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Hobart Ironman 210 Manual

1. Terminal 3 Negative Black Output Shown As Shipped Set For Electrode Positive DCEP Terminal For Solid Steel Stainless Steel Aluminum or Flux Core with Always read and follow wire Gas Wires GMAW Process manufacturers recommended E polarity Close door Wire Drive Assembly 1 GUN Lead To Positive TT POLARITY Output Terminal CHANGEOVER Work Clamp Lead CONNECTIONS To Negative Output Terminal PE Reverse Lead Connections Set for Electrode Negath Negative DCEN For Gasless Flux Cored Wires FCAW Process Drive Assembly Becomes Negative 2 3 Ref ST 192 432 A V SS Tools Needed 7 N BE E 3 4 in T Ref 802 601 A OM 927 Page 13 3 9 Installing Gas Supply DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional COs gas regulator flow meter A CAUTION USING AN OVERSIZED GAS CYLINDER CAN CAUSE TIPPING resulting in cylinder and equipment damage and personal injury 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 4 Regulator Flowmeter e Do not exceed maximum cylinder weight of 100 Ibs 45kg
2. 1 tin 1461612 BASE Luc rrap a ele ts 1 oe A 135 390 AXE asst teas At it hai 1 e TTT 186758 WHEEL o od EE SEN 2 n ho cd 121 614 RING retaining HHT 2 TO 209 870 CASTER swvl 4 00 in X 1 250 in poly olefin 2 DEn Ke Fig 8 4 PANEL front w components 1 EIA 196 328 CABLE work 10 no 3 w clamp amp boot including 1 E serie 196 818 CABLE COVER a a an 1 EE EE EE 000 CABEE EE 1 A arr Ga 130750 i CLAMP WOK orrs e ra aa a E E S A D 1 DRE 195 605 GUN M 10 8 5 1 E EE 199 187 CAPACITOR elctit 120000uf 85VDC 1 Sai OF wh wena 022 160 CLAMP capacitor 1 paige ates ae ee 220 747 REGULATOR FLOWMETER 10 50 CFH ARGON CO2 1 AE git dau 183 581 2 HOSE gaS Dft ia r a A EE dard NN de cl Re da 212 492 REGULATOR FLOWMETER 10 50 CFH CO 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 927 Page 43 Hardware is common and not availabl
3. 7 2 5 Principales normes de s curit 8 2 6 Information EMF vse in A A A RE A A ACA 8 SECTION 3 INTRODUCTION lt c aS Y 9 X YR 5 RR NN esse 9 e Hee EE 9 3 2 Welding Power Source Duty Cycle And Overheating 9 3 3 Welding Gun Duty Cycle And Overheating 10 3 4 Volt Ampere Curves rpi aoea p nnn eee a a ee ee 10 3 5 Installing Welding GUN iia A Gade Re Be 11 3 6 Connecting To Weld Output Terminals 12 3 7 Installing Work Clamp Cable asusa seurannu anrea 12 3 8 Setting Gun Polarity For Wire Type 13 3 9 Installing GaS Supply saccade en aa Nae ah ee a ei a eed So eae 14 3 10 Installing Wire Spool And Adjusting Hub Tension 15 3 11 Changing Input Voltage 15 3 12 Electrical Service Guide 16 3 13 Selecting A Location And Connecting Input Power 17 3514 Threading Welding Wire 0 000 ada a EE cade 18 3 15 Installing Optional Spoolmate Spoolgun Switch In Welding Power Source 19 3 16 Connecting Spoolgun To Welding Power
4. 230 EJ 6 lt PLG1 204 205 Figure 7 1 Circuit Diagram For Welding Power Source OM 927 Page 41 SECTION 8 PARTS LIST Hardware is common and not available unless listed 10 Fig 8 3 17 Fig 8 4 802 602 C Figure 8 1 Main Assembly OM 927 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly cD Peas ed cl ha 203 481 PANEL side lower 1 Dd 151487 x EAT CH Side TUS a at ve ae eee te ia 2 e WEE 134 464 LABEL warning general precautionary 1 PA nt unes 205 868 DOOR ASSEMBLAY oc heen ennui hs aie 1 ES rene 205 867 2 WRAPPER cata Rare RS an RU E TT 1 6 T1 202077 TRANSFORMER pwr main 200 230 1 7 Z 199220 STABILIZER including 1 As TP2 213414 THERMOSTAT NC 1 8 SR1 199 188 RECTIFIER including 1 EE TP1 604515 THERMOSTAT NC open 211F close 186F 1 EE eat win an Fig 8 2 CENTER BAFFLE w components 1 TO on ei Fig 8 3 PANEL rear w components 1 11 PLG1 199192 CORD SET 250V 6 50p 12ga 3 c
5. 1 11 0194012 LINER monocoil 035 045 wire x 15ft including 1 Sue 079 975 O RING 187 ID x 103CS rbr 1 TEN het 196 255 lt SWETECH TIGGER curtido a a Gd ees tada 1 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 927 Page 48 Item Dia Part No Mkgs No Description Quantity Optional Spool Gun Switch D eee een tact 186 420 SWITCH ASSY 1 ig A dek SORTE ete 202449 gt PLATE SWITCN A AER iia Vas AE AE a ae A eege Eh 6055105 CABEE TIE ta cuit A ea EE 604 804 SCREW 008 15x 37 hexwhd pin 2 D A en NE 202 910 LABEL spoolgun mig gun A 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 927 Page 49 Notes Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement parts can b
6. 1 sl ae 199 206 LABEL nameplate 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 927 Page 47 11 12 8 a 9 802 388 A Ref 800 792 C Figure 8 5 M 10 Gun Item Par No No Description Quantity Figure 8 5 M 10 Gun Fig 8 1 Item 20 see 169 715 NOZZLE slip type 500 orf flush 1 2 087 299 TIP contact scr 023 wire x 1 125 2 000 067 TIP contact scr 030 wire x 1 125 2 000 068 TIP contact scr 035 wire x 1 125 2 000 069 TIP contact scr 045 wire x 1 125 E WER 169 716 ADAPTER contact mp 1 A 170470 RING CT Une 2455 iaa A 1 Die 169 718 TUBE DO ad mes raa sens a SEEN iri 1 B siura 169 738 NUT locking handle 2 1 FAR 16971953 NUT Fame ans dr eu et te AS dE ca eg 1 8 180 433 CORD trigger assembly 1 Sip OE EES 209 495 CONNECTOR feeder 1 VO EA 079 974 O RING 500 ID x 103CS rbr 2 11 194010 LINER monocoil 023 025 wire x 15ft including 1 11 194011 LINER monocoil 030 035 wire x 15ft including
7. Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 927 Page 39 Notes OM 927 Page 40 SECTION 7 ELECTRICAL DIAGRAM amp WARNING e Do not touch live electrical parts r J 7 e Disconnect input power or stop g ei engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install E je N SHOCK HAZARD use or service this unit 8 H re b N 3 3 D 5 e S z 5 E 5 D D P Q N 5 z e ol NI N Laad 4 o l o al H lt m me o lt a lt rie N lt N lt lt H e E L 4 SI SI RSI SI S Za o RR RR RR a ka Kal N wo o o ae ee e L VE 2 2 2 2 2 2 5 g lt RC1 1 lt RC1 3 PC1 RC1 PLG10 T POSITIVE A NEGATIVE D C8 C7 iN N H N y gt PF a a a Es E ZAZA gX L H o H s o N YC O E os SH A Im bn kb le 5 A N Io ES E iz aw e T Ae 2 TT N a a ES TC y Let A NI E L N 9 t e E Us gt NES GS lal _o 90 SDS o gt SR NJ N B ka
8. OM 927 Page 11 3 6 Connecting To Weld Output Terminals Do not place anything between weld cable terminal Tools Needed 22 3 4 in 19 mm A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine and copper bar Correct Installation 4 2 3 4 Remove supplied nut from weld output ter Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar 803 778 A Incorrect Installation minal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean 3 7 Installing Work Clamp Cable EE Tools Needed IZ 3 4 in 1 Work Cable Route cable through opening in front panel 2 Negative Black Output Terminal Connect cable to terminal Close door Ref 802 601 A Ref 801 566 B OM 927 Page 12 3 8 Setting Gun Polarity For Wire Type 5 ear 1 Polarity Changeover Label 2 Positive Red Output
9. HOBARI fs OM 927 199 213K 2005 11 Processes Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding an Description DCR El El Arc Welding Power Source and Wire Feeder IronMan 210 And M 10 Gun Online Forum www HobartWelders com Includes Installation Instructions For Optional Spoolmate Spoolgun Switch OWNER S MANUAL File MIG GMAW A 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 150 9001 2000 QUALITY SYSTEM Hobart is registered to the ISO 9001 2000 Quality System Standard Hobart Welders manufactures a full line of welders and welding related equipment For information
10. ET INPUT POWER Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire Tighten Ty N e gt DS 3 D WOOD S Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire comes out of gun Reinstall Tighten knob enough to prevent slipping Close door contact tip and nozzle OM 927 Page 18 3 15 Installing Optional Spool Gun Switch In Welding Power Source ws GO Tools Needed C_x HA 1 4in IT 9 16 in EF A Turn Off unit and disconnect input power 1 Welding Power Source Center Baffle 2 Switch Location 3 Switch Mounting Plate Remove 2 screws securing switch mounting plate to center baffle Pull switch mounting plate to pull wiring harness through center baffle hole 4 Plastic Plug Remove and discard plastic plug from center hole in switch mounting plate panel 5 Nylon Cable Tie Cut and discard nylon cable tie 6 Jumper Plug 7 Wiring Harness Switch Plug Remove jumper plug from wiring harness switch plug Retain jumper plug by placing looped lead over unit wiring harness 8 Switch Plug Connect switch plug to wiring har ness switch plug 9 Jam Nut Remove top jam nut from switch switch is equipped with two nuts a
11. LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de 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 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont Etat de Californie reconna t qu ils provoquent des malform
12. 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 70 hobart_warr 2 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at l l 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 PRINTED IN USA O 2005 Hobart Welding Products 6 05 Protect Your Investment Register your product at HobartWelders com Hobart Welding Pro
13. 1 31 hex 27 H nyl blk 1 AM ae 604 102 CONN clamp cable 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 927 Page 46 Hardware is common and not available unless listed 802 604 C Figure 8 4 Front Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 8 4 Front Panel w Components Fig 8 1 Item 17 fl pene ns 143974 HAND B gel eaten diacetate See 1 R RE 206 589 PANEL Tr tt aert a anne sata na Adicta 1 ea 207 074 HANDLE switch 1 a et ser 2010177 KNOB hf da nan ne aa a tates eat wm ES eme 1 E EE 208 207 POTENTIOMETER CP flat 1 T 2W 1K linear wire feed speed 1 EN EE S2 153 197 SWITCH selector 6 position 1 dd 136 343 SCREW K50X 20 pan hd phl stl pld pt thread forming 4 E EE ANNE 124511 SWITCH tgl DPST 40A 600 VAC 1 sity rare Martens 170 647 BUSHING snap in nW aa 1 LD A 204 413 BUSHING snap in ml 1 oh K O ica tae es 048 282 RECEPTACLE W SOCKETS
