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Manual A - Northern Tool + Equipment

1. KEE 184 946 CONTACTOR def 40A 2p tees 14 TE 188 910 TERMINAL ASSY pri 1 PH 200 230 voltage 15 cere e 038 618 LINK jumper term bd pri Gr AN 188 917 DOOR access changeover 1 Rn 242 743 SWITCH tgl SPST 15A 125VAC on none off spd term TO srt erbe 180912 SUPPLEMENTARY PROTECTOR man reset 1P 5A 250V RS WEE 183 492 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 20 PCI 229 235 CIRCUIT CARD ASSY control E Ir 039 046 TERMINAL pwr output black laa dd 039 047 TERMINAL pwr output red E E ER 134 201 STAND OFF SUPPORT PC card 2A Ne 021 469 LABEL warning electric shock 5 2D ramener te 216 830 LABEL warning electric shock 8 moving parts 820 ts naa 234 206 DRIVE ASSY wire 44eueeu ru 146524 HOSE GIS EE OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 235 281 Page 45 Hardware is common and not available unless
2. 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM 9 SECTION S INTRODUCTION 25m mure dames messe era ae ESQ A AA 11 3 1 Specifications EE 11 3 2 Welding Power Source Duty Cycle And Overheating 11 3 3 Volt Ampere Curves tte EE Ded m AEN a eux ede Meca e Ros 12 3 4 Installing Welding GUN vicio AA aia Sed nti dt E dd AR E 13 3 5 Connecting To Weld Output Terminals 14 3 6 Installing Work Clap sete emo mr ne at Geka WEE E INE EUN Eds 14 3 7 Setting Gun Polarity For Wire Type 15 3 8 Installing 2 Ib Wire Spool And Adjusting Hub Tension 15 3 9 Installing 10 lb Wire Spool And Adjusting Hub Tenelon eee eee 16 3 10 Installing 33 lb Wire Spool And Adjusting Hub Tension 16 3 11 Installing Gas Supply Sala EE EE a ee Di xg next Ms 17 3212 Positioning Jumper Links 5 ur nr WAKA at n e BEN EK E RAM ARE 18 3 13 Electrical Service Guide 19 3 14 Serial Number And Rating Label Location 20 3 15 Selecting A Location And Connecting Input Power 20 3 16 Threading Welding Wire isis Rh Rer I m Rr RI re x ee en NN 21 3 17 Installing Optional DP 3545 Spool Gun To Weldi
3. DUA Tools Needed Bo CAF 3 8 in 242 688 A OM 235 281 Page 18 3 13 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 60 Hz Single Phase Input Voltage V 200 230 Input Amperes A At Rated Output 37 0 32 5 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 2 45 40 Normal Operating Fuses 3 60 50 Min Input Conductor Size In AWG 4 10 10 Max Recommended Input Conductor Length In Feet Meters i25 ei Min Grounding Conductor Size In AWG 4 10 10 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum condu
4. 150 Amperage 200 250 300 va_curvel 4 95 240 913 A OM 235 281 Page 12 3 4 Installing Welding Gun N e 1 Drive Assembly EX SEN 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive assembly Tighten knob SPOOL GUN WA 4 Gun Trigger Plug 5 0 e Insert plug into receptacle and Ki tighten threaded collar MIG GUN 5 MIG Spool Gun Switch 1 Switch is shown in MIG position Close door 3 fm Ref 242 143 A OM 235 281 Page 13 3 5 Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar Tools Needed 2 3 4 in 19 mm 803 778 A Correct Installation Incorrect Installation Weld Output Terminal output terminal and secure with nut so that Supplied Weld Output Terminal Nut weld cable terminal is tight against copper A Turn off power before connecting to 1 2 3 Weld Cable Terminal bar Do not place anything between weld 4 weld output terminals Failure to properly connect weld cable terminal and copper bar Make cables may cause excessi
5. 230 VAC 1 v Ref 242 691 A 802 286 E 11 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to dis connect device line terminals 12 Over Current Protection Select type and size of over current protection using Section 3 13 fused dis connect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position OM 235 281 Page 20 3 16 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight before threading wire Oo O1 250 nmnmc Tools Needed COP lt gt Hold wire tightly to keep it from unraveling o amp AN A ANY o HE Open pressure assembly Pull and hold wire cut off end Hold wire in groove before closing pressure assembly e Du Lay gun cable out straight and remove gun nozzle and contact tip Close and tighten pressure assembly and let go of wire Tighten WOOD Press gun trigger until wire comes out of gun Rei
6. Di 59 A S vi Q Inside Unit and apply light coat of oil or grease to drive motor shaft Every 3 O Al Months Damaged Or Unreadable X Cables 1 Q Tighten Weld Labels Terminal Every k 6 l Months 14 Remove drive roll 5 2 Supplementary Protectors T EE NOZZ FEEDROL Greg A Turn Off unit 1 Supplementary Protector CB1 CB1 protects main circuit board PC1 2 Supplementary Protector CB2 CB2 protects the drive motor circuit from overload If drive motor shorts or fails check gun liner blockage or kinks check for jammed wire or bind ing drive rolls Correct problem Press button to reset supplementary protector Ref 242 160 A OM 235 281 Page 25 5 3 Replacing Drive Roll And Wire Inlet Guide X 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two differ ent sized grooves The stamped markings on the outer surface of the foll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread wire see Section 3 16 4 Drive Roll Securing Nut Turn nut one click to secure drive roll 242 533 A 5 4 Removing Knob From Front Panel A Turn Off
