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Handler 210 - Hobart Welders

1. 34 9 8 Troubleshooting Excessive Spatter 35 9 9 Troubleshooting Porosity 35 9 10 Troubleshooting Excessive Penetration 2 35 9 11 Troubleshooting Lack Of Penetration 36 9 12 Troubleshooting Incomplete Fusion 36 9 13 Troubleshooting Burn Through 1 2 00 cece ete teen eens 36 9 14 Troubleshooting Waviness Of Bead 37 9 15 Troubleshooting Distortion 37 9 16 Common MIG Shielding Gases 37 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment 38 SECTION 10 PARTS LIST scission niet aide eae Pere sete tenons been 40 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 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 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 in
2. 1 Alan 228 400 KNOB pointer voltage 1 AD ee ad 211 338 KNOB pointer WFS 1 28 GAS TEEN 217 148 MOTOR Cal tes ee yee Aer eee beta ae ered 1 Der AA Percent TS 193189 CONNECTOR oun 1 BR iar atthe es 196 654 SCREW thumb afe a y a a a E e a 1 sip dt E 230012 FITTING gas barbed 1 pe AL SN ete SEE 202 925 ROLL feed 024 in 030 085 in 1 EA ails ete Desire ara 194 508 HEAD feed assy 1 se VE 203 025 GUIDE wire met 1 d Sandra 227 949 LABEL weld chart 1 ee DT RER EEE herr 204 7112 LATOR se orien beet are wah aaa nena nda tr cdas 1 DD en 217 585 2 CONTACTOR Panier van aaa ee 1 OS a 203572 LABEL warn gen precaution EN FR models only 1 E LABEL nameplate order by model and serial number 1 DD TS TE 048 282 RCPT W SKTS service kit 1 DO nn 202 661 LED yellow 1 D Le DE ae 233 346 PLATE stiffener base 1 SOG tentar var 229 793 WINDTUNNEL 4444 eens 1 When ordering a component originally displaying a precautionary label the label should also be ordered To mai
3. 1 Dee ds al 196 005 WRAPPER 0 0 cc ccc didier ue 1 TA a AA 204 036 LABEL warning 1 E 203 491 CLAMP capacitor 1 dae DD damage 226 191 CAPACITOR electrlt 100000uf 1 TE e e 225891 REACTOR ASSY is NH aaa aan 1 e 1 waar ha Qu 193 316 RECTIFIER ASSY EE 1 DO seine eg 227 780 BUS BAR positive 1 DO res der same he tata ds 228 106 ts BAFFEE Center a sub a ds da aden a a te a 1 Pas O rene seat 19606 5725 OWITCH dr WEEN 1 Bl A 193 144 INSULATOR output stud 1 ee E 193 194 BUS BAR negative 1 RS E 216 830 LABEL warning ENEE hd porn aber AN AN 1 BE EE 134201 Go STANDOFF Ense al rn ea a AE 4 see SD ee 226 813 SWITCH rotary 32A 7 position 1 OO ee ea 209873 POTENTIOMETER 4 4444 44e ue ue 1 E RECH 229 738 PANEL front black 1 Se EN 208820 CLAMP work 1 BI ren 196 619 CABLE Work 3 ana een 1 OM 227 978 Page 41 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly Continued e EE 196 574 SWITCH rocker DPST
4. 8 2 6 Information EMF u Ste ee doute ern AA AAA AA A EA E 8 SECTION 3 DEFINITIONS 5225258253 73 2 E ieee EE ENEE E EE EEN Ee nen 9 3 1 Symbols And Definitions NEEN pa La ee a 9 SECTION 4 SPECIFICATIONS 3 2 4 23 22 27H 22H ii 9 4 1 Sp cifications vio anti rar A Rees bh es 9 4 2 Duty Cycle And Overheating 10 4 3 VolbAmpere Cues iia ee en ee EN Ee 10 SECTION 5 INSTALLATION 2 2 2 ee o es 11 51 Installing Welding Gun ee ns en tante en net yaad weed EN es 11 5 2 Installing Work Clamps 2 7422 ne Me vai en En Ringe 11 5 3 Process Polarity Table 2 A E EE ee eee e 12 5 4 Changing Polarity EE AS 12 5 5 Installing Gas EEN ct A A a Poe RACINE 13 5 6 Selecting A Location And Connecting Input Power 14 5 7 Electrical Service Guide gu 2a Seefe a A DL RO 15 5 8 Installing Wire Spool And Adjusting Hub Tension 15 5 9 Installing Contact Tip And Nozzle 16 5 10 Connecting Optional Spool Gun 17 5 11 Threading Welding Wie 18 SECTION 6 OPERATION a 22 55 3222 ss ae 19 621 Controls she rien aan Tate eae Deda babe RRA AAA EE 19 6 2 Weld Parameter Chart For 230 VAC Model 20
