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    R 400 S (1) .

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    HOBART OWNER’S MANUAL IMPORTANT: Read these instructions before installing, operating, or servicing this product. Specifications covered by this manual: TECHNICAL MANUAL NO. TM-635 Model R-400-S 400 A Constant Current Type Arc Welding Machine This manual covers units displaying the following specification numbers. 6038-1 6040-1 6042—1 6038-2 6040-2 6042-2 6038-3 6041-1 6039-1 6041-2 6039-2 DO NOT DESTROY, HOBART BROTHERS COMPANY, TROY, OHIO 45373, U.S.A. ‘Manufacturers of Arc Welding Systems/Aircraft Ground Power Equipment/industrial Battery Chargers 4fted-by-a~" TM prefixed —ninber us ually covers just the underlined specification or assembly numbers in the listing below. If none of the numbers are underlined, they are all covered. EQUIPMENT IDENTIFICATION ~ The unit's identification number (either a Specifica~ tion number, or an Asseubly number), model, and serial number usually appear ona nameplate attached to its control panel. A “specification number” starts out with a “series number" (first four-digit mumber with a possible. letter suffix). A "dash number” (-I, -2, etc.) mst follow the series number to make a complete “Specification number”. For example, 1234A-1, 1234A-2, etc. TECHNICAL MANUAL NO. TM-635 Model R-400-S 400 A Constant Current Type Arc Welding Machine This manual covers units displaying the following specification numbers. 6038-1 6040-1 6042=1 6038-2 6040-2 6042-2 6038-3 6041-1 6039-1 6041-2 6039-2 Issued: May 26/78 Revised: Feb 10/86 Table of Contents : | Page 1 Page TY WARNINGS Grounding ies ISTRUCTIONS = Welding Leads 15 RECEIPT OF EQUIPMENT 1 OPERATION tt j DESCRIPTION OF EQUIPMENT Z Sequence of Operation 15 | Controls and Connections 1 ‘MAINTENANCE 1 6 | INSTALLATION 2 Lubrication 1 6 Location 2 Inspection and Cleaning i; 6 Wiring 3 GENERAL TROUBLESHOOTING ; 7 Connecting Welding Machine DETAILED TROUBLESHOOTING.! 10 + Line Voltage 3. PARTS LIST 4. Hobart Brothers Company ‘Troy, Ohio 45373 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 910081 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ARC WELDING can be hazardous. ROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OA DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUC- ‘TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. ‘Welding products and welding processes can cause serious injury or death, or damage to other equipment or property ithe operator does ‘ot strictly observe all safety rules and tke precautionary actions. ‘Sato practices have developed from past experience inthe use of welding and cutting. These practices must be learned through study and training before using this equipment. Anyone not having extensive taining in welding and cutting practices should not attempt to weld. Certain ofthe practices apply to equipment connected to power ines; other practices apply to engine driven equipment. Safe practices are outined in the American National Standard 249.1 ented: AND CUTTING. This publication and ‘ther guides to what you should leam before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE. live when power is on. in somiautomatio or auto- matic wire welding, the wiro, wi reel, ive rol housing, and all metal parts touching the welding wire are electically ive. incorrectly installed ot ‘ropery Grounded equipment isa hazard, 1. Do not touch live electrical parts 2. Wear dry, hole-ree insulating gloves and body protection. 3. Insulate yourself from work and ground using dry insulting ‘mats or covers. 4. Disconnect input power or stop engine before instaling or servicing this equipment. Lock input power disconnect such ‘open, oF remove fine fuses 20 power cannot be tured on accidentally. 5. Property install and ground this equipment according to it ‘Owner's Manual and national, state, and oval codes. lecticallylve whenever the outputis on. The input powor circuit and machine ntamal cuits are aleo ELECTRIC SHOCK can Ki Tuo aaa st uae pono toured ntended or at oonice Thin fv acca pars can case ft hocks = Touching aacicalparecancausefeaitccks 7 1 faynalted leo hore. Never cp hearin water onahes Secon ‘to C00! it or lay it down on the ground or the work surface. Do. not touch holders connected to two welding machines atthe ‘same tie or touch other people with the holder or elactroce. 8. Do not use wom, damaged, undersized, or poorly spliced ca- bles. 8. Donot wrap cables around your body. 10. Ground the workpiece to a good electrical (earth) ground, 11. Do not touch electrode while in contact withthe work (ground) creat. 12, Use only wellmaintained equipment. Repair or replace dam- ‘aged parts at once. 18, Inconfined spaces or damp locations, do not use a welder with ‘AC output unless itis equipped with a voliage reducer. Use ‘equipment with OC output. 14, Wear a safety hamess to prevent fling if working above floor level. 