7. 242 143 A 242 154 A OM 235 281 Page 22 SECTION 4 OPERATION 4 1 Controls re 1 Wire Speed Control SM E GH Control varies the rate of wire being fed through the welding gun 2 Voltage Control Control varies the voltage level of the welding arc The voltage range is 1 minimum to 12 maximum 3 Power Switch The fan is thermostatically controlled and only runs when cooling is needed 4 Power Light 5 Gun Trigger Receptacle 6 5 7 2 4 3 2 12 VOLTAGE 4 POWER Tue 3 OFF a TRIGGER Ref 242 155 A OM 235 281 Page 23 Weld Parameters 4 2 ung Jg 4390 ww6 0 een wxUOBIY 00 I Tv 9GEG wwg 0 Oe xXUnUlUnlV unbjoodg SYGE dd red euondo WM UOBIY 001 ownuwnv ununi suoyeoddy sooping IN390 10 06 8 vv 0v 9 vS 2 vS 4 08 9 02 01 29 6 09 6 9 14 92 9 89 9 ve 9 ve 9 ce s 9v 4 9v 4 07 9 02 8 09 4 97 9 c 9 ce 9 0 G vS 4 vS 4 ev 9 04 4 02 4 09 9 09 7 92 6 06 6 wwa you 2 1 08 2 08 2 0 2 8e 9 8e 9 9 9 29 6 08 8 9 2 09 7 vv 9 0v s 0 9c D I 02 8 09 2 97 9 0 v v 0 8 v118 04 4 02 9 Ov v Ov ve e wwoz wwg wwz uug 6 uugg uugy wuze uougz0 Uuouzgo uou gro usu 9 uou p L Wougi e yourg ebneby neg abnebgl Bumes poo 9JIM S 1461y uo jequinw Bunjes eB
8. Operation And Maintenance YA FIRE OR EXPLOSION hazard d 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 FALLING EQUIPMENT 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 An d t OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle dd e Reduce current or reduce duty cycle before MES D starting to weld again e Do not block or filter airflow to unit N FLYING SPARKS can injure e Wear a face shield to protect eyes and face e 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 y e Put on grounded wrist strap BEFORE handling boards or p
9. SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2010 03 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on Pevite 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 Indique une situation dangereuse qui si on l vite pas 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 A 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 gt Seul un personnel gualifie est autorise a installer faire fonc tionner entretenir et reparer cet appareil Pendant le fonctionnement maintenir a distance toutes les personnes notamment
10. 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 Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service G LA CHUTE 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 Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N294 110 lors du levage manuelle de pi ces ou quipements lourds N 3 n L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT pa e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal po H e R duire le courant ou le facteur de marche avant de poursuivre le
11. 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat 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 gt Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l tat de Californie 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 gt Ce produit contient des produits chimiques notamment du plomb dont l tat de Californie reconna t qu ils provoquent OM 235 281 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A 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
12. And Face Protec tion ANSI Standard Z87 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 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 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 235 281 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A 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 48rd 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 Asso
13. EXTENSIONS STICKOUT le e Iv Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT p L AA uo Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 235 281 Page 34 6 5 Gun Movement During Welding CS 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 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 EE DM S 0054 A 6 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration O E ND A S 0053 A 6 7 Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals oO m being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 235 281 Page 35 6 8 Troubleshooting Excessive Spatter A Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead e 56888 Possible Causes Corrective Actions Wire feed speed too high Select lower wire fe
14. M1 235 283 MOTOR gear 24VDC 190 RPM 1 EPIO ET 235 284 CARRIER drive roll assy 1 hup MR TP TTC 602209 SCREW 250 20 x 1 25 sochd 1 RE E 166072 SPACER gear etu E e Rech ee os 1 A GE 235 285 CARRIER drive roll 10mm shaft 1 we 174609 SCREW MA xi hh nn 1 NOU REDE 173 620 BUSHING motor mig 3 D EE 174610 SCREW M6 1 0 x 20 soc hd button cap 3 Eh Aad eet eka e c 192 029 WASHER flat 250 ID x A2 ODn oo 3 xd aue YA 235 288 COVER motor drive 1 MENT UNE NA 196 654 SCREW thumb 1 4 20 1 RA IU EE 235 286 ROLL drive v groove 030 035 wire 2 Ene AAA RE UNA 079240 SCREW 375 16 x 1 75hexhd 1 ian d Ded d Ua e RA ac 602 243 WASHER flat 438 ID x 1 00 OD 1 EE 602213 WASHER lock 380 ID x 691 OD 1 Pd f WAWA MTAA MENA 193632 NUT 375 16 56 hex 34h 1 EG KEE 238304 WASHER flat 170 ID x 375 OD 1 IA dedos 222035 KNOB T 1 562 bar w 312 18 1 oe EE 604538 WASHER flat 344 IDxvGppOn eee eee 1 A WEE 146 524 HOSE sae 1871Dx 410O0D
15. Shape 34 6 5 Gun Movement During Welding 35 6 6 Poor Weld Bead Characteristics 35 6 7 Good Weld Bead Characteristics 35 6 8 Troubleshooting Excessive Spatter 36 6 9 Troubleshooting Porosity 36 6 10 Troubleshooting Excessive Penetration 36 6 11 Troubleshooting Lack Of Penetration 37 6 12 Troubleshooting Incomplete Fusion 37 6 13 Troubleshooting Burn Through 422 20 37 6 14 Troubleshooting Waviness Of Bead 38 6 15 Troubleshooting Distortion 38 6 16 Common MIG Shielding Gases 39 6 17 Troubleshooting Guide For Semiautomatic Welding Equipment 39 SECTION 7 ELECTRICAL DIAGRAM occcccoccccco nn nh nnne 41 SECTION 8 PARTS LIST l9 mu genee a acks Seege RE ae e cdi E 42 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2010 03 A Protect yourself and others from injury read
