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Handler 187 And H100S2−10 Gun

1. 22 36 9 8 Troubleshooting Excessive Spatter 2 37 9 9 Trodbleshoolig PO SIES MEL dec bu d ir hc ien ari a ous eon Dn SS e oe apte 37 9 10 Troubleshooting Excessive Penetration enaena 37 9 11 Troubleshooting Lack Of Penetration 22 38 9 12 Troubleshooting Incomplete Fusion 4 n 38 9 13 Troubleshooting Burn Through 0 38 9 14 Troubleshooting Waviness Of Bead 39 9 15 Io bleshooting DISIOMION c E oon rri Aone ds Gin Sat oak AN eee Que Did ALAN aha a NG 39 9 16 Common MIG Shielding Gases x ua nee duree Rr rir Re ern itte NAKA ADD date ung aa ends 40 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment 40 SECTION 1T0 PARTS LIST aise vate ees Canes As 42 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2009 08 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided DANGER Indicates a hazardous situation which if could result in death or
2. e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards 7 Indicates special instructions e a A This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Properly install and ground this equipment according to its Owner s Manual and national stat
3. 30 70 20 80 10 90 100 WIRE FEED VOLTAGE DO NOT SWITCH WHILE WELDING 3 Voltage Switch The higher the selected number the thicker the material that can be welded see weld setting label in welding power source or Section 6 2 as applicable Do not switch under load Ref 228 178 A Ref 246 668 A IF Switch must click into detent position 4 Trigger Switch When pressed energized wire feeds and shielding gas flows Notes OM 228 187 Page 21 6 2 Weld Parameter Chart Welding Guide for 230 Volt Settings are approximate Adjust as required Thicker materials can be welded using proper technique joint preparation and multiple passes Material Wire Type Suggested Diameter ml ee Being and Shielding Gas of Wire 24 ga 20 ga Welded Polarity Setting 20 30 CFH Flow Rate Being Used 024 In 036 in 0 6 mm 0 8 mm Stainless Steel Flux Cored E71T 11 Set Polarity for DCEN Solid Wire ER70S 6 Set Polarity for DCEP Solid Wire ER70S 6 Set Polarity for DCEP Stainless Steel Set Polarity for DCEP Aluminum Set Polarity for DCEP Match feedroll groove to diameter of wire being used Set Tension Knob Setting to 3 at start Adjust tension per instructions in the manual Multiple passes required OM 228 187 Page 22 osm w5 nome tete nes 035 0 9 mm 1 30 SS AAA AA 045 1 2 mm ll 024 0 6 mm SE e
4. Solid wire with shield DCEP Reverse polarity Connect to positive out Connect to negative output ing gas put terminal terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal 5 5 Changing Polarity Turn off welding power source 1 Lead Connections For Direct Current Electrode Negative I7 Connection hardware must be tightened DCEN with proper tools Do not just hand tighten DCEN Lead Connections For Direct hardware loose electrical connection Electrode negative for Current Elactrode Positiva will cause poor weld performance and flux cored wire DCEP excessive heating at the terminal block Always read and follow wire manufacturers recommended polarity and see Section 5 4 Close door Electrode positive for solid wire Ref 209 228 Ref 209 229 OM 228 187 Page 15 5 6 Installing Gas Supply 2 Obtain gas cylinder and chain to tJ running gear wall or other DS stationary support so cylinder cannot fall and break off valve EF DO NOT use Argon Mixed gas regulator flowmeter T di 1 Cap with CO shielding gas See Parts List for optional CO gas regulator flowmeter 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Pad Install so face is verti
5. Tools Needed 7 Hold wire tightly to keep it from unraveling 4 in 4 NC 6 in 150 mm Open pressure assembly Make sure Pull and hold wire cut off end Push wire thru guides into gun feed roll is set to correct groove to continue to hold wire match wire size see Section 7 4 7 Use pressure indicator scale to set a desired drive roll pressure Pressure Indicator Scale T Be sure that wire is positioned in proper drive Remove gun nozzle Turn power on Be sure that Voltage range roll groove and wire is laying in the groove and contact tip switch is set to range 1 2 3 4 5 6 or 7 to Close and tighten pressure assembly feed wire Rotate knob until it clicks into det and let go of wire ent Wire will not feed if range switch is set between ranges Press gun trigger until wire comes Be sure that tip matches wire diameter Feed wire to check drive roll pressure out of gun Reinstall contact tip and nozzle Tighten knob enough to prevent slipping Cut off wire Close door Ref 804 623 B Ref 246 669 A OM 228 187 Page 19 SECTION 6 OPERATION 6 1 Controls pak 1 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting increases wire speed range also increases see weld setting label in welding power source or Section 6 2 as applicable 2 Power Switch OM 228 187 Page 20 e Kb m 1