15. Keep all panels and covers securely in place. "ARG RAYS can bum ‘and skin; NOISE can damage hearing. $B sxe wn poe rence ef ‘host and strong ultraviolet rays that can bum eyes x and sin. Nolo from some proceses can damage hearing. T. Wear a wolding helmet fited with a proper shade of filer Gee ANG! ZA.1 listed in Safety Standards) to protect your face and ‘eye when welding or watching. 2. Wear approved safety glasses. Side shields recommended. 8, Use protective sereens or barirs to protect others from flash and glare; war others not to watch the arc. 4. Wear protective clothing made from durable, flame-resistant ‘material (wool and leather) and foot protection. 5. Use approved ear plugs or ear mutts noise levi Eve protection fiter shade selector Tor welding or outing (goggles or helmet) rom AWS A623. ectode Size Blectode Sze Biter Welding or Cuting Metal Thickness Welding or Cutting Metal Thickness | Shade |__or Weiging Current ‘Operation corWelding Current |__No. “Torch seidering Gas metabare welding (MIG) ‘Torch brazing = ‘Nonferrous base metal a " oygen cutting ram ae net ay al 8 ight Under tn, 25 mm Gastungston areweiding a Medium 1106in, 25-180 mm ‘Atomic hydrogen al % Heavy (Over én, 150 mm aro a 2 Gas welding Plasma are welding al ” ght Under 18 in, 3mm Carbon ae air gouging Mediu $i t2in, 12mm 2 Hea ‘Over Vin, 12mm 4 ‘Shielded meta-are welding| __ Under f32 in. 4 ram Plasma are cutting (Git) electrodes 98210 Vain, 400 6.4 Under 200 Amp 9 Over Ain, 64mm Medium ‘30010 400 Amp 2 Heavy ‘Over 200 Amp a March 24, 1993 at ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Hobart Brothers Company Instruction 910081 Troy, Ohio 45373 FUMES AND GASES can be hazardous + fead the Material Safety Data Sheets (MSDSs) and the ‘to your heaith. a ‘instruction for metals, consumables, coatings, | i ND oe cenenees EEE 2 momeenuenee “EEE = ee 1. Keep your head out ofthe furs. De not breath the fumes. 2. i inside, ventilate the area and/or use exhaust at the arc to ‘Femave welding fumes and gases. ‘3. ventilation is poor, use an approved air-euppli respirator. 6. Do not weld in locations near degreasing, cleaning, or spraying ‘operations. The heat and rays ofthe are can react with vapors 10 form highly toxic and initating gases. 7. Do not wold on coated metals, uch a8 galvanized, lead, or ‘cadmium plated steel, unless the coating is removed from the ‘wold ar, tho area is well ventiated, and if necessary, while ‘wearing an ar-uppled respirator. The coatings and any metals ‘containing these elements can give of toxic umes if welded. WELDING can cause fire or explosion. ‘Sparks and spatter fy off frm the welding arc. The ‘ying sparks and hot metal, weld spatier, hot work: plece, andhot equipment ean cause fres and burns. ‘Accidental contact of electrode or welding wire to ‘metal objects can cause sparks, overheating, oF fre. ' "4 1. Protect yourself and others from fying sparks and hot metal. 2. Donotweid where fying sparks can strike flammable material. 3, Remove all lammables within 35 (10.7 m) ofthe wading arc. If thisis not possible, tightly cover them with approved covers. 4. Beale that welding sparks and hot materia from welding can ‘easly go through small eacks and openings to adjacent areas, ‘5. Walch for fre, and keep a fre extinguisher nearby. {6 Bo aware that welding on acoling, floor, bulkhead, or pation can cause fire on the hidden side, 7. Donot weld on closed containers euch as tanks or drums, 8. Connect work cable to the work as close tothe welding area as practcalto prevent welding curentfrom traveling long, possibly ‘unknown paths and eausing electric shock and fe hazards. 9. Do not use welder to thaw frozen pipes. 10. Remove stick electrode from holder or cut off welding wie at contact tip when notin use. 11, Wear oreo protective garments such as lather gloves, heavy shit, cufless trousers, high shoes, and a cap. FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause fying metal. As welds ‘ool, they ean throw of slag. 1. Waar approved face shield or safety goggles. Side shields recommended. 2. Wear proper body protection to protect skin. ‘CYLINDERS can explode if damaged. ‘Shielding gasoyinders contain gas under high pres- ‘sure. damaged, aoylinder can explode. Since gas ES | ‘oyinders are normally pat ofthe welding process, be sure to treat them carey. 1. Protect compressed gas cylinders from excessive heat, me- ‘chanical shocks, and ares. 2. neta and secure oylinders in an upright position by chaining ‘hem tp a stalonary support of equipment cylinder rack 10 revert faling or ping. ‘Keep cyinders away rom any welding Or other electrical ci cuits. ‘4. Never allow a welding electrode to touch any cylinder. ‘5. Use only correct shielding gas ovindes, regulators, hoses, and ‘tings designed forthe speciic application; maintain them and associated parts in good condition. 6. Tum face away from valve outlet when opening cylinder valve. 7. Koop protective cap in place over valve except when cylinder is in use or connected for use, ‘8 Read and follow inetrctions on compressed gas cinders, associated equipment, and CGA publication Pi listed in Safety ENGINE EXHAUST GASES can kill, Engines produce harmful exhaust gases. 