16. and discrete rectifier modules Reactors Stabilizers Transformers 2 3 Years Parts and Labor Drive Systems Idle Module PC Boards Rotors Stators and Brushes Solenoid Valves Spot Welder Transformer Switches and Controls 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Accessories Batteries Trek 180 Only Contactors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor HF Units MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Regulators Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Water Coolant Systems 4 Engines batteries except Trek 180 and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 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 oth
17. 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 A Indicates a hazardous situation which if not avoided A DANGER Indicates a hazardous situation which if could result in death or 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 A 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 A Only qualified persons should install operate maintain and repair this unit A 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 electricall
18. 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 yeux 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 Porter des lunettes de s curit avec crans lat raux m me sous votre casque 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 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 OM 235 281 Page 6 LE SOUDAGE peut provoquer un 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 peu
19. 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 En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons 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 e 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 E SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la bro
20. les enfants de l appareil UNE D CHARGE LECTRIQUE peut entra ner 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 fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ques 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 A Fe 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 piece couper ou le sol 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 tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D
21. listed 9 1 242 510 A Figure 8 3 Rear Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 8 3 Rear Panel w Components Fig 8 1 Item 10 eege geg 049 399 NUT 312 18 push on enn k tees 1 a wa 148 809 FAN 9 in 5wg 34 deg 1 Ce FM 188 706 MOTOR fan 230V 50 60 HZ 1 piu OA tee ante hes 203 711 WINDTUNNEL 9in 1 see TEE 216 395 VALVE 2 way 35 VDC custom port 1 8 orf w frict 1 De WEE 203478 PANEL reat vacas EA aa A EC Ve net E AE E ea 1 T EEN 169 654 BRACKET support tank 1 NE EE 188 441 CHAIN safety 1 T demie es 137 761 NUT 750 NPT 1 31 hex 27 H nyl blk 1 ENK DEEN 604 102 CONN clamp cable 1 To maintain the factory original performance of your eguipment use only Manufacturer s Suggested Replacement Parts Model and serial number reguired when ordering parts from your local distributor OM 235 281 Page 46 E Hardware is common and i not available unless listed 5 11 6 emm e d JE Set 7 8 12 9 242 216 A Figure 8 4 Front Panel w Components Item Dia Part No Mkgs No Description Quantity F
22. x 125 A 200 ipm ipm inches per minute y Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate OM 235 281 Page 32 6 3 Holding And Positioning Welding Gun 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 1 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout P 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 4 EE 09 15 PA A 90 90 8 39 End View of Work Angle Side View of Gun Angle GROOVE WELDS e 0 15 EH 45 7 N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 235 281 Page 33 6 4 Conditions That Affect Weld Bead Shape CS Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage p 10 l laeeeem A gt Push PY 10 l len 223 mn AA lt lt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE
23. 9 5 et seq A 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 A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins 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
24. AN 2 092077 HE WEEN 1 800 SAL 529 e E WEE 1 Dai ias Fig 8 2 CENTER BAFFLE w components 1 VO Fig 8 3 PANEL rear w components 1 11 PLG1 199192 CORD SET 6 50p 1299 3 c 1 ee EEN E EE 1 T9 WEE 130890 MAKER eta rr A AA KUBA EE a 1 Vir 230 799 WHEEL cuota NA echt E E EN Eesti 2 Dita its 121614 RING retaining 442 2 106 hum ons 235 875 CASTER swvl 4 00 in X 1 250 in 2 en bre Fig 8 4 PANEL front w components 1 E WEE 233 473 CABLE work 10 no 3 w clamp 8 boot including 1 19 A 196 318 x COVER Cable cui id ee Pme tone did t 1 20 146149 s CABLES darso N ad 1 e emnes 2399452 xz GEAMBWOIEK 1 dir dt Tra do eot XOT a EGER 1 22 scams 235263 BRACKET capacitor 1 Pan 234212 CAPACITOR 1O0 0D00uf en 1 EEN 233 RE CHOKE TEE 1 e EE 091685 RESISTOR 25 ohm 50W 1 EE 238 759 REGULATOR FLOWGAUGE 0 50 CFH ARGON CO2 kit 1 VITE ER ARE RE 144 108 2 HOSE g s AA DO va ee Ma Gata tated nU Louise aa 238 810 HANGER cable 2 tata Ee ba 239 173 H200L4 15 GUN replacem
25. OM 235 281B 2010 04 Processes Ne ZN C a Gas Metal Arc MIG Welding x Flux Cored Arc FCAW Welding Description a 2 E Arc Welding Power Source and Wire Feeder WELDERS IronMan 230 And H200L4 15 Gun Online Forum www HobartWelders com OWNERS MANUAL File MIG GMAW ES 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 of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular model are also provided ISO 9001 REGISTERED QUALITY SYSTEM Hobart is registered to the ISO 9001 Quality System Standard Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor to receive the latest