14. 230 volt lead 4 Lead Marked 200 Volt Remove cable tie and slide short piece of sleeving off 200 volt lead and slide sleeving over end of 230 volt and fan motor leads Fold sleeving over and secure in place Connect 200 volt lead to S1 where 230 volt lead was removed Reinstall wrapper Tools Needed XT 3 8 7 16 in 801 580 A OM 927 Page 15 3 12 Electrical Service Guide 60 Hz Single Phase Input Voltage 200 230 Input Amperes At Rated Output 29 25 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 35 30 Normal Operating 45 35 Min Input Conductor Size In AWG 4 12 12 Max Recommended Input Conductor Length In Feet Meters tia on Min Grounding Conductor Size In AWG 4 12 12 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp 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 conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements
15. A 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 Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 outp
16. A Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard These recommendationsare for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source OM 927 Page 16 3 13 Selecting A Location And Connecting Input Power A Da PA U e 9 ESP 18 in 457 mm of space for airflow A Do not move or operate unit where it could tip GND PE Earth Ground 230 VAC 1 N A Installation must meet all Na tional and Local Codes have only qualified persons make this installation A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Disconnect and lockout tag out input power before con necting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never to a line ter minal 1 Rating Label Supply correct input power 2 Plug 3 Receptacle Connect plug to receptacle 4 Black And White Input Conductor L1 And L2 5 Green Or Green Yellow Grounding Conductor 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conduc
17. Parc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Si la ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur e Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente a
18. 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 SA 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 CO2 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 wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted i
19. champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut sau ai e e Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures N Se rar A t S l Si dc SL ee Ge nt Se i S graves Le circuit de l lectrode et de la pi ce est Ge ergue TOUS GS PANNEAUX E REES HE sous tension lorsque le courant est d livr la place p l sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de fa on obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse e Ne pas toucher aux pi ces lectriques sous tension e 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 af
20. jam nut and a backing nut Insert switch shaft through switch mounting plate Switch should be positioned so lead with resistor is facing down Secure switch to plate with jam nut Tighten jam nut enough to keep switch from rotating Push wiring harness back through hole and reinstall switch mounting plate to center baffle Operation Place switch in On position for spool gun operation Place switch in Off position for wire feeder MIG GMAW gun operation When spool gun switch is in On position spool gun wire feed speed is controlled by welding power source Wire Speed control 802 936 A OM 927 Page 19 3 16 Connecting Spool Gun To Welding Power Source GO Z Tools Needed LS 5 LT 3 4 in A Turn Off unit Disconnect and remove MIG GMAW welding gun if applicable 1 Front Panel Opening 2 Spool Gun Weld Cable Route weld cable through front panel open ing 3 Positive Output Terminal Connect spool gun weld cable to positive output terminal 4 Work Clamp Lead Work clamp lead should be connected to negative output terminal 5 Existing Gas Hose 6 Spool Gun Gas Hose 7 Gas Diverter Valve To install diverter valve cut existing gas hose above barbed fitting at wire drive housing Install supplied hose c
21. skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or par
22. 039 047 TERMINAL pwr output red w nut 1 MODs hu 039 046 TERMINAL pwr output black w nut 000 cece eee 1 17 C7 10 136735 CAPACITOR 1 uf 500 V 1 cence ens 4 TOR a 199 191 DRIVE ASSEMBLY wire including 1 IR EE 199 215 scx MOTOR gesat AE acaricia mens ait d EENS eau eat are aaa 1 E DEER 203 081 SCREW feedroll 1 TEEN 079 633 FITTING hose brs barbed nipple 1 PA witch EAS oes 126 652 KNOB T 2 000 bar 1 OF i wie ht tice oh 193 681 BLOCK connector gun 1 EEN 184 735 GUIDE wire adapter 1 EE 184741 HEAD feed oi a e aa NC data na 1 TA Eer 197 309 GUIDE inlet 1 2 1 6 mm wire 1 5 ae PO os ET ee Deda ee 202 925 ROLL drive V groove 024 080 035 1 EECH 407 230 004 ROLL feed 024 and 045 1 MT Id 193330 ROLL drive VK groove 030 035 wire 1 ET EE 193 331 ROLL drive VK groove 039 045 052 1 16 wire 1 e i ware Hansa nance 134 201 STAND OFF SUPPORT PC card 4 30 PC1 171986 CIRCUIT CARD ASSEMBLY control 1 Ree e
23. 137653 B Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturers recommended flow rate Argon Gas Or Mixed Gas Rear Panel Tools Needed 22 1 1 8 5 8 in Ref 220 747 A 802 028 A Ref 802 286 E OM 927 Page 14 3 10 Installing Wire Spool And Adjusting Hub Tension Use compression spring When a slight force is needed with 8 in 200 mm spools to turn spool tension is set ESP d Installing 1 Or 2 Ib Wire Spool To install either a 1 Ib or 2 Ib wire Spindl spool follow the procedure as RATE Install these shown in the illustration Spindle components onto spindle Se Ta Order extra spring Part No 186 437 Remove these components from spindle Tools Needed LS THB II ane 072573 B 802 922 3 11 Changing Input Voltage e s c A Turn Off unit and disconnect gt gt We EEN input power Unit was shipped from factory set for 230 volts 1 Transformer T1 2 Rear Of Power Switch S1 3 Lead Marked 230 Volt And Fan Motor Lead Disconnect 230 volt lead and fan motor lead from rear of S1 Leave fan motor lead connected to