1. Use equipment outside in open, well-ventilated areas, 2. used in a closed ares, vent engine exhaust outside and away ‘tom any building ai intakes. ‘April 1, 1992 Replaces June 2, 1987 Hobart Brothers Company Ohio 45373 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ENGINE FUEL can cause fire or explosion. Engine fuels highly tammabie, Instruction 910081 1. Stop engine before checking or adding fuel. 2. Do not add fuel while smoking ori unit is-near any sparks or ‘pen flames. ‘3 Allow engine to cool before tusting. Hf possible, check and ad ‘uel to cold engine before beginning job. MOVING PARTS can cause injury. ‘Moving parts, such as fans, otors, and belts can cut ‘fingers and hands and ezich loos clothing. 1. Keep all doors, panes, covers, and guards closed and securely in place. 2. Stop engine before instaling or connecting unit. "Z Have only qualified people remove guards or covers for main- tenance and troubleshooting as necessary. 4 Toprevent accidental starting during servicing, disconnect neg- ative (-) battery cable from battery. 5, Keep hands, hit, loose clothing, and tools away from moving parts 6. Reinstall panels or guards and close doors when servicing is finished and betore starting engine. SPARKS ‘can cause BATTERY GASES TOEXPLODE; BATTERY ACID can burn eyes and skit Batteries contain acid and generate explosive gases "7 Aways wear a face shield when working on a batery. 2. Stop engine before disconnecting or connecting battery cables. '3. Donot alow tools to cause sparks when working on a baer. 4. Do1not use welder to charge batteries or jump start vehicles. 5. Observe correct polarity (+ and ~) on batteries. # ,,| STEAM AND PRESSURIZED HOT Pa GOOLANT can bum face, eyes, and Ta cootantin the radiator can be very hot and under pressure. 1. Donat remove radiator cap when engine is hot. Allow engine to cool. 2. Wear gloves and put a rag over cap area when removing cap. 3. Allow pressure to escape before completely removing cap. ‘NOTE: Considerations About Welding And The Effcts Of Low Frequency Electric And Magnetic Fads ‘The following i a quotation from the General Conclusions Section of the U.S. Congress, Cifioe of Technology Assessment, ‘9 Power Frequency Glectic & Magnetic Feids — Backoround Paper, Biclocical fects ,OTABP-E-63 (Washington, DC: U.S. Goverment Printing Ofice, May 1960): "there isnow a very lage volume of scientific incings based on experiments at the collularleve and from studies with animale and people which clearly establish that low frequency magnetic felds can interact with, and produce changes i, biological systems. While most ‘ofthis work is of very high qualty, the reeuits are complex. Curent scientific understanding does net yt allow us to interpret the evidence {na single coherent framework. Even move frustrating, i does not yet allow us to draw definite conclusions about questions of possible risk ‘orto offer clear science-based advice on statogies fo minimize or avold poterial risk.” ‘To reduce magnetic feds in the workplace, usa the following procedures: 1. Keep cables close together by twisting or taping ther. 2. Arrange cable to one side and away from the operator. 8. Do not col or drape cables around the body. ‘About Pacemakers: ‘4. Keep welding power source and cables as faraway trom body as practical. '5. Connect work clamp to workpiece as close to the weld as possible. “The above procedures are among those aiso normally eeommended fo pacemaker wearers. Consult your doctor for complete information. PRINCIPAL SAFETY. STANDARDS ‘Safetyin Welding and Cutting, ANS! Standard 249.1, rom American ‘Welding Society, 50 NW. LeJeune Fa, Miami FL 33126, ‘Safoty and Health Standards, OSHA29 CFR 1910, from Supeinion- Gent of Document, U.S: Goverment Ping Oe, Washington, DG, 20802. ‘Recommended Safe Practoue {or the Preparation for Welding and ‘Gating of Gontainers That Have Held Hazardous Substances, Amor- ican Welding Society Standard AWS F4.1 from American Welding Society, £50 NW. Laeune Fa, Miami, FL33125. National Elechical Code, NFPA Standard 70, fom National Fre Protection Association, Batterymarch Park, Quincy, MA 02269. ‘Safe Hancting of Compressed Gases in Oviinders, CGA Pamphlet 51, rom Compressed Gas Association, 1235 Jefferson Davis High- ‘way, Suite 501, Arington, VA 22202 ‘Code for Safety in Welding and Cutting, CSA Standard W117 2, from Ginacan ‘Sancars Assocation, Sunda Sale, 179 Pesca Boulevard, Rexdale, Onto, Canada MOW IRS. for and ‘woton, ANSI Standard 237.1, from American National Standards Intute, 1490 Broadway, New York, NY 10018. ‘Qutting and Welding Processes, NFPA Standard 518, from National Fie Protection Association, Batieryinarch Park, Quincy, MA 2260. March 24, 1993 Replaces April 1, 1992 23 (ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Hobart Brothers Company Instruction 910081 ‘Troy, Ohio 45373 This page intentionally left blank. 