6. E Wire size stamped on tip check and match wire size Tools Needed TE 8mm 246 669 A 5 2 Installing Welding Gun e 1 Drive Assembly YA kao 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew Welding gun must be inserted completely to prevent leakage of 2 shielding gas 4 Gun Trigger Leads Co Insert leads one at a time through gun opening on front panel Connect female friction terminals to TE matching male terminals in unit Polarity is not important ubt na Il n v Close door Exposed O rings will cause shielding Incorrect gas leakage Correct Gun Not Seated Gun Fully Seated 804 621 A OM 228 187 Page 13 5 3 Installing Work Clamp Nut Work Cable From Unit Work Clamp Screw Work Clamp Tabs 7 Connection hardware must be tightened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor Bend tabs around work cable weld performance and excessive heating of the work clamp 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp Slide insulating sleeves over handles Tools Needed 7 16 in 32 7 16 in 802 456 A OM 228 187 Page 14 5 4 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW
7. USA 2009 Hobart Welding Products 2009 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 HOBART 0 WELDERS
8. WAMINO Sa apa diese avi dde a ee ea eed mp 1 a ia abah madonna 203491 o CLAMP capacitor se cene dr dcc SE SALT near KG BAG eu eS NU 1 35 PAA V ele 193 040 CAPACITOR electrit 100000uf 1 A A AE 225891 REACTOR ASSY magaan irrita doe a 1 POE eeu us pokes 1939310 sA RECTIFIER ASS rien et ta d due icta owe dob wd duri iat 1 SO PENES ores RE 193 193 BUS BAR positive ili RR RA EREGaLARESAITTRG A XRESXARENRS EX 1 pe eins ee mE 217 831 4 BAFFLE Cemer int y ames Nectar dae Eus an wed oe Bes ds 1 Ecc PEE 405 576 001 BUSHING terminal 444444 eens 1 O beet 193 144 INSULATOR output stud 1 o qur sud neo 193 194 BUS BAR negative 1 Vac uta occu P sd d 216 830 sx LABEL WAMING vs obe e veda que Upa rede qu Eee Eis 1 AAA 194201 c9TAND OBE i232 oai iia Adi 1 Pi o E EEEE 226 813 SWITCH rotary 32A 7 position 1 A Pee base 209873 se POTENTIOMETER coord nue abere 1 Na esd PR Ne RASE 290 385 2 PANEL TONE serri 3 a kw tese Nantes tie ee RU a 1 OO Be O lanl hones Beta aie 208 B20 wc CLAMP WOK 1 mwa tee cacti Seana Reb dei eee hee ac 1 oc pp 196 619 CABLE WOM ideato abia RAT HIE E Eee A Teal ut dos 1 OM 228 187 Page 43 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly Continued TIC REP 196 574 SWITCH rocker DP
9. des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements gt Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californ
10. far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 9 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces LIZ base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 228 187 Page 39 9 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel pali piti Aluminum Argon X Argon 25 CO X 80 or greater Argon X x1 balance CO or Oxygen 100 CO X Tri Mix X 1 Limited short circuiting use 2 90 HE 7 1 2 AR 2 1 2 CO 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure o
11. l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment a AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalon
12. or pressure bearing if worn or slipping see Section 7 4 Secure gun trigger leads or repair leads See Section 5 2 Check and clear any restrictions at drive assembly and liner See Section 5 10 or Section 7 5 Release gun trigger and allow gun and motor protection circuitry to reset see Section 7 3 Gun is not secured to feed head Check thumbscrew securing gun end to feed head adapter and tighten if necessary Have nearest Factory Authorized Service Agent check drive motor Weld porosity Remove weld spatter buildup in nozzle Check O rings on gun connector and replace if damaged Make sure inner head tube is tight in cable connector Check gun connector to be sure it is fully inserted into drive assembly Check shielding gas flow supply OM 228 187 Page 28 Notes OM 228 187 Page 29 SECTION 8 ELECTRICAL DIAGRAM 4 amp WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install HOCK HAZARD use or service this unit GAN OR CAN TEL S1 POWER SWITCH PLG4 3 27 gt RC2 9 2 9 gt RC2 10 277 gt Rc2 11 D CONTROL BOARD 272 RC2 12 PC1 RC6 PLG6 EAS af S RC2 1 IN a 14 2 es RC2 PLG2 d TRIGGER 2 zz RC2 2 Figure 8 1 Circuit Diagram OM 228 187 Page 30 4 amp WARNING e Do not touch live electr