24. 27 ou Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 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 1 Battery March Park 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 Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance de l op rateur 8 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder
25. 346 802 280 E OM 927 Page 25 5 5 Replacing Gun Contact Tip Ee e A Turn Off power before EX aw 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 gt Ref 802 399 A OM 927 Page 26 5 6 Cleaning Or Replacing Gun Liner ar Tools Needed A Disconnect gun from unit SB Ts 2 3 8 in lt QD lt 7 Pp E 4 Head Tube Remove nozzle contact tip adapter gas diffuser and wire outlet guide 1 2 in i N P gt Remove liner Lay gun cable out straight before installing new liner da To Reassemble Gun Install and tighten new liner Cut liner off 3 4 in 20 mm 3 8 in a 9 5 mm for aluminum from head S tube Blow out gun casing Install adapter contact tip and nozzle Ref 802 399 A OM 927 Page 27 5 7 Replacing Switch And Or Head Tube D Disconnect gun first 1 Remove handle locking nut FO EA 4 Secure head tube in vice a j 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable JE
26. A 11 3 Slide handle Remove switch housing Note If installing new switch push switch lead connectors onto terminal of new switch polarity is not important Install switch back into handle and secure with handle locking nut If replacing head tube continue to end of figure 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch housing Secure with handle locking nut O Tools Needed IT 3 Ain O gt Y gt Ref 800 795 C OM 927 Page 28 5 8 Welding Troubleshooting Table Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 3 13 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 13 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Sections 3 5 and or Parts List Thermostat open overheating Allow fan to run the thermostat will close when 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 5 Low weld output Connect u
27. AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards 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 Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do nat touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any p
28. Source 20 SECTION 4 OPERATION a a ques Roepe ARR RR EE 21 421 ed EE 21 L Neld Param ters sis oiei wasisan ep eee de Dee di ag da 22 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 24 5 1 Routine Maintenance recono an weed D ne MAR ue n aaa 24 5 2 Supplementary Protectors 4 24 5 3 Replacing Drive Roll And Wire Inlet Guide 25 5 4 Removing Knob From Front Panel eens 25 5 5 Replacing Gun Contact Tip 26 5 6 Cleaning Or Replacing Gun Une 27 5 7 Replacing Switch And Or Head Tube 28 5 8 Welding Troubleshooting Table 29 5 9 Wire Drive Gun Troubleshooting Table 29 TABLE OF CONTENTS SECTION 6 MIG WELDING GMAW GUIDELINES 444 ssscssssesesssss 30 6 1 Typical MIG Process Connections miii A a a 30 6 2 Typical MIG Process Control Settings 31 6 3 Holding And Positioning Welding GUN 32 6 4 Conditions That Affect Weld Bead Shape 33 6 5 Gun Movement During Welding 34 6 6 Poor Wel
29. The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 927 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 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 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables c
30. age range and reduce wire feed speed Increase travel speed OM 927 Page 35 6 11 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of O 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 6 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Ls 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
31. arts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 OM 927 Page 1 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
32. as Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 927 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 67
33. as drive rolls WELDING WIRE can cause injury 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 E 5 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 25249 5 et seq gt 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 s MOVING PARTS can cause injury Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owners Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency H E can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this
34. ations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation gt Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconna t qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation OM 927 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed G