2 “April 1, 1992 Replaces June 2, 1987 Hobart Brothers Company ‘Troy, Ohio 45373 PRECAUTIONS DE SECURITE EN SOUDAGE A L'‘ARC MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX ‘PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS TES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU'ILS N'AIENT CONSULTE UN (MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D'OPERATION OU LES INSTRUCTIONS AVANT D'INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT. Les produits ot procs de soudage peuvent sauser des blessures graves ou la mor, de méme que des dommages au reste du matériel ‘ela propriét, si ulisatourn’achére pas strctement A toutes les rbgles de stcurts et ne prond pas les précautions nécessaies, En soudage et coupage, des praiques stcurtuire se sont développtes sult &'exptrience passée. Ces pratiques doivent ave apprises ar étude ou entrainement avant utliser equipement. Toute personne n‘ayant pas subi un enrainernentintensif en soudage et coupage ‘ne devrait pas tenter de souder. Certaines praiques concement les équipements raccordés aux lignes d'aimentaion alos que d'autres, ‘adressent aux groupes élecrogines. {La norme 249.1 de American National Standard, inttuée “SAFETY IN WELDING AND CUTTING” présante les pratiques sécurtaires & sua, Ca document ainsi que dauies guides que vous Geir connaive avant cae et équperent sont peer lane cot Instructions de sbeur ‘SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D'INSTALLATION, DE REPARATION, D'ENTRETIEN ET DESsAL. PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 910309 FR Une décharge électrique peut tuer ou broler grave ‘ment. '6lectrodeetle circuit de soudage sont sous tension dds la mise en circuit. Le circuit d'alimentation et les circuits internes de équiperment sont aussi sous tension dia mise en marche. En soudage auiomatique ou eomi-au- {omatique avec fi ce derier, fe rouleau ou a bob- ine de fie logement des gaits fontainement et ‘putes les pitoes métaliques en contact avec le ‘de soudage sont sous tension. Un équipement ‘nacéquaternentintallé ou inadéquatement mis la torre ast dan gereux. 1. Netouchez pas. & des pidoes sous tension, 2. Portez des gants et des vatementsiolants,sace et non trou, 8. lsolez-vous dela pldce & soucer ot de lamise Ala tere au moyen de tapi ieolants ou autres, 4. Déconnectez ia prise d'almentation de équipement ou aétez |e moteur avant de installer ou den faire entrtion, Boquez le ‘commutateur en circuit ouvert ou enlovez les fusibles de ‘alimentaion afin ¢'éviter une ise en marche accidental. 5. Veuillez installer cet 6quipement et tle metre Aa tare salon 4e manuel q'utiisason et les codes nationaux, proviniaux et Jocaux applicables. TELECTROCUTION PEUT ETRE 6 Antiartout Gquipementapris usage. Couper Taimentaton de ] MORTELLE, : equipement sil est hors d'usage ou inutisd. 7. Nubia: que des porte-électrodes bien isos. Ne jamais plon- ‘get les porte-lectrodes dane Teau pour les refricr. Ne eras leslaisser trainer par terre ouaurlespldces A soucer Netouchez as aux porte-bectrodes raccordés & deux sources de courant ‘en mime temps. Ne jamais toucher queiquiun cautre avec ‘Electrode ou le porte-dectrode. 8. Nutisez pas de cAbles électriques usée, endommagés, mal ‘paste ou de sacion top patie. 9. Nenroulez pes de olbles électriques autour de votre corps. 10, Nutiisez qu'une bonne prise de masse pour la mise la terre do i pidca & souder. 11, Netouchez pas &'électrode lorequion contact avecte circuit de soudage (tere). 12, Nutiisaz que des équipoments en bon état. Aéparez ou ‘empiacez ausstt les piteas endommagées. 18, Dana des espaces confinés ou mouilésn'utlisez pas de source de courant atemat, & moins quit soit muni d'un réducteur de ‘wnsion.Uslisez pltbt une source de courant continu. 14, Pontez un hamais de stout si vous travalez en hauteur. 15, Fermez scildement tous les panneaux et les capots, LE RAYONNEMENT DE L’ARC PEUT BROLIN LES YEUX EF La PEATE a BRUIT PEUTENDOMMAGER LOUIE. fA) eo ay aan x = rayons ultraviolet intenses, sutceptibies de, Drier les youx ot la peau, Le brut caus par ‘BOUT vous protiger le visage et les yeux loreque vous soudez Ou ‘que vous observez 'exécution d'une soudur. 2. Portzdes luneties de steurt approuvées, Des éorane atraux ‘sont resommancés, 3. Entourez aio de soudage de rideaux ou de clolsons pour ‘rotiger les autres des coups d'are ou de Iébloulssement, ‘averdsez les observateurs de ne pas regarder Faro. ‘4. Portez des votements on matéraux igituges et durables Jaine ‘certains procédé peut endommager louie. oui) erdesoheneues cocker 1. Portez une casque de soureur avec fire cculaie de nuance 5: Prtez un casque antbrut ou des bouchons corel approwés ‘appropriée (consuitez ia norme ANSI 249 indiquée ciaprbe) _‘foraque le niveau de bruit est Glows, 30x82 a 13:1V-88 Révisée PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Hobart Brothers Company Instruction 910309 ‘Troy, Ohio 45373 ROANCES OCULARES POURTA DES YEDXEN URGE (selon AWS A&273) ‘Optraton ‘Dimension déiecwode ou ‘Nuance de oo Epaisseur de mital ou do five ‘Coupage ou soudage intensité do courant oxuiare “Brasage endre au chalumeau Toutes conditions 2 Brasage fort au chalumeau toutes conditions sous ‘Cxycoupage ‘mince ‘moins de 1 po. (2 men) 2ous moyen 60 146 po. @5a 150 mm) sous pais ‘lus de 6 po. (150 mm) Sous Soudage aux gaz mince moins de V8 po. (mm) sous ‘moyen do 181/250. 