13. solenoid valve not operating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage OM 228 187 Page 40 Problem Probable Cause Remedy Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 228 187 Page 41 SECTION 10 PARTS LIST 37 Hardware is common and not available unless listed 22 RE n Maal 804 624 A Figure 10 1 Main Assembly OM 228 187 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly n ects ects ate Be aes 199 566 DOOR ACCESS cs oe cee aie RENE ER De EORR DOON iced NH ee 1 uu BA Sue Eng ha dala ARA 196 006 z HINGE GOOF 51e dae be eai udine ee ead al a ce e la Due 2 T pm 211 597 RUBI ou sto id vo oe one oer muli ita 1 m MD PEN 204608 x NUT sten aded o rege tu Dane eme acto op put
14. stance inflammable P 4 Q NI e LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 228 187 Page 7 GO Les PI CES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PI CES MOBILES peuvent causer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS all e Lire et appliquer les i
15. 0 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 212 64
16. 2 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les po
17. 7 50 3 35 4 30 5 40 7 40 7 50 2 100 6 90 7 90 Wire Speed listed is a starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleanliness of metal etc 227010 Make sure that hub tension is not too tight and keep the torch straight as possible A push angle for the torch is recommended 227 010 A OM 228 187 Page 23 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance Replace Repair or Clean and unreadable replace tighten weld labels cracked terminals weld cable 6 Months Blow out or vacuum inside During heavy service clean monthly 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 802 441 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again OM 228 187 Page 24 7 4 Changing Drive Roll Or Wire Inlet Guide Turn off welding power source Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Retaining Pin To remove d
18. NI OM 228 187B 2010 01 gt aaa Processes MIG GMAW Welding Flux Cored FCAW Welding Description 8 Ng KH Arc Welding Power Source And Wire Feeder Handler 187 And H100S2 10 Gun Online Forum www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years NI 0001 of reliable service with proper maintenance And if for some reason the unit needs repair REGISTERED E there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered to the you may need to fix the problem Warranty and from Hobart is backed by FR Quality System Service information for your particular model the best warranty in the business are also provided Protect Your Investment Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your
19. PMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do SO e Do not point gun towa
20. Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 9 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld m Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 228 187 Page 37 9 11 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher vo
21. ST 1 uud AA dte 228 400 KNOB pointer voltage 1 o PA AE 211 338 KNOB pointer WES 0 0 eee 1 man AD thet kean acd das EA ZAP f0 x3 MOTOR OA ACT 1 44 193189 CONNECTOR QUN 00 owe ote GANG NA KANAL ABA te ae e cuba 1 PAD added ra erdt 196 654 x SGREW INUNDA A A 1 MO kaaa eu 230012 FITTING gas barbed 1 mc n 237 338 ROLL drive v groove 024 030 035 wire 1 OD CON NE 194 508 HEAD feed 59V c ouai a RIP CR e UR Bd Ced des EU RUE ead 1 erii A Baa aa Bala BORE 203 025 GUIDE wire inlets 2228888 deret e Ce AC e recae es 1 Ma PC 227 010 LABEL weld chart surta de Pan de er e o din ste 1 91 ds beate 204 FTE ss O bess opted te eto en cu ode ot o dee e o ded e eta lem edge 1 SMOD Ld T E 217585 xx GONTAGTOB is nn E re E US t bes bor d es 1 NOD KA a tado 203 572 LABEL warn gen precaution EN FR models only 1 ande cau mE E LE E LABEL nameplate order by model and serial number 1 NODE ER 221037 REGULATOR FLOWMETER 10 50 CFH argon mix 1 egets i E N 183 581 HOSE assembly Gas ia Se bao e RS quia Cra aes 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Ma