26. 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 porteurs 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 235 281 Page 9 OM 235 281 Page 10 SECTION 3 INTRODUCTION 3 1 Specifications Amps Input at Rated Output 60 Hz Single Phase Max Open Rated Output Circuit Voltage 200 V 230 V KVA KW 175 A at 25 5 VDC 37 0 32 5 74 6 3 60 Duty Cycle 38 2 4 2 3 0 54 0 30 While idling No Load Wire Feed Wire Type and Diameter Speed Dimensions Weight Solid Stee
27. Turn off welding power D EE source wire feeder Nozzle Contact Tip Tip Adapter A Go N Nozzle Adapter Wire size stamped on tip check and match wire size Cut off wire and disconnect gun from feeder 7 16 in 5 8 in Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out gun casing c straight before P installing new liner CA ii a Reassemble gun in reverse order from taking it apart Install As Liner eem Stickout AS y P d CS Thread wire according to welding power source wire feeder manual Tools Needed COP C Xie 3 5 8 7 16 in 242 207 A OM 235 281 Page 29 5 9 Welding Troubleshooting Table Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 3 15 Place Power switch in the ON position Place MIG Spool Gun switch in the proper position Check and replace Power switch if necessary Check supplementary protectors CB1 and or CB2 and reset if necessary see Section 5 2 Replace building line fuse or reset circuit breaker if open see Section 3 15 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Sections 3 4 and or Parts List Thermostat open overheating Allow fan to run the thermostat will close whe
28. WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart warr 2010 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which eguipment was delivered to original customer Distri
29. arts e Use proper static proof bags and boxes to store move or ship PC boards O 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 toward any part of the body other people or any metal when threading welding wire PAL r MOVING PARTS can injure e Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place Have only gualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary 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 Use only genuine replacement parts from the manufacturer 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 p
30. 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 F Indique des instructions sp cifiques cal 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 rateu
31. butor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location 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 USA O 2010 Hobart Welding Products 2010 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 Se KA HOBART Cho
32. c d de soudage les manipuler avec pr caution e Prot ger les 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 Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer 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 Le couvercle 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
33. ciation 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 Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The 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 Donot 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
34. ctor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 235 281 Page 19 3 14 Serial Number And Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 3 15 Selecting A Location And Connecting Input Power A A A pan Wa T i 3 YA d AE 18 in 457 mm of space for airflow Installation must meet all National and Local Codes have only guali fied persons make this installation Special installation may be required where gasoline or volatile liquids are present see NEC Ar ticle 511 or CEC Section 20 Disconnect and lockout tagout in put power before connecting input conductors from unit Always connect green or green yel low conductor to supply grounding terminal first and never to a line terminal 4 Plug NEMA Type 6 50P 5 Receptacle NEMA Type 6 50R Connect plug to receptacle 6 Input Power Cord 7 Black And White Input Conductor L1 And L2 8 Green Or Green Yellow Grounding Conductor 9 Disconnect Device switch shown in the OFF position Disconnect Device Grounding Terminal 10 Do not move or operate unit where it could tip
35. de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins 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 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS 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 a 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 re
36. e 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 H 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 cylinder 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 solenoid valve not operating Have Factory Authoriz
37. e 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 dans 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
38. ed Q 1 1 8 5 8 in 4a 4 7 Argon Gas Or Mixed Gas 4b O 2 H fH 3b 7 CO Gas 0 Rear Panel Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Cap 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 a Argon Or Mixed Gas Cylinder b CO Cylinder 4 Regulator Flowmeter a Argon Or Mixed Gas Regulator Flowmeter b CO Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For MIG Gun Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Gas Flow Adjustment Control Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturers recommended flow rate 242 687 A OM 235 281 Page 17 3 12 Positioning Jumper Links N Z e y Turn off and disconnect input D 4 ED power Check input voltage available at site 1 Jumper Links Access Door Open door 200 VOLTS 2 Jumper Link Label Check label only one is on unit 3 Input Voltage Jumper Links 3 Move jumper links to match input 230 VOLTS voltage o Close and secure access door S 153 980