35. ause cancer birth defects and other reproductive harm OM 927 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that
36. clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils maient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es 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 exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Po
37. d Bead Characteristics 34 6 7 Good Weld Bead Characteristics 34 6 8 Troubleshooting Excessive Spatter 35 6 9 Troubleshooting Porosity 0 e eee 35 6 10 Troubleshooting Excessive Penetration anaana 35 6 11 Troubleshooting Lack Of Penetration 36 6 12 Troubleshooting Incomplete Fusion rnrn nnnnn 36 6 13 Troubleshooting Burn Through eee 36 6 14 Troubleshooting Waviness Of Bead 37 6 15 Troubleshooting Distortion 37 6 16 Common MIG Shielding Gases 38 6 17 Troubleshooting Guide For Semiautomatic Welding Equipment 38 SECTION 7 ELECTRICAL DIAGRAM 0 x ccc eee eect eee eee eee eee eee ai SECTION 8 PARTS LIST A vere hat EA ad 42 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message EF Means Note not safety related 1 2 Arc Welding Hazards A A
38. d bead Y ED 802 600 C OM 927 Page 31 6 3 Holding And Positioning Welding Gun N OTE Ex 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 7 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 4 es 0 15 WA d 90 90 y A End View of Work Angle Side View of Gun Angle GROOVE WELDS E 0 15 e N 45 N ANOS End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 927 Page 32 6 4 Conditions That Affect Weld Bead Shape NOTE IE 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 Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES a Short Normal Long ELECTRODE EXTENSIONS STICKOUT Le Le Lv Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT SS goa AS Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 927 Page 33 6 5 Gun Movement During Welding N OT E Ex Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove we
39. des gants de soudage et des v tements pais pour viter les br lures 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 peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester danger SSC D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologu es Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d
40. ding 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 6 9 Troubleshooting Porosity ON Porosity small cavities or holes resulting from gas pockets in weld metal PAI S 0635 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 welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 6 10 Troubleshooting Excessive Penetration Mn a 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 volt
41. ducts An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call 1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se KA HOBART HS
42. e 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 5 3 11 WARRANTY Effective January 1 2005 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LF or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will
43. e unless listed 16 802 603 B Figure 8 2 Center Baffle wComponents OM 927 Page 44 Item Dia Part No Mkgs No Description Quantity Figure 8 2 Center Baffle w Components Fig 8 1 Item 9 E gta Reba 058 427 RING retaining spool 1 E E aaa 085 980 NUT 625 11 94 hex 1 rra ont io 605 9415 2 WASHERS flati pis rar Sech ze a ao hey heh RARE Alma ra ed 1 WA 186 437 SPRING cprsn 84500 x 110W 1 EE 057 971 WASHER flat 632 ID x 1 500 OD x 12 1 our 057 745 SPRING cprsn 2 430 OD x 90 wire x 2 500 1 US o ria 186435 7 HUB ee st ess a nee ba dt a ee fiers 1 E GER 186 436 WASHER brake plastic 1 NE WE 197 521 BAFFLES TEE 1 EE 198425 CAP finishing 1 19 X 37 aa atada 198426 WASHER CAP vers manger mate ete dat a data la JK R2 091 685 RESISTOR Ed T RR a at de E dd 1 Ai se W 189 486 CONTACTOR DEF PRP including 1 EE 034 260 LINKS connecting contactor terminal 2 12 Chi 072817 RELAY encl 24VAC DDT 1 13 CB2 180912 SUPPLEMENTARY PROTECTOR man reset 1P 5A 250V 1 14 CB1 183492 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 Manr
44. ehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter Shielding Gas Supply Gas Wire Feeder Hose Power Source Workpiece light mig 5 967 Ref 802 601 A OM 927 Page 30 Typical MIG Process Control Settings 6 2 NOTE 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 Us 1 8 or 0 125 in Convert Material Thickness to L Amperage A T 0 001 in 1 ampere 0 125in 125A Wire Size Amperage Range 4 0 023 in 30 90 A 0 030 in 40 145A Select Wire Size 0 035 in 50 180 A 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 x 125 A 200 ipm ipm inches per minute Low voltage wire stubs into work Select Voltage High voltage arc is unstable spatter Set voltage midway between high low voltage Wire speed amperage controls weld penetration wire speed burn off rate Voltage controls height and width of wel
45. es panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FR QUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles
46. es 165 745 HOUSING PLUG amp PINS 1 Re RE 194965 COVER THI TTT TTT 1 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 927 Page 45 Hardware is common and not available unless listed gt 9 ei N D 10 Su lie o Sy N yd A 8 a A D N ge gt L 802 283 Figure 8 3 Rear Panel w Components N A XL Item Dia Part No Mkgs No Description Quantity Figure 8 3 Rear Panel w Components Fig 8 1 Item 10 ofan I e Rees 049 399 NUT 312 18 push on 1 sn wae ek eda bie 148 809 FAN 9 in 5wg 34 deg 1 Lt EE M 188706 MOTOR fan 230V 50 60 Hz 1 ce re una 203 711 WINDTUNNEL om 1 S lt TTT 216 396 VALVE 24 VAC 2 way custom port 1 8 orf w frict 1 sh OT share 203 478 x PANEL reat sf vin ovis Aa drag aan aia a 1 de moe ee Det is 200 179 BRACKET support tank 1 EE 137 653 LABEL warning 1 se One ts 188 441 CHAIN safety 4 1 i een 137761 NUT 750 NPT
47. evage 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 SUR ar nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT A e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste amn an ee amp LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC y E DES ORGANES MOBILES peuvent provoquer 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 e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage Z 5 DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels S que des ventilateurs e Maintenir ferm s et verrouill s les port
48. ggested Shielding Wire Sizes Gases and Flow Rate Diameter Steel Solid or hard 100 CO 20 cfh 023 0 6 mm ER70S 6 030 0 8 mm 035 0 9 mm 75 Ar 25 CO 20 023 0 6 mm Ch Ar CO gt produces 030 0 8 mm less spatter better 035 0 9 mm overall appearance Steel for outdoor Flux core No shielding gas required 030 0 8 mm windy applications or E71T GS 035 0 9 mm when weld appearance 045 1 1 mm is not critical Stainless steel Stainless steel Tri Mix 20 cfh 023 0 6 mm ER 308 90 He 7 5 030 0 8 mm Ar 2 5 CO 035 0 9 mm Aluminum with Aluminum 100 Ar 20 cfh 030 0 8 mm Optional Spoolmate 4043 AL 035 0 9 mm 185 or Spoolmate 3035 spool gun Aluminum 100 Ar 20 cfh 030 0 8 mm 5356 AL 035 0 9 mm Do not change Voltage switch position while welding Wire Speed is a starting value only and can be adjusted while welding Weld conditions also depend on other variables such as stickout travel speed weld angle cleanliness of metal etc Input Line Parameter Voltage Chart Settings Higher Weld Will Be e g 240 Hotter Volts AC Lower Settings Use Parameter 230 Volts AC gt Chart Inside Door Lower Weld Will Be e g 218 Or Colder Volts AC Raise Settings OM 927 Page 22 Select Voltage and Wire Speed Based on Thickness of Metal Being Welded 3 8 1 HI To read settings Number on lef
49. 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 927 Page 36 6 14 Troubleshooting Waviness Of Bead nil 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 nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 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 927 Page 37 6 16 Common MIG Shielding Gases This is
50. in d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation 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 une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en position coinc e comme assise ge
51. installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e 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 e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f 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 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to c
52. lamp onto end of hose at wire drive housing and insert either of the two output barbed ends of diverter valve into hose Secure with hose clamp Install another supplied hose clamp onto end of hose from gas supply and insert in Ref 802 582 A put barbed end of diverter valve into hose Secure with hose clamp Slide hose clamp down gas hose from gun and cut barbed fitting off hose Route gas hose through front panel opening and insert remaining output barbed end of diverter valve into hose Secure with hose clamp 8 Trigger Control Plug Insert plug into receptacle and tighten threaded collar Close welding power source door OM 927 Page 20 SECTION 4 OPERATION 4 1 Controls The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide and Section 4 2 3 Power Switch Le 9 ar 1 Wire Speed Control r FA _ NZ WIRE FEED SPEED ZN olo He IronMan 210 1 oh DO NOT SWITCH UNDER LOAD VOLTAC ONTROL 3 o me y INPUT POWER Es OFF TRIGGER MAD A vwa Ref 199 206 OM 927 Page 21 4 2 Weld Parameters Selecting Wire Gas and Control Settings What Material are You Welding Suggested Wire Types Su
53. ld 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 GE D S 0054 A 6 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration Qn E ND A S 0053 A 6 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 927 Page 34 6 8 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead S 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shiel
54. le hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to 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 con
55. ler s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain
56. liser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que 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 lors que 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 suf fisamment de personnes pour soulever et d placer les bouteil les 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 curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits 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 LA CHUTE DE L APPAREIL peut blesser 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 l