88 12mm) 50u6 pats. lus de 1/2 po. (12 mm) Sous Soudage Aare avec moins de 552 po. (4mm) 0 ‘ecrode enrobbea (SMAW) de 5/328 1/4 po. (446.4 mem) 2 Plus de 1/4 po. (8.4 mm). 1 Soudage a are sous gaz avec ft plan (GMAW). métaux non-eroux toutes conditions " métau foroux ‘utes conditions 2 Soudage & are sous gaz avec blectrode de tungstine (GTAM) toutes conditions 2 Soudage &ycrogine atomique (AHW} toutes conditions 2 Soudage a Fare avec Aectrode de carbone (CAM) toutes conditions 2 Soudage & are Plasma (PAW) toutes dimensions 2 Gougeage Aitee avec ‘lectode de carbone ‘mince 2 pais “ (Coupege & rare Plasma (PAC) mince ‘main de 300 amps 9 moyen 0300 400. amperes 2 toais ‘Plus de 400 ampares 4 angereuses a respirer. 1. Bhigne latte des tutes pour évitr cele repre, Le soudage dégage dee vapours ot dee fumées propre la respiration. ‘& No tavallez dane un espace canfind Que Sil eat bien veraley ‘spon, portez un respirataur & adduction dai, Lee gaz ro ‘wctours de soudage peuvent déplacer Foxypine ce Fair et ‘ainsi causer des malaises outa mor. Assurez-vous que air st 6. No souder pas & proximité dopérations de dégraissage, de 2. A Tinthreur, assurezvous que Tai de soudage eat bien foxiquea at writants. \entiée ou que les fumes et les vapours sont aspirées Aare. 2. Sila ventilation ext inadequate, porte un respirateut A adduc- tion air approuvt. "4. User les fiches signaiétiques et les consignes du tabricant ‘waives aux métaux, aux produits consumables, aux ‘evdtements et aux produits netoyants. ‘ettoyage ou de pulvrisation. La chaleur et le rayons de are euvent agir avec des vapeurs et formar des gaz hautement 7. Ne soudez des ties gaivanies ou plaquées au plo ou au ‘cadmium que sles zones i soucer ort 6 gratibes fond, que ‘siTespace est bien venti; si néceseaie portez un reepiratour ‘moment du soudage. ‘Aadduction ac, Car cos rovttements et tout métal ql cond ‘nt cen éléments peuvent dégager des furbes toxiques au 1341V-88 Révisée Hobart Brothers Company ‘Troy, Ohio 45373 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 910309 LE SOUDAGE PEUT CAUSER UN IN- CENDIE OU UNE EXPLOSION Lore produit des 6tincais ot des projections. Las ‘particules volantes, 6 métal chau, es projections de soudure et Méquipement surchaulié peuvent ‘causer un incendie et des brolures. La contact ‘accidental de élecrode ou dufi-loctrode avec un cet bialique pet proveque des incaes, un hutemere 1. Protégez-vous, ainsi que le autres, contr ls 6incalles ot ‘mital chau. 2. Ne soudez pas dans un endroit ot des partcules volantes ou des projections peuvent steindre des matériauxinfiammables, ‘3, Enlovez toutes matioes infarmmables dans un rayon de 10, 7 ‘mites autour de ar, ou couvreries soigneusement avec des aches approuvées. “4. Mifezorous des projections brulantes de soudage suscept- bles de pint dana des alres adjacontes par de petites uvertures ou esures. 7. Ne soudez pas un récipient fms, tl un réservir ou un bar '& Connecaz le ctbie de soudage'e plus prs possible dela zone de soudage pour emplcher le courant de sure un long, parcours inconnu, et prévenir ain les risques délectocution etdincendle, 9. Ne dégolez pas les tuyaux avec un source de courant. 10. tar blectrode du porte-sectrode ou coupez_efilautube-con- tact lorequinutiisé aprée le soudage. 11, Portaz des vetaments protectaurs non huiloux, tls des gants en cuir, une chemise 6paisea, un pantalon ravers, des botines io stourté et un casque. LES ETINCELLES ET LES PROJEC- TIONS BRULANTES PEUVENT CAUSER DES BLESSURES. Te piquage otto meulage produlsent des partcules métaliques volantes. En refroiissant, la soudure peut projter du éclats de later 1. Portaz un éeran facial ou des lunetes protechices approuvbes. ‘Des éerans latraux sont recommandés. 2. Porter des vetements appropriés pour protéger ia peau. LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les boutsiles contennent des gaz protectaurs F; | soushaute pression. Desbouteles “| peuvent exploser. Comme les bouteles font ormalement partie du procédé de soudag ‘waitaies avec soln. |. Protéges les boutoilles de gaz comprimé conte fee sources de ‘chaleur intense, les chocs et les arcs de soudage. 2. Enchainaz vericalement les bouts & un support ou & un cae fie pour es empcher de tomber ou ce renversbes. 