39. ed 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 235 281 Page 39 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 235 281 Page 40 SECTION 7 ELECTRICAL DIAGRAM 2 T u O E 1 294 es r NNO SIN d I GS zen NNO 10048 ET 29 E Fre Seat lt 2 691d EN ZA Bd 4 gt HOLIAS 6 228 NND SIA eu PI Aaa lt lt lt F gt S 294 g 1 623 T G91d 91 91 208 YOLOM 9 Ge NN9 208 EI OXO EN A 240 907 A OM 235 281 Page 41 use or service this unit engine before servicing Do not operate with covers removed Do not touch live electrical parts Disconnect input power or stop Have onl
40. ed 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 6 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal LAA m 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 Remove all grease oil moisture rust paint coatings and dirt from work surface before w
41. elding 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 6 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld 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 235 281 Page 36 6 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and T m Mm base metal 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 voltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct p
42. ent 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 Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 235 281 Page 43 Hardware is common and not available unless listed 12 13 MA Ny e NEA ez S Tan T LUE X x 17 amp m 242 215 A Figure 8 2 Center Baffle w Components OM 235 281 Page 44 Item Dia Part No Mkgs No Description Quantity Figure 8 2 Center Baffle w Components Fig 8 1 Item 9 Ee VE 211877 NUT retaining spool Phrase 2 0 195 lt NUT TENSION sus e y aei a Rr bh e x et aa he d oda e EE 605 941 WASHER Hai n DEE 186 437 SPRING cprsn 2 430 OD x O0wirex 2b n eee COD used TT 057 971 WASHER flat 632 ID x 1 50 OD x 12 keyed D W 238 652 HUB ee e EE Der en 238653 ADAPTOR spoolhub DB ee 186436 WASHER brake eet Lese eem te ta da nantes qu rover ifr 234 207 x BAFFLE Center cita Wierder EE ETS as BITTE 238445 REEL SUPPORT aaa KA eee hh PM ista o 236 771 TRANSFORMER control A ege 239 923 BLOCK terminal 5 pole
43. er 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 reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT
44. erform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 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 electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 235 281 Page 3 1 4 California Proposition 65 Warnings A 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 2524
45. es OM 235 281 Page 2 La 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 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 Shutoff 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 N
46. eyoA s ya uo jequinN papiaM urg eau Jo SSAUADIYL 10 SBumes peeds am pue eBejoA pepueuiuio29H een 10 pulM 10 poor Aelod 19S 19918 oefonben ser Buipjalys ON ad SEO 080 209 2 Iv 86 wug0 en d390 10 Aelod 18S lod 198 Gre EIS SSelUIe S wug 0 0 0 v 9692 3H 9606 ssejures XIIN H ww9 0 en Ls 4S 0 209 9601 JV 06 JO e 209 8 OSO N 26 VO d390 10 ejod 18S 209 962 IV 9686 S 9 S02u3 9JIM PHOS 209 96001 Y 1 eouejeeddy Jayog WW6 0 S 0 Jeyeds sse seonpold x a 9 JV o 92 1 02 1 wug 0 080 Ge AS 9 2 ell wug 0 en uugo uugo pesn Bug youl O 0 You 720 M JO ne zz abneb yz Jojo We Sumas pepieM GIE MOL UI 0 0c seseo Duipjeius ipd Dee polsebbns ISUeIgI ed M sessed ednnw pue uonejedaud juiof anbiuyos 1edoad Buisn papjam eq ued sjeuojeu 19H9IUL pasinba se sn py abeyjon aul Indu pez e uo paseq aJe pue ajewixoldde aie suyas sDunies 01U09 pue ses ar Dunoajes OM 235 281 Page 24 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5 1 Routine Maintenance SW y A Disconnect power E To be done by Factory Authorized Service Agent U GS Ge E before maintaining e Se EF Maintain more often during severe conditions Y Check Change Q Clean Replace Reference Fee LU E h i ER
47. full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 877 Hobart1 or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 2009 09 5 31 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com AC PAU THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Let SYMbOl iii memes n er PO VUE TUR UNSER S 1 122 Are Welding Hazards tette rb re PRI E uper prc we C ISSUE S 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 2 4 1 6 EMP formations ins siente a nn rm px Fa er a di x Fee e P 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Sy Mboles VIS ee ta edo ed n Ve E e dk St 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements
48. igure 8 4 Front Panel w Components Fig 8 1 Item 17 Ee WE 2399 2601 HAND Dee Bee 1 ud NE EE 234208 PANEL FORE ota er Leg xat races aa e gea 1 CE SEE gn 207 074 HANDLE switch 1 pa Dor 207 077 KNOB potentiometer 1 dub ZA R2 208207 POTENTIOMETER CP flat 1 7 2W 1K linear wire feed speed 1 bia d gua S2 237378 SWITCH rotary 63A 12 position 1 paraa DEE Seu 124511 SWITCH tgl DPST 40A 600 VAC 1 TX m 210 389 BUSHING snap in nyl 1 p PL1 238764 LIGHT ind wht lens 28V power on 1 10 RC5 048282 RECEPTACLE W SOCKETS 1 zai T WEE LABEL nameplate order by model and serial no 1 12 C2 C3 C4 C5 136735 CAPACITOR cer disc 1uf 500 VDC 4 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 235 281 Page 47 242 526 A Figure 8 5 Wire Drive Assembly Item Part No No Description Quantity 234 206 8 5 Wire Drive Assembly Saaz ich EE 235 282 HEAD FEED ASSY iia a acm ac aci a ecce d d ise 1 eh oh PERS