57. lose together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body EO D Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som _3 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Attention Cette pro Le c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques a id p d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer
58. mponents such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Mil
59. nected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A k FIRE OR EXPLOSION hazard dl 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 UNIT can cause injury 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 nn d t I OVERUSE can cause OVERHEATING e Allowcooling period follow rated duty cycle ee e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling ASS boards or parts So e Use proper static proof bags and boxes to store move or ship PC boards E MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such
60. nit to proper input voltage or check for low line voltage see Section 3 13 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 14 Replace inlet guide contact tip and or liner if necessary see Sections 5 3 5 5 and or 5 6 5 9 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts see Section 5 6 Adjust drive roll pressure see Section 3 14 Readjust hub tension see Section 3 10 Check supplementary protectors CB1 and or CB2 and reset if necessary see Section 5 2 Replace contact tip if blocked see Section 5 5 Clean or replace wire inlet guide or liner if dirty or plugged see Sections 5 3 and or 5 6 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 5 and or see Parts List Check and clear any restrictions at drive assembly and liner see Section 5 6 Have nearest Factory Authorized Service Agent check drive motor OM 927 Page 29 SECTION 6 MIG WELDING GMAW GUIDELINES 6 1 Typical MIG Process Connections A Weld current can damage electronic parts in v
61. nto 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 Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage OM 927 Page 38 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
62. of oil or grease to drive motor shaft 5 2 Supplementary Protectors Deo r o A Turn Off unit 1 Supplementary Protector CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 Supplementary Protector CB2 CB2 protects the trigger circuit from overload If CB2 opens weld output stops Check gun switch and trigger leads Correct problem Press button to reset supplementary protector Close door Ref 802 601 A OM 927 Page 24 5 3 Replacing Drive Roll And Wire Inlet Guide 1 Inlet Wire Guide Securing ae Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw C 3 Drive Roll Install correct drive roll for wire size O and type 4 Drive Roll Securing Screw 2 Secure drive roll with screw as W shown E 4 O Tools Needed Ref 802 601 A 5 4 Removing Knob From Front Panel A Turn Off power 1 Front Panel 2 3 4 Knob Slot Control Shaft Rotate knob to allow access to slot Insert tip of screwdriver into slot and while pushing on spring clip pull knob off control shaft To reinstall push knob fully onto control shaft Ref 803
63. on other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 877 Hobartl or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob_Thank 4 05 5 3 11 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 Ga NUI HO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 AS RANA 1 1 27 Arc Welding Hazards vta RA A A ee eS 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 000 c cece teen eee eee 3 1 5 Principal Safety Standards 0 cece nett eee eens 4 126 EMFnformation sis ug e a mn te pial ese dee Mae alls net wy wena Saale seed enrol 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 21 Sy Mboles VIS ee do sited a Te MOLES nr En E Lie 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
64. ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 INTRODUCTION 3 1 Specifications Max Open Amps Input at Rated Output 60 Hz Single Phase Circuit Rated Output Voltage 200 V 230 V KVA Kw 150 A at 23 VDC 29 25 5 8 4 9 40 Duty Cycle 33 2 3 2 0 4 0 1 No Load Wire Feed Wire Type and Diameter Speed Dimensions Weight Solid Steel 90 750 IPM H 31 1 4 in 794 146 Ib Stainless Steel 2 3 19 m min mm 66 kg Aluminum Flux Cored W 18 7 8 in 479 mm 023 045 in 030 035 in 030 045 in D 36 1 2 in 927 0 6 1 2 mm 0 8 0 9 mm 0 8 1 2 mm mm While idling 3 2 Welding Power Source Duty Cycle And Overheating 500 Duty Cycle is percentage of 10 min 450 utes that unit can weld at rated load 400 without overheating 350 If unit overheats thermostat s 79 300 opens output stops and cooling 11 250 fan runs Wait fifteen minutes for D unit to cool Reduce amperage or O 200 voltage or duty cycle before gt welding lt 150 A Exceeding duty cycle can o damage unit and void He warranty 50 10 15 20 30 40 50 60 70 80 90100 DUTY CYCLE 40 dutycycle S Ky TR gt O 4 Minutes Welding 6 Minutes Resting Overheating CBR Reduce Duty Cycle Min