22. TE DE L QUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste bh LES TINCELLES PROJET ES peuvent provoquer des blessures e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub
23. a roe gem d debe ed pt 1 DU dM ILU E 202 998 lt SPRING CHEST 2 oo eu nba SER ORE EUR Cb CU Be bet Se eee E qas 1 up d Sat urine 2090712 WASHER flat ma ct eh ANA ha NA NA Da 1 NA EA E E E 211339 s HUB SPOON dad nee 1 UL A 202 726 ADAPTER SpOOLDUD sitial Donat desto KA eee oe widen et Re ts 1 PD A DURO 217 078 CIRCUIT CARD ASSY control 1 UNE LO M NEN ROTE 195 999 x BASE OWEN zuo a EAR cede da deceat dede St des vase 1 ls Sn cud 210 109 SUPPLEMENTARY PROTECTOR 25 amp 1 m or 196 467 TUBING PVC 187 ID x 312 OD x 23 00 1 E E sab toto ES 216 398 VALVE OS sena nn De ROS Repub cri alertes bees dt uus Saeed 1 cc dd ai Sternen 197 198 CABLE TIE 700 799 bundle dia 2 uulgus cce mM m CE 152 118 CORD SET 250V 6 50P 12GA 3 C 7ft SPT 3 jkt 1 06 2 Sir nd 111 443 BUSHING strain relief 1 KN KPA te Want 137 761 NUT gasWVale Se co id UN kan NG ted cec re eee 1 x m 196 064 e MOTOR Tal os iue ot ir created tetes 1 ma OO cube 409 953 001 BLADE fan cooling 0 ccc Ie 1 nag AO Aa head ode iet pen 226 069 TRANSFORMER power assy 1 Sele A i 208 015 s HANDEE Car VINO ssa a gat DP e bbe wel erg eed oe eee ee 1 T ms 196 005 WRAPPER serias ii OU e Uu Soie o Sob bent pis 1 o irons 204090 LABEL
24. ad Tube e ERI Turn Off welding power source wire feeder and disconnect gun 1 Remove screws 5 2 Remove handle halves and nuts 4 Remove screw on 3 Remove switch housing Install new da el switch and connect leads polarity is opposite side not important Reassemble in reverse order If replacing head tube continue to end of figure 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 7 Place head tube in vice and tighten until 6 Hand tighten head tube into cable connector nuts are tight 9 Reinstall screws 8 Remove from vice Reposition handle halves and and nuts install switch housing Reinstall screw on opposite side Tools Needed C 3 45mm phillips 243 840 A OM 228 187 Page 27 7 7 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle See Section 5 7 Replace building line fuse or reset circuit breaker if open Place Power switch in On position See Section 6 1 Reset welding power source supplementary protector see Section 7 2 No weld output wire does not feed fan motor continues to run Thermostat TP1 open overheating Allow fan to run with gun trigger switch off thermostat closes when unit has cooled see Section 4 2 Check Voltage range switch position Rotate kno
25. al 1 Rating Label GND PE Earth Ground Supply correct input power 2 Black And White Input Conductor L1 And L2 3 Green Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Receptacle NEMA 6 50R Connect receptacle as shown 9 Over Current Protection Select type and size of over current protection using Section 5 8 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 10 Plug NEMA 6 50P Connect plug to receptacle L2 up Je o 0 U 230 VAC 1 v ssb2 2 1 94 804 622 B OM 228 187 Page 17 5 8 Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source Input Voltage V 230 Input Amperes A At Rated Output 20 5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker Time Delay Fuses 2 25 Normal Operating Fuses 3 30 Min Input Conductor Si
26. at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes dle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted
27. at them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit NEZ FALLING EQUI
28. available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province ae P P hobart_warr 2009 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Contact your Distributor for Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN
29. b until it clicks into detent at desired range setting Secure gun trigger leads see Section 5 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 7 5 Check for proper polarity connections See Section 5 5 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Wire does not feed wire is not ener gized wire feeds unevenly Check contact tip Check for kinks in gun cable and liner Check gun trigger plug connection at welding power source wire feeder Check and if necessary replace gun trigger switch see Section 7 6 Check contact tip Check for kinks in gun cable Blow out liner and gun casing See Section 7 5 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure See Section 5 10 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 9 Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove Replace contact tip if blocked see Section 7 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 or Section 7 5 Replace drive roll