49. ire slippage 242 146 A OM 235 281 Page 15 3 9 Installing 10 Ib Wire Spool And Adjusting Hub Tension GO Spool Hub Spool Hub Adapter Spool Hub Nut Keyed Washer 2 Compression Spring Washer Nut Assemble components in numer ical order as shown NO oO P WD Slide spool hub adapter up on hub for the smaller spool making sure it is positioned in the anti rotation notches Secure hub nut on spool hub ad aptor Position remaining components Hand tighten nut to create a slight drag while rotating wire spool Over tightening nut may cause wire slippage 242 147 A 3 10 Installing 33 Ib Wire Spool And Adjusting Hub Tension GO Spool Hub Spool Hub Adapter Spool Hub Nut Keyed Washer 2 Compression Spring Washer Nut Assemble components in numer ical order as shown NO oO BR WD Slide spool hub adapter up on hub for the smaller spool making sure it is positioned in the anti rotation notches Secure hub nut on spool hub ad aptor Position remaining components Hand tighten nut to create a slight drag while rotating wire spool Over tightening nut may cause wire slippage 242 148 A OM 235 281 Page 16 3 11 Installing Gas Supply ad DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional CO gas regulator flowmeter Tools Need
50. l 0 700 IPM H 32 in 813 mm 185 lb Stainless Steel Aluminum Flux Cored 0 17 8 W 18 7 8 in 479 mm 84 kg m min D 37 in 940 mm 023 045 in 030 035 in 030 045 in 0 6 1 2 mm 0 8 0 9 mm 0 8 1 2 mm 3 2 Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 min 250 utes that unit can weld at rated load Sl without overheating If unit overheats thermostat s 200 opens output stops and cooling OX fan runs Wait fifteen minutes for unit to cool Reduce amperage or m e voltage or duty cycle before V 150 welding n NOTICE Exceeding duty cycle z can damage unit or gun and void a warranty m 100 50 30 40 50 60 70 80 90 100 DUTY CYCLE 60 dutycycle 6 Minutes Welding 4 Minutes Resting Overheating ir gt amp gt A Im E 31 Reduce Duty Cycle Minutes duty1 4 95 227 953 A OM 235 281 Page 11 3 3 Volt Ampere Curves 40 0 Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown 35 0 30 0 25 0 Voltage 15 0 10 0 5 0 0 0 50 100
51. le 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 6 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i 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 235 281 Page 38 6 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 WA Aluminum Argon X Argon 25 CO X 80 or greater Argon X x 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 6 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure on wire feed rolls Increase pressure setting on wir
52. llation Si le 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 L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi 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 c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne
53. mag 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 fa on 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 raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 235 281 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup 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 PI CES 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 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 votr
54. n the unit has cooled see Section 3 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 5 6 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 3 15 Low high or erratic wire speed Readjust front panel settings see Section 4 1 Change to correct size drive roll see Section 5 3 Readjust drive roll pressure see Section 3 16 Replace inlet guide contact tip and or liner if necessary see Sections 5 3 5 6 and or 5 8 5 10 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding or wire feeding intermittently Straighten gun cable and or replace damaged parts see Section 5 8 Adjust drive roll pressure see Section 3 16 Readjust hub tension see Section 3 8 Check supplementary protectors CB1 and or CB2 and reset if necessary see Section 5 2 Replace contact tip H blocked see Section 5 6 Clean or replace wire inlet guide or liner if dirty or plugged see Sections 5 3 and or 5 8 Replace drive roll if worn or slipping see Section 5 3 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Section 3 4 and or see Parts List Check and clear any restrictions at drive assembly and liner see Section 5 8 Have neares
55. nces 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 c bles 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 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 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
56. nd degreasers 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 Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 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 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 Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and f
57. ng Power Source 22 SECTION A OPERATION 26 0 Ee e NER ER antenne cancers 23 4 1 Controls x eti uni A RC ane ed ear ened MARE eR 23 4 2 Weld Patameters osos EES SE dee anges NEEN ee dere ie AL RSA 24 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 25 5 1 Routine Maintenance ns deer d A Gre e EN aene Ere OA cea 25 5 2 Supplementary Protectors oooccocccoccccccc nnn beet teen eee 25 5 3 Replacing Drive Roll And Wire InletGuide 26 5 4 Removing Knob From Front Panel 26 5 5 Aligning Drive Rolls and Wire Guide 27 5 6 Replacing Guin Contact Tip ire kr kde REN EE NEEN Oda YEG ENNEN A 27 5 7 Installing Cable Hangers kim ee EEN EN OY Yi Y raa d E epe e EAE 28 5 8 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing 29 5 9 Welding Troubleshooting Table 30 5 10 Wire Drive Gun Troubleshooting Table 30 TABLE OF CONTENTS SECTION 6 MIG WELDING GMAW GUIDELINES azamamamanananananaaza 31 6 1 Typical MIG Process Connections vota 31 6 2 Typical MIG Process Control Settings 32 6 3 Holding And Positioning Welding Gun 33 6 4 Conditions That Affect Weld Bead