65. 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HE Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable co
66. qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les nest pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort instructions aff rentes pour viter tout risque Les instructions en e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s gans les normes oe eier hand mer dans la Section 2 5 Lire et lt No pas enrouler les c bles autour du corps GE ee E a g e Sila pi ce soud e doit tre mise la terre le faire directement avec un A Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine 1 z z x sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en e e m me temps cause de la pr sence d une tension vide doubl e 1 UNE DECHARGE ELECTRIQUE peut e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le _e entra ner la mort
67. rter des lunettes de s curit avec crans lat raux ou un cran facial OM 927 Page 6 distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager I 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 endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Uti
68. s espaces confi n s ou se servir d un respirateur d adduction d air homologu LES RAYONS D ARC peuvent entra ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI 249 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter
69. t of slash is voltage number on right of slash is wire speed Means not recommended E L PA Example 2 40 40 de 50 30 70 20 80 10 90 4 VOLTAGE 3 16 1 8 14 ga 16 ga 18ga 20ga 22 ga 9 5 mm 6 4 mm 4 8 mm 3 2 mm 2 0 mm 1 6 mm 1 2 mm 0 9 mm 0 8 mm 4 74 3 46 3 46 2 18 2 18 2 18 2 16 RS E BSAS SSA EA Zda EEN 4184 3 20 3 18 2 12 2 12 4 80 4 80 3 68 2 36 2 36 1 16 1 16 4 62 3 42 3 40 2 24 2 24 1 16 1 16 4 50 3 40 3 36 2 20 2 16 2 14 3 46 2 20 2 14 1 12 1 12 3 20 2 10 2 4 1 0 4 20 3 10 5 86 5 82 4 70 3 50 3 46 3 42 3 42 5 68 5 64 4 56 3 46 3 46 3 40 2 32 5 66 5 66 4 40 3 32 3 28 2 24 5 72 4 68 2 68 1 56 we 5 66 4 60 2 58 5 88 4 88 2 80 1 70 5 84 4 84 2 70 5 58 4 48 5 52 4 34 5 100 5 100 5 72 4 62 5 60 4 52 5 66 4 52 5 44 4 36 5 30 5 30 6 90 6 76 6 70 T 6 78 6 72 6 100 6 84 Ref 199 208 OM 927 Page 23 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5 1 Routine Maintenance e gt gt em A Disconnect power before maintaining 3 Months W gt RNIN Replace unreadable labels CR H 6 Months Blow out or vacuum inside During heavy service clean monthly Repair or replace cracked weld cable OL 39 Clean and tighten weld terminals A vi e Remove drive roll and apply light coat
70. tition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby A FLYING METAL 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 OM 927 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed Oo e Allow cooling period before working on gun or torch e To hand
71. tor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line termi nals 10 Over Current Protection Select type and size of over current protection using Section 3 12 fused disconnect switch shown Close and secure door on discon nect device Remove lockout tag out device and place switch in the On position 803 766 B Ref 802 286 E OM 927 Page 17 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob 3 14 Threading Welding Wire Drive Roll 4 Outlet Wire Guide N Gun Conduit Cable S Lay gun cable out straight 7 pee l rar Tools Needed el CH SD BEI LL Ref 802 601 A 3 5 6 gt Hold wire tightly to keep it NO oO BR WD from unraveling x 9 xo Y Gin HE 150 mm aa a 102 mm Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire CS Use pressure indicator Tighten scale to set a desired a drive roll pressure 1 Pressure 2 Indicator 93 Scale o 4 Sch eS esch I N OFF ON
72. ucun danger s e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de puiv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute SES eg d el ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal 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 conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxi ques en cas de soudage OM 927 Page 5 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 le
73. ut control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill
74. utes duty1 4 95 199 211 OM 927 Page 9 3 3 Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty e Do not weld at rated load longer than shown below e Using gasless flux cored wire reduces gun duty cycle warn7 1 8 93 Definition 023 To 045 in 0 6 To 1 1 mm 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 0 Hard Or Flux Cored Wires 60 Duty Cycle At 100 Amperes 100 Duty Cycle At 100 Amperes Using Mixed Gases TO Using CO Minutes gt Duty Cycle is percentage of 10 Ka minutes that gun can weld at rated load without overheating Continuous Welding 6 Minutes Welding 4 Minutes Resting SB1 1 8 93 3 4 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit 35 Curves of other settings fall be tween curves shown 30 25 20 DC VOLTS 15 10 0 50 100 150 200 250 DC AMPERES va_curvel 4 95 199 212 OM 927 Page 10 3 5 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door Ref 802 601 A

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