3, Bloigner les bouteiles de tout circuit blectique ou de tout soudage. “© Emptchez tout contact ene une boutelle et ure Slecode de soudage. ‘5. Nusiisez que des boutailes de gaz protecteur, des dbtendeurs, ea boyatns at des raccords congus pour chaque application spéciique: ces Squipements et los pidcas connexes doWvent {re maintenus en bon état. 6. Ne placez pas le visage face & Towverture du robinet de la bout lore de son ouverture, 7. Lajanaz an place le chapeau de bout saut sien uslsation ou loreque raccordé pour utilisation. £8. Lisez ot respectez les consignes relatives aux boutsiles de gaz comprimé et aux équipements connexes, ain! que la publica ‘on P-1 de la CGA, identi dans la liste de documents eidessous. MISE EN GARDE | aged] LES GAZ D'ECHAPPEMENT DES $89) MOTEURS PEUVENT ETRE MORTELS. Los metoure produlsent des gaz céchappernent oats. LES MOTEURS PEUVENT ETRE DANGEREUX Tr Ualloez Fequipement & Tentiiour dane des aires ouveries & ion ventides. 2. vous utlisaz cas équipements dans un endroit confiné, tos fumntes dl tchappement doivent te envoybes AF extésieur, fein des prises car du Batiment. LE CARBURANT PEUR CAUSER UN IN- CENDIE OU UNE EXPLOSION. Le carburant eat hautement inflammable. 1. Arbtaz Je motour avant de vérer a niveau do Ne faltes pas Te plan en fumart ou proche dune source étneales ou dune famme Aue. ‘3. Si clest possible, laissez le moteur refoidc avant de fare le plein de carburant ou den vériier fe niveau au début du sondage. ‘4A. Ne faites pas te plein de carburant & ras bord: prévoyez de ‘espace pour son expansion. cearburant ou de fel pain. ‘5 Faitesatention dene pas renverser de carburant. Netioyez tout carburantrenveroé ava de faire démarer le moteur. 30x82 23 131-88 Révisée PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC. Instruction 910309 Hobart Brothers Company ‘Troy, Ohio 45373 ENT CAUSER DES BLESSURES. Despidces enmouvement, els des ventilateur, des rotors et des courrcies peuvent couper doigis et ‘mains, ou accrocher des vatemionts amples, Z ‘DES PIECES EN MOUVEMENT PEUV- 1. Assurezvous que les pores, es panneaux, les capots et les rotecteurssoient bie ferme, 2, vant installer ou de connecter un systime, anéteze moteur. ‘3 Seules des personnes qualiiées dohent démonter Ges pro- tecteurs ou des capots pour faire Tenration ou le dépannage nbcessaire. ‘4. Pour empécher un démarrage accidentel pendant entretion, ‘branche: le cable 'accumulateur la bome négatve. ‘5. Napprochez pas les mains ous cheveux de pitces en mouve- ‘ment oles peuvent aussi accrocher dee vitements amples et des out 6, Pintle les capots ou les protectours at formez ls portes ards des travaux dlentretion et avant de five démarrer te moteur, DES ETINCELLES PEUVENT FAIRE EX- PLOSER UN ACCUMULATEUR; UELECTROLYTE D'UN ACCUMU- LATEUR PEUT BRULER LA PEAU ET LES YEUX. Les accumulateurs contionnent de Télectrotyte cide et dégagent des vapeurs explosives. 1. Pore toujours un Geran facial en Wavallant eur un acura lataur, 2. Attar le moteur avant de connecter ou de déconnecter des ‘bles d'eccumulateu. 3. Nutosz que des outls ant-étincalles pour trvaller sur un ‘accumuiateur. “ Unaccur Elta sunt momontanocanted vec ‘5. Uso ia polar comecte (+ at - de Faccurulatur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX. Le Hiquide de rettoicissement d'un radiatour peut {ire brant ot sous pression. 1, Notez pase Bouchon de radiatour tant que le moteur n'est pas retro ‘2. Metiez des ants et posaz un torchon surle Bouchon pour ter. ‘3. Laissez Ia pression s'échapper avant deter complatement le Douetion. PRINCIPALES NORMES DE SECURITE ‘Safotyin Welding and Cutting, norme ANSI 40.1, American Wold ing Society, 550 NW. LeJoune Fd. Mami, FL 33128. ‘Seteand Heat: Standards, OSHA 2 CF 110, Superetndent Printing Office, ‘et Documents, US Government Washington, Di owe, ‘Recommended Safe Pracies forthe Preparation fr Welding and ‘Gutting_of Containers Thet Have Held Hazardous Substances, ‘ore AWS Ft, american Welding Socay, SO NW. Laloune Ra, Miami, FLS3t28. National Electrical Code, norme 70 NFPA, National Fre Protection ‘Association, Gatirymarch Park, Quincy, MA 2269, {Sale Handing of Compressed Gases in Ovinders, document P1, ‘Compressed Gaus Association, 1235 oefferson Davis Highway, Suite S501, Afington, VA 22202. in Welding and Cutting, norme CSAW117.2 Asso- ‘ation canadienne de normalisation, Standards Sale, 276 Rexdale ‘Boulevard, Rexcisle, Ontario, Canada MEW 173, ‘Sat Pracioes for Qncuaton and Etucatonl Eye and Face Pro: ‘Beso, ore ANS! 2571, American Naional Stnderds iat, "790 Bronaway, Now Yor NY 10078. ‘Gutting and Welding Processes, norme 518 NFPA, National Fie Promcton Association, Baterymarch Park, Quincy, MA C2269. 30X-92 134V-88 Révisée Instructions M635 RECEIPT OF EQUIPMENT Check the equipment received against the Hobart Broth- ers Company invoice to make certain that the shipment is complete and undamaged. If the equipment has been damaged in transit, notify the carrier (railroad, trucking company, etc.) at once and file a claim for damages. If you require assistance with a damage claim, furnish Hobart Brothers Company full information about the claim. If the shipment isin error, contact: Order Depart- ment, Hobart Brothers Company, Troy, Ohio 45373. Give the MODEL, SPECIFICATION, and SERIAL num- bers of the equipment, and a full description of the parts in error. Refer to the first page of this manual for an ‘explanation of the specification numbers. Generally, itis good practice to move the equipment to the