58. nneaux recouvrements et dispositifs de protection e 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 e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LI LIRE LES INSTRUCTIONS e Lire et appliquer les instructions 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 e N utiliser que les pi ces de rechange recommand es par le constructeur E e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement 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 Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l insta
59. ns e Le 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 state 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
60. nstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Push wire thru guides into gun continue to hold wire o ON or POWER Turn power ON Cut off wire approximately 5 16 in 8 mm from contact tip Close door 242 692 A OM 235 281 Page 21 3 17 Installing Optional DP 3545 Spool Gun To Welding Power Source 3 Pa ES SPOOL GUN 6 MIG GUN DH A Turn Off unit and disconnect input power Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew Insert gun end through opening until it bottoms against drive assembly Tighten thumbscrew BOND a Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position 7 Polarity Change Over Terminal Block To make proper polarity connection see Section 3 7 Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Feed Speed control see Section 4 1 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see Section 4 1 10 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed
61. oise 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 treat 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 cylinder 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
62. olarity at welding power source 6 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 6 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 235 281 Page 37 6 14 Troubleshooting Waviness Of Bead Wet ERI Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal LA Ka S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozz
63. oot protection WELDING can cause fire or explosion es 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 eguipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding 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 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 Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 Do not use welder to thaw frozen pip
64. power 4 2 3 4 5 Front Panel Knob Spring Clip Control Shaft Slot Rotate knob to allow access to slot Insert Allen wrench or stiff piece of wire into slot and while depressing spring clip slide knob off control shaft To reinstall push knob fully onto control shaft 242 693 A OM 235 281 Page 26 5 5 Aligning Drive Rolls and Wire Guide A Turn Off power View is from top of drive rolls look ing down with pressure assembly open Correct Incorrect 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw eq in or out until drive roll groove lines up with wire guide Close pressure roll assembly Tools Needed eu Ref 800 412 A 5 6 Replacing Gun Contact Tip 3 e A Turn Off power before D ERIT replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed EF C ee Ref 242 164 A OM 235 281 Page 27 5 7 Installing Cable Hangers A Turn Off power before installing cable hangers 1 Cable Hanger 2 Screws P3 of Tools Needed E Ref 242 165 A OM 235 281 Page 28 5 8 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing e A
65. r 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 humidit 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 entra ner 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 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 deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endom
66. serial number reguired when ordering parts from your local distributor OPTIONAL Table 8 1 Accessories PART NO DESCRIPTION REMARKS 042 758 Dual Bottle Rack Kit Converts Single Cylinder Rack To Dual Rack 212 492 Regulator Flowmeter For Use With 100 CO Shielding Gas 235 287 Dual Drive Roll 024 045 Allows Use Of 024 Solid Wire And 045 Solid And 0 6 1 2 mm Flux Cored Wire 132 958 Drive Roll 035 0 9 mm VK Groove V Knurl Drive Roll For Hard Shell Cored Wires 132 957 Drive Roll 045 1 2 mm VK Groove V Knurl Drive Roll For Hard Shell Cored Wires 300 349 DP 3545 20 Spool Gun Provides Excellent Feeding Of Aluminum Wire OM 235 281 Page 50 Warranty Questions Call 1 800 332 3281 7 AM 5 PM EST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART S WELDERS HOBART 331 WARRANTY Effective January 1 2010 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other g
67. serial number required when ordering parts from your local distributor OPTIONAL OM 235 281 Page 49 Item Part No No Description Quantity 237 374 Figure 8 6 H200L4 15 Gun zu anres OU is 120468 LO RING ae credere C eed d erat et A ER pan 1 Au O esie reb uet 169 730 gt WASHER SHOCK eoe Ere t c Fo ce aa 1 ab ES 242 585 TUBE HEAD ASS a ENN oped geen phate eae Jedi regis 1 ENO LI ER 242635 HANDLE front H 20 welding gun 1 UO vocet eet 225410 SWITCH trigger 1 sp AA rie 242597 HANDLE rear H 20 welding gun 1 SIM asa has sentis 242 597 COLLAR adapter feeder connector 1 E EEN 242 604 CONNECTOR feeder H 20 welding gun 1 Da E EE 079974 O RING So0plDxv10p cerbtr RII 2 TL EET 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 EE EELER tk AA Ee 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 A ka 194 012 LINER monocoil 035 045 wire x 15ft consisting of 1 KEE 079975 O RING 312 ID x 062 70 Dura BUNA N 1 Maa a 227 800 CORD trigger assy 1 To maintain the factory original performance of your eguipment use only Manufacturer s Suggested Replacement Parts Model and
