A @ 25 Volts DC,
20% Duty Cycle
25 – 200 72 VDC
70
5.4*
67
3.6*
39
1.8*
34
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
95
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
70
5.4*
67
3.6*
39
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.
3
Locked Pin
4
5
6
1
2
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]
70
[100]
[60]
35
[50]
Min Input Conductor Size In AWG/Kcmil
8 [8]
12
[10]
[14]
14
[14]
Max Recommended Input Conductor Length In Feet (Meters)
32 (10) [75 (23)]
87 (26)
[82 (25)]
[101
(31)]
138 (42)
[87 (27)]
Min Grounding Conductor Size In AWG/Kcmil
8 [8] 12 [10] [14]
14
[14]
[ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models
Reference: 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
2
34 5
6
7
8
9
10
11
12
13 14
7
6
4513
14
3
2
10
11
12
230V Connection 115V Connection
1
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
1
2
3
4
56
7
2
3
5
6
7
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.
2
230 VAC,
1
GND/PE
L2
L1
GND/PE
L2
L1
3
1
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
1
2
3
47
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
2
6
1
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
4
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
OR
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.
1
2
1
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
- Category
- Welding System
- Type
- Owner's manual
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