site of installation before uncrating. Use care in tunerating in order to avoid damage to the equipment when bars, hammers, etc., are used. Lifting eyes which extend through the top of the cabinet have been pro- vided to facilitate handling with a crane or hoist. Best results with this equipment will be obtained ONLY if the responsible operating personnel have access to and are familiar with thesé instructions. Additional copies may be obtained at a small cost per copy by writing to: Hobart Brothers Company, Troy, Ohio 45373. Supply ‘the technical manual no. (TM-G35} plus the model, |[specification, and ‘serial number of your equipment. DESCRIPTION OF EQUIPMENT ‘This unit is a constant-current transformer rectifier type DC welding machine that provides vott-ampere charac- teristic curves that are basically drooping, with a slight slope. See Table 1 for rated output of the model covered by this manual. Modet Load | No Load Duty No. |Amps| Volts | Volts | kw oye R400] 400] 36 | 80 [144] 60x Table 1 CONTROLS AND CONNECTIONS POSITIVE TERMINAL (+) — Serves as connection point for the welding lead to the workpiece when straight polarity is used. ARC FORCE AMPERE CONTROL — Varies the short-cirouit-(welding arc) current and produces an in- ‘crease of amperage when arc length is shortened, such as in a tight groove. This control provides more are force ‘and eliminates the tendency of snuffing out the arc, ‘when using electrode manipulation. The control is ‘especially suited for use with E-6010 and E:7018 elec- ‘trodes for pipe welding applications. See NOTE at Paragraph 5 in OPERATION section, CURRENT CONTROL LOCAL/REMOTE SWITCH = Selects either the local (pane! mounted) current con- ‘trol, or some remote control device to control welding May 26778 June 5/79 Revised current. NOTE: See OPERATION section for details on setting all controls. REMOTE CONTROL RECEPTACLE — Serves as @ ‘connection point for the Remote Control Pendent. CONTACTOR CONTROL —_LOCAL/REMOTE SWITCH — In LOCAL (UP) position, the SCR (silicon Controlled rectifiers) are energized, and open-circuit Voltage is applied to welding output terminals. In RE- MOTE (DOWN) position, a remote switch must be used. NEGATIVE TERMINAL (.) ~ Serves as a connection point for the electrode lead, when on straight polarity. FUSE -3A. CONTACTOR “ON” PILOT LIGHT — Indicates when the contactor is closed for power ON mode of ‘the unit. INPUT CONTACTOR CONTROL ON/OFF SWITCH This toggle switch is the master power switch for the ‘welding machine, and must be in the ON position be- ‘ore any other section will operate. The primary circuit of the control transformer is energized whenever line voltage is present at the input terminals. This switch ‘loses the secondary circuit of the control transformer, ‘energizing the contactor, which energizes the power ‘transformer. See “DANGER” on Safety Weming Page. Page 1 CONTROLS AND CONNECTIONS (Continued) RANGE SWITCH, LOW/HIGH — The welding cur- rent range suitable for the work application and elec- trode selection will be selected by this switch. See Table 2 for current ranges. CURRENT CONTROL — Adjusts the welding cur- rent. See Table 2 for ranges of control. METERS (Optional) — Provision for welding am- ‘meter and voltmeter is made. On SPEC numbers 6038-2, 6039-2, 6040-2, 6041-2, ‘and 6042-2 machines, a thermostat to control the start- ing and stopping of the cooling fan motor is present, When the machine reaches its intemal operating tem- Anput Contactor ~ Range Switch f ON/OFF. Switch Contactor ON Pitot Light——_| Contactor Céntrot k Local/Remote Remote Control _ Receptacle ‘Sui co Twess perma, the fn motor wil came on. Alter he cooing unt tu tr tae meee tne spy tpnaare to hie ond We toramlsusemcietoe a ra te terperetre ache high evel pa The proces earache sesinisieen oer Saewidin he atl ‘See Addendum supplied (0-195) for reference to 6038-3 and information on Voltage Changeover Switch used on. that spec. model only. WELDING CURRENT RANGES Modet_| Range 1 (Low) | Range 2 (High R400 | 2010 240A 40 to 500 A Table 2 Voltmeter eaters ammeter Optional Current Control Local/Remote AC as (Control Panel INSTAL LOCATION For best operating characteristics and longest unit life, take care in selecting an installation site. Avoid locations exposed to high humidity, dust, high ambient tempera- ture, or corrosive fumes. Moisture can condense on elec- trical components, causing corrosion or shorting of cir- Page 2 Figure 1 LATION cuits. ‘on components helps retain this moisture. ‘Adequate air circulation is needed at all times in order to ‘assure proper operation. Provide a minimum of 12 inches (305 mm) of free air space at both front and rear Of the unit. Make sure that the ventilator openings are not obstructed. . Revised Oct 2/79 cS be operated. If necessary, rearrange internal wire or lnk connections as instructed on the Voltage Changeover ram supplied with this manual. Remove cabinet ‘op for access to changeover CONNECTING WELDING MACHINE TO LINE VOLTAGE — The input power cable should