68. soudage e Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuvre 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 stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir o cuits imprim s SIS 2o e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 235 281 Page 7 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 e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pa
69. sse 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 servir 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 o 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 pro
70. t Factory Authorized Service Agent check drive motor OM 235 281 Page 30 SECTION 6 MIG WELDING GMAW GUIDELINES ENS y 8 4 A 6 1 Typical MIG Process Connections A 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 Wire Feeder Power Source e Gun Shielding Gas CO uem OS SS Gas S Rf E gt t Workpiece CT CT Ex Work Clamp Ref 801 909 A OM 235 281 Page 31 6 2 Typical MIG Process Control Settings CS 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 parameters e 1 8 or 0 125 in Convert Material Thickness to P Amperage A ii 0 001 in 1 ampere 0 125 in 125A y Wire Size Amperage Range A 0 023 in 30 90A P 0 030 in 40 145 A Select Wire Size 0 035 in 50 180A Wire Wire Speed Select Wire Speed Size Recommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6
71. t 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 soigneusement avec des protections homologu s e Ne pas souder dans un endroit 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 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 cable de masse sur la piece le plus pr s possible de la zone de soudage pour viter
72. uarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes
73. 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 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 i OM 235 281 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 Ifinside 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 a
74. ve heat Copper Bar sure that the surfaces of the weld cable and start a fire or damage your Remove supplied nut from weld output ter terminal and copper bar are clean machine minal Slide weld cable terminal onto weld 3 6 Installing Work Clamp 1 Work Cable e EX SSC Route cable out front panel opening from inside 2 Negative Black Output Terminal Connect cable to terminal 3 Hardware 4 Work Clamp Route cable through clamp handle and secure as shown Close door Tools Needed 3 1 2 3 4 in Ref 242 145 A OM 235 281 Page 14 3 7 Setting Gun Polarity For Wire Type N Changing Polarity Wire Drive Assembly Lead Positive Terminal S Negative Terminal DT Work Clamp Lead Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with gas wires GMAW Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux core wires FCAW Drive assembly becomes negative Tools Needed IZ 3 4 in Ref 242 145 A 3 8 Installing 2 Ib Wire Spool And Adjusting Hub Tension 1 Keyed Washer aw 2 Wire Spool 2 LB 3 Keyed Washer 4 Compression Spring 5 Washer 6 Nut Assemble components in numer ical order as shown Hand tighten nut to create a slight drag while rotating wire spool Over tightening nut may cause w
75. x27 1 ar OO di A rdg 242 524 0 0 GUIDE wire inlet cai ia ec er Cie pela RAE 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 235 281 Page 48 242 630 A Figure 8 6 H200L4 15 Gun Item Part No No Description Quantity 237 374 Figure 8 6 H200L4 15 Gun Ee WEE 200 258 NOZZLE slip type 500 orf flush 1 AUAWA EC D EN 169 724 NOZZLE slip type 500 orf 125 recess 1 a eg 169 725 NOZZLE slip type 625 orf 125 recess 1 EEN 169 726 NOZZLE slip type 625 orf flush 1 Maas 169 727 NOZZLE slip type 625 orf 125 stich out 1 EE 087 299 TIP contact scr D32wirexl1 b eee ees 1 teg 000 067 TIP contact scr 030 wire x 1 125 1 TE e Sr d 000 068 TIP contact scr 035 wire x 1 125 1 E ee ee et 000 069 TIP contact scr 045 wire x 1 125 1 ia EE 169 728 ADAPTER contact mp 1 Pr 169 729 ADAPTER nozzle w retaining ring 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and
76. y 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 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 Additionalsafety 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 E Indicates special instructio
77. y qualified persons install FP ELECTRIC SHOCK HAZARD WARNING For Welding Power Source ircuit Diagram Figure 7 1 C xi n aX lt 21 vw 208 lt k Es les 2 13 e m gt wa YOLON NND eM Y 1004S Jp ub gt 33 Z 3 1 228 co 3 E 294 T L t 102 Vul SL 01 Ei GI 208 L AA veer t 7 NOLLO3138 39VLT0A T m e ECH TM ig M Wer eS ZY ET 189 T T1 Sete ke ez 1 IZ k en Tas Cv Ry tz 2 INd bo I x 0 971 I Zdl LE Ee zd ES IX Tit Tad TL SECTION 8 PARTS LIST x Hardware is common and not available unless listed 10 Fig 8 3 17 Fig 8 4 242 214 A Figure 8 1 Main Assembly OM 235 281 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly Le qu DE 234210 22 PANEL SIde i d ss MUR ALL HERI Uer S ET ds e da 1 Sas 2 visse 204711 2 EATGH side flush E exeat at Via a net E x RR Cac ERAT VA 2 VE d toe eta dog 134 464 LABEL warning general precautionary 1 ia sels 2934211 5 DOOR ASSN Losses ee ed ee e tee Pati EE 1 A ah stance 235 268 LABEL parameter consumables polarity 1 Din 234 209 WRAPPER Aere dis 1 6 T1 236760 TRANSFORMER pwr main 200 230 1 L

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