30. by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Donot place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 228 187 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S C
31. cal 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection 3 Connect supplied gas hose y between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open feedhead pressure assembly so that wire will not feed Press gun trigger to start gas flow Argon Gas Or Mixed Gas Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate After flow is set close feedhead pressure assembly E e LI Citi D Feedhead Pressure Feedhead Pressure Assembly Open Assembly Closed Tools Needed TI 5 8 1 1 8 in Ref 804 654 A 802 441 Ref 804 623 B OM 228 187 Page 16 5 7 Selecting A Location And Connecting Input Power Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Installation must meet all Na tional and Local Codes have only qualified persons make this installation Disconnect and lockout tag out input power before con necting input conductors from unit 18 in 457 mm of space for airflow A Always connect green or green yellow conductor to supply grounding terminal first and never to a line ter Do not move or operate unit where it could tip min
32. cer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service AY LA CHU
33. d panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagneticallycompatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 228 187 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Stan
34. dard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers
35. der plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 228 187 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler da
36. dit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s a deux machines en m me temps cause de la pr sence d une tension vide dou bl e e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccor
37. e and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal
38. easing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection FRA 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
39. ervir d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone ou se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais pla
40. eux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc OM 228 187 Page 6 e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection gt n LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit
41. ical parts Q e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 307 o PRI T Li zo m 5 EF ala gt A J 4 PRI 2 i 7 i l c x4 12 ANC De S HA PRIS SR1 i 1 1 gt a X2 ei M O0 370 A PRI 4 2 e BOSE x1 ES rotg o l c C1 EH 48 308 PRI 5T VOLTAGE Bs TET 00 BANGE 6 306 PRI 6 SWITCH 3 O O gt a m x D RER e 4 e NEGATIVE K IOA E l I I 2 5 502 PRI 8 MEM NOTE DENOTES SWITCH TERMINAL MARKINGS RCI pen AED ai HU WIRE DRIVE MOTOR RC1 2 lt EA PLG5 RC5 RC2 6 lt 20 3 27 cu WFS RC2 lt 2 el ros RC2 B qe 2 1 228 180 A OM 228 187 Page 31 SECTION 9 MIG WELDING GMAW GUIDELINES mig1 2009 12 Ref 801 909 A 9 1 Typical MIG Process Connections Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter E Wire Feeder Power Source Shielding Gas Workpiece STAR Work Clamp OM 228 187 Page 32 9 2 Typical MIG Process Control Settings 7 These settings are guidelines only Material and wire type joint design fitup position shielding gas etc affect settings Test welds to be sure they comply to specifications Material thickness determines weld parameter
42. ie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 228 187 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents telephone 1 877 413 5184 site internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 270
43. il le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique a courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants IF Indique des in
44. lla ld S 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty
45. local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 Hobart1 or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 ORARI AS Hob Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad O MPSS on ed tute abad Mn a MO Re Neue 1 162 Are Welding Hazard 3 orsus ae oe ale o ar de a ane uim deu ade a eee ua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 4 5s P ncipal Satety Standards enterarte arroz AU 4 156 EME IBITOFITIS BOTE su auci ai dar n c acr 8 to ata dica is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS USES Sn de free a re etse dnce o ee Dalee aah RERUM een ban 5 2 2 Dangers relatifs au soudage l arc 2 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de S curit ss sas cas din aos naines a dis 9 2 6 Informations relatives a
46. ltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of 0 to 15 degrees 9 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 228 187 Page 38 9 14 Troubleshooting Waviness Of Bead gt Waviness Of Bead weld metal that is not parallel and does not cover jointformed by base metal S 0641 Possible Causes Corrective Actions Welding wire extends too
47. n wire feed rolls Increase pressure setting on wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas oylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas
48. nable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be
49. ns un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et y
50. nstructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e nergie lectromagn tique risque de provoquer
51. nufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 228 187 Page 44 246 670 A Quantity Figure 10 2 H100S2 10 Gun Item Dia Part No Mkgs No Description 245 924 Figure 10 2 H100S2 10 Gun KA Mm 169 715 NOZZLE slip type 500 orf flush b NU 226 190 NOZZLE flux cored slip type E REND 087 299 TIP contact scr 023 wire x 1 125 E eek ty eee 000 067 TIP contact scr 030 wire x 1 125 A ne 000 068 TIP contact scr 035 wire x 1 125 DR OB 000 069 TIP contact scr 045 wire x 1 125 o DE M 170470 RING retaining ETT 169 716 5 ADAP LER COnIaet lp iaa uM aces ZAS es TUBES ari ie LL un uso ours ON rm 243 865 lt NUT JAM entra ma ba tt eet Dor ees nee 242002 sa HANDLE iei ec a a argo nor De um tes dede m Du die 225 10 wa SITE AMOO sra dendo De ce dca b nl ee a Ro m eta Dues e ETETE TIERT 246 380 2 HOUSING POWET DIN eras t terors taa deant qe meta EE ae 0 AAA 245 0927 CONNECTOR feeder urls A A AAA A RN eS Oh ee gt 197 123 O RING 312 ID X 062 70 duro buna n An ee 194 010 LINER monocoil 023 025 wire x 15ft con
52. object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns Pini OM 228 187 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degr
53. objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen pipes OM 228 187 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from
54. onsumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW Cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Do not weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2009 08 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte DANGER Indique une situation dangereuse qui si on Indique une situation dangereuse qui si on l vite pas
55. peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le f
56. r gera du noe 20 a AU 20 6 2 Weld Parameter Chart For 230 VAC Model 22 SECTION 7 MAINTENANCE 8 TROUBLESHOOTING 2 222m 24 Tell Routine Maneno E o kaka irae A eic abi EX ee SEN Ga bi ia ba SAME 24 7 2 Overload Protector aco a nn ei RR ERE 4 ROS an Ret tne CI DYAN PAS ER n horde Sd 24 1 9 DEVE Motor Protec hOM sexa cien doma totus SUE Aa Cx NAKAT TA NAAT A dte dd doa an 24 7 4 Changing Drive Roll Or Wire Inlet Guide 2 25 7 5 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing 26 7 6 Replacing Switch And Or Head Tube ooococcococrcc 27 TL VEOUDIGSHOCUNG Table cnet eee eee Oras ETE RAE d cr dem x c me 28 SECTION 3 ELECTRICAL DIAGRAM 00023 E CU P AAA ASAS 30 TABLE OF CONTENTS SECTION 9 MIG WELDING GMAW GUIDELINES 4 44 ees 32 9 1 Typical MIG Process Connections 32 9 2 Typical MIG Process Control Settings 33 9 3 Holding And Positioning Welding Gun ooooooccococccoc 34 9 4 Conditions That Affect Weld Bead Shape 35 9 5 Gun Movement During Welding nananana annann eee hne 36 9 6 Poor Weld Bead Characteristics eee eee hn 36 9 7 Good Weld Bead Characteristics
57. rcentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty Output Amperes 30 40 50 60 70 80 100 Duty Cycle 30 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz DBO 3 Minutes Welding 7 Minutes Resting o cT gt lo OS Reduce Duty Cycle Overheating Minutes duty1 4 95 217 757 A 4 3 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown 0 o 0 20 3 4 DP A P DM MW 10 12 13 10 15 10 10 18 10 A Amperage ssb1 1 10 91 228 183 A OM 228 187 Page 12 SECTION 5 INSTALLATION 5 1 Installing Nozzle Contact Tip And Adapter Turn off welding power source Nozzle Contact Tip 3 Tip Adapter