be con- nected to the welding machine through a fused discon- ect switch, furnished by the user. A hole is provided in the back panel of the welding machine, near the upper righthand comer, for the entry of the input power cable. Remove cabinet top for acosss to all connection points. Consult local electrical codes for power cable and fuse sizes, or if none exist, refer to the National Electri- cal Code or to Table 4. WARNING: Make sure line voltage is tumed off before making any connéc- tions. Tum off fused disconnect switch ‘that supplies power to welding machine and remove its fuses. a INPUT VOLTAGE DATA Line Line When possible use “an TM635 VOLTAGE CHANGEOVER — Consult the Voltage Changeover Diagram in the back of this manual. Note ‘the input voltage specs on the nameplate on the control panel. * On Spec. 6038-3 machines, a Voltage Changeover ‘Switch Box is installed on the rear panel of the cabinet. ‘This switch allows switching from 230 volts to 460 volts input power by merely throwing the switch, GROUNDING — Thi frame of this welding machi should be grounded for personnel safety. Where grou ing is mandatory under state ‘of logst codes, itis the responsibility of the user to comply with: applic rules and ‘regulations. Where no state OF local: exist, it is recommended that the: National! a Code be followed. See Table 4 if thes not available. “Thee requiciments and ecole rubberstie mounted equipments et. personnel agpinst the hazard of electri fault in the equipment, groundings sees the static electrical charges whiol the surfaces of rubbor-tre statie charges can cause painful which includes @groundino this equipment to the input gner supply cluded in the cable assembly,, the grou will be green, green with & rect the grounding condictor 3 ing tarminal, if provided,’ frame, taking care-to ma Line | Load Line Vos .| Amps | Fuse Rating [ln Conduit 200 700. 740. Nod No.4 ‘Ned 220, 31 740) No. No.6 Wo. 8 220 a7 140) No. No.6 tio. | * 380, 53 80. No. 8 ~ No. 8 No. 8 416; 48. 30, No.8 No. 10 No.8) 460 43.5 “80. No.8 Mo: 40. No.8 - 500 20 + 7 No.8. ueio [Cae | 575 35 60 ‘No. 10. No. 10 No. 8 edi ~~." Wire size calculated for 60% duty cycle. poe i : Pages Mar 12/79 Revised Recommended Wire aiid Fuse Size Table Table4 Fm WIRING (Continued) a. TREATING AN OUTSIDE GROUND — The soil treating materials are placed in a circular trench around If, for any reason, an input cable which does not include the rod, but not in direct contact. The crystals are 1 grounding conductor is used, the equipment may be gradually dissolved by surface waters and the solution is. grounded with a separate conductor if permitted under carried into the most useful area of earth surrounding applicable code or by special permission of the juris- the electrode (rod). Flood the trench several times | ‘After locating the desired part in the following figures and parts lists, if the “Application Code" column says “All”, proceed to order the part. If there are several part numbers after the same “Item No.”, order only the part number ‘corresponding to the “Application Code" letter that you selected above. Page 1 Control Panel Group Figure 1 “Sept 19/78 = PL636 Units Fig. Item Part er Application No. No. No. Nomenclature ‘Assembly Code 367845-2 Kit-Meter (Optional) . . at Al “4 aowa7 Shunt. 5 1 all 2 a00sa1-8 + Ammeter “DC Single Scale. 1 all 34008424 = Voltmeter - DC Single Sale. 1 all = 4 4040404 Nameplate Ident... 1 all 3677073 Panel = Front, Assembly . 1 ABCDEFG 3677078 Panel - Front, Assembly . 1 HOKE 5 3681053 Panel - Front. 1 ABCDEFG 3681056 Panel - Front 1 HOKE 6 AW133 + Cover - Meter Hole 2 all 7 3e7732 + Shunt « 1 Al 8 AAWS35A, Knob « 1 All 8 402663 + Bushing - Pot. Lock 2 all 10 402658 + Fuseholder 1 all 11 WA11166-10 Fuse -3 Amp, AGC 1 all 12 4024212 “Light Pilot, Red. af all 13 -367703-4 + Resistor 1/2 Watt, Asembiy« 60 All 14 TeDA2t62 “Knob - Are Force ot all 15 4053193 + Label - Ident. “a All 35766841 + Kit Terminal and Cover, Assembly a All K 16 NoNumber Serew - Machine,#6-32 Rd. Hd. . wat all K 17 NoNumber Serew - 1/213, HHCS (Drilled for !tem 16) ot all K 18 NoNumber Washer LK... ae} all K 19 NoNumber Washer - Flat Stool... a al K 20 NoNumber Washer -Bakelite... 2... 2 Al K 21 NoNumber = Insulator, Cable Stud - ot All K 22 NoNumber Bar-Bus (L Shaped)... ot all K 23 NoNumber «Washer -ST. Cad. Plated . ot A K 24 No Number ++ Serew = 1/213, HHCS, Cad. Plated 6 ll K 25 NoNumber Nut- 1/213 . a al K 26 No Number ++ Cover = Cable Stud ==. a all K 27 NoNumber s-Pin= 1/8 x24. Broo all K 28 NoNumber Nut -Steel Push +2 all K 29 3576682 inal & Cover, Assembly (Same as 367668-1 except ttem 16 not drilled)... - eet al = 3681282 Hamess- Wire and Component 5 eeeog ‘AD 3681284 Hamess- Wire and Component Assembly CFHK B12 Harness - Wire and Component Assembly BE 3681288 Harness -Wire and Component Assembly . Gils etn 30 400758 + Receptacle -6 Pin Amphenol... alt 31 405965-1 + Switch - Togole All S 367673 + Socket -J2 Assembly - A aoe

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