58. rd any part of the body other people or any metal when threading welding wire 4 3 MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place d D e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors an
59. re feed speed weld current and voltage b 10 leeeeem 2 Push na i EM n ara ba o creces 1 Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT ke te LE Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT joi UA Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 228 187 Page 35 9 5 Gun Movement During Welding 7 Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better Stringer Bead Steady Movement Along Seam Weave Bead Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 9 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 228 187 Page 36 9 8 Troubleshooting Excessive Spatter necs Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Ardi
60. rive roll push drive roll in and rotate it 1 4 turn to the open slot and slide it out over the retaining pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot Tools Needed 4 Drive Roll 3 The drive roll consists of two different sized grooves The stamped markings on the end 030 035 Groove 023 025 Groove surface of the drive roll refers to the N groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 10 Stamped 024 CJ Stamped 030 035 Ref 803 714 A OM 228 187 Page 25 7 5 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing N Tum off welding power D E source 1 Nozzle 2 3 2 Contact Tip Cc 4 3 Tip Adapter gt Head 5 Tube E Wire size stamped on tip check 7 P and match wire size Cut off wire and disconnect gun A from feeder 8 mm Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out gun casing E straight before installing new liner Reassemble gun in reverse order from taking it apart Install Liner Liner Stickout 7 Thread wire according to welding power source wire feeder manual Tools Needed gt J 8mm 10mm 246 669 A OM 228 187 Page 26 7 6 Replacing Switch And Or He
61. rteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 228 187 Page 9 OM 228 187 Page 10 SECTION 3 DEFINITIONS 3 1 Symbols And Definitions A Amperage Voltage H Z Hertz Negative Positive dico un 1 Na Single Phase Le Input gt Output Lv Voltage Input Q Off On Do Not Switch G Gas Metal Arc f Flux Cored Arc D E While Welding SR olo Lu e Welding GMAW Welding FCAW SECTION 4 SPECIFICATIONS 4 1 Specifications p Amperes Input at Rated Welding Amperage Pan ipa Rated Load Output KVA KW Weight Overall Output Range DC g 230 V 50 60 Hz W Gun Dimensions Single Phase Length 19 1 2 in 130 A 21 5 Volts 495 mm DC 30 Duty Cycle MONS RS At 60 Hz Input 20 25 185 31 20 5 4 7 3 88 E dip eau Duty Cycle At 50 Hz g 270 mm Input Height 12 3 8 in 314 mm Frs Flux Cored Aluminum Wire Feed Speed Range Wire Type And Diameter 023 035 in 030 045 in 030 035 in 50 740 IPM 1 3 18 8 m min At No Load 0 6 0 9 mm 0 8 1 2 mm 0 8 0 9 mm 40 700 IPM 1 0 17 8 m min Feeding Wire OM 228 187 Page 11 4 2 Duty Cycle And Overheating Duty Cycle is pe
62. s Wire Speed 0 023 in 3 5 in per ampere 0 030 in 2in per ampere 0 035 in 1 6 in per ampere Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage Voltage controls height and width of weld bead s 1 8 or 0 125 in 3 5 x 125 A 437 ipm 2 X 125 250 ipm 1 6 x 125 200 ipm Convert Material Thickness to Amperage A 0 001 in 1 ampere 0 125 in 125 A Select Wire Size Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Select Voltage Wire speed amperage controls weld penetration wire speed burn off rate OM 228 187 Page 33 9 3 Holding And Positioning Welding Gun E Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm Cradle Gun and Rest Hand on Workpiece End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS OM 228 187 Page 34 9 4 Conditions That Affect Weld Bead Shape E Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wi
63. s SJ 030 0 8 mm a ME 035 0 9 mm AAA SSS A 024 0 6 mm parres es 030 0 8mm ____ __ AS 035 09mm _ 7 A A eet 024 0 6 mm 030 0 8 mm 035 0 9 mm 030 0 8 mm ARAS A AAA A CAUTION Do not change Voltage switch position while welding See owners manual for more information No Shielding Gas Required Good for windy or outdoor applications C Gas Mixture 75 Argon 25 CO Produces less spatter Better appearance 100 CO Tri Mix 90 He 7 5 Ar 2 5 CO 100 Argon Aluminum wire is soft so feedability is not as good Wire Welding Package Recommended Voltage and Wire Speed Settings for thickness of metal being welded Number on left of slash is Voltage Setting Number on right of slash is Wire Feed Setting CHANGING POLARITY 18 ga 16 ga 11 ga 048 in 060 in 1 8 inch 3 16 inch 1 4 inch 5 16 inch 1 2 mm 1 6 mm 3 2 mm 4 8 mm 6 4 mm 8 0 mm DCEN Electrode Negative For Flux Cored Wire 1 40 2 40 4 60 5 40 6 40 1 35 2 40 3 50 5 50 6 60 7 60 ww Jj 1 25 3 30 4 35 5 35 6 35 3 50 4 60 5 80 6 90 NE ar AE AAA AAA AA A ee 2 50 3 50 5 60 6 60 6 70 7 80 4 40 5 40 5 50 6 50 7 50 7 60 3 35 5 40 5 60 6 80 7 90 4 40 5 40 5 50 6 50 7 50 7 50 O me Electrode Positive For Solid Wire E 3 35 4 30 5 35 6 50
64. s sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES wack SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se s
65. separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reaso
66. serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground
67. sisting of des 194 011 LINER monocoil 030 035 wire x 15ft consisting of a AE 194 012 LINER monocoil 035 045 wire x 15ft consisting of Mmm 079975 s O RING 2187 ID 3x 103CS IDE ios HRS tl dee OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model is required when ordering parts from your local distributor OM 228 187 Page 45 10 3 Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PARTNO INCHES mm 237 338 023 025 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 10 4 Options PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 Ib 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg max 246 800 H100S2 10 Replacement Gun 10 ft length 030 035 wire size 195 186 Protective Cover Weatherproof nylon 212 492 Regulator Flowmeter For use with CO shielding gas 10 50 CFH 144 108 Gas Hose 5 ft For use with regulator flowmeter 212 492 NOTE If individual parts are required see Parts List chapter of this manual for part number to order OM 228 187 Page 46 Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Mos
68. structions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humi
69. t replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com WELDERS HOBART 331 WARRANTY Effective January 1 2009 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of LK or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure
70. ux CEM hn 9 SECTION 3 DEFINITIONS zd gie ie A FE REX Ou RUNE FIER RC eae eee eat 11 35 lu Symbols And Bellnitiotls 335 dator EE aee due Rx aue er eU Pes eda we dd Es 11 SECTION 4 SPECIFICATIONS eri aab uS gw E E NS ENEREI ci EE Ge 11 d lx KOPECMCANONG hacia m eru a etes 11 4 2 Duty Cycle And Overheating ser ces cows REO T due Nae ates p DATA NG AAA 12 4 3 Volt Ampoere QUIVOS a src CR AUR dre NANA an ME ea i Ok GG EE Rn E EN Papa 12 SECTIONS INSTALLATION iud opt x cree es b urn e atre KG eee cn creto RAE 13 5 1 Installing Nozzle Contact Tip And Adapter 13 5 2 Installing Welding GUN an ert e a ore en REI 13 5 3 Installing Work Camps ar dc E ese ee eae Se Seema ae NFA ee 14 5 4 Process POY Table x pia e ro e weed MANG dra m i d de Ae as eae es dia 15 S Changing PORN arcet er rnc B iR he rie cd eot de x dl Dot a ates ds Done 15 5 6 Iristallinig Gas oUpDly a0 sce NATA AK A cR heri c br i e qiu IR P Re Rs eGR Res SUR 16 5 7 Selecting A Location And Connecting Input Power 2 17 5 B Electrical Service Guide ya i ii a AAA A A NA CR WA A RUN D eee RR 18 5 9 Installing Wire Spool And Adjusting Hub Tension 1 18 5 10 Threading Welding Wire iussu un ite ake ROS Ce Sabe a ee D Kc re doe er aep 19 SECTION 6 OPERATION vicario ERE ennui entame ne oO de
71. your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high 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 tre
72. ze In AWG 14 Max Recommended Input Conductor Length In Feet Meters LO Min Grounding Conductor Size In AWG 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 SM data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements 5 9 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only When a slight force is needed to turn spool tension is set with 8 in 203 mm Tools Needed spool only i C gt O 1 2 in 803 012 803 013 B Ref 802 971 C OM 228 187 Page 18 5 10 Threading Welding Wire San Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight oc WAN

Handler 187 And H100S2−10 Gun

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Handler 187 And H100S2&minus;10 Gun

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Handler 187 And H100S2−10 Gun