5. Argon Gas Or g 5 A Mixed Gas Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended N flow rate After flow is set close pressure assembly O E CD CD ESOO E E E EY OCH e Pressure Assembly Pressure Assembly Open Closed Tools Needed JS 5 8 1 1 8 in Ref 804 654 A 802 441 Ref 804 688 A OM 227 978 Page 13 5 6 Selecting A Location And Connecting Input Power 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 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Installation must meet all Na tional and Local Codes have only qualified persons make this installation 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 Black And White Input Conductor L1 And L2 3 Green Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Devi
6. S 0052 B OM 227 978 Page 34 9 8 Troubleshooting Excessive Spatter ann Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead AHA Saar Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal LAU ie 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
7. gt 1 Lead Connections For Direct Fe CHANGING Current Electrode Negative POLARITY DCEN 2 Lead Connections For Direct DCEN Current Electrode Positive Electrode negative for DCEP flux cored wire Always read and follow wire manufacturers recommended polarity and see Section 5 3 Close door Electrode positive for solid wire Ref 209 228 Ref 209 229 OM 227 978 Page 12 5 5 Installing Gas Supply Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve DO NOT use Argon Mixed gas regulator flowmeter 1 Cap with CO shielding gas See Parts List for optional 1 2 Cylinder Valve CO gas regulator flowmeter Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve 4 Close valve i 3 Cylinder 4 Regulator Flowmeter 2 Install so face is vertical A N 5 Regulator Flowmeter Gas 7 D N Hose Connection a 6 Welding Power Source Gas D Hose Connection f Connect supplied gas hose between regulator flowmeter gas 3 hose connection and fitting on rear Ve of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open pressure assembly so that wire will a not feed Press gun trigger to start gas flow
8. 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 9 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 227 978 Page 35 9 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and rm rg 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
9. Pour les moteurs essence A 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 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 OM 227 978 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 Gas 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 St
10. EF gt MIG Nozzle Use with solid or flux cored wire Push nozzle over contact tip and adapter until it is seated onto adapter End of contact tip will be flush with end of nozzle when installed properly A Turn off welding power source 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Thread welding wire through gun see Section 5 11 Slide contact tip over wire and tighten tip into tip adapter Install nozzle Ref 802 399 A OM 227 978 Page 16 5 10 Connecting Optional Spool Gun Her Spool Gun 6 MIG Gun 0000 a Incorrect Gun Not Seated Exposed O rings will cause shielding gas leakage O O ob Z Correct Gun Fully Seated ER 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew 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 Changeover Terminal Block To make proper polarity connection
11. facial OM 227 978 Page 6 de gougeage ou de soudage par points 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 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 Utiliser 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
12. 2 k BLK PLG8 RC8 RC1 18 lt gt 3 10 a WFS RC1 10 9 gt 2 gt amp MIG SPOOL GUN 19 CONTROL RC1 19 K gt 1 gt 227 951 B OM 227 978 Page 29 SECTION 9 MIG WELDING GMAW GUIDELINES APA a A ES si E 9 1 Typical MIG Process Connections Shielding Gas Regulator Flowmeter OM 227 978 Page 30 Dr Wire Feeder Power Source Gas Hose 920 Oj O ur NO ei o N sod H AS D EK 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 Work Clamp Workpiece light mig 5 97 Ref 804 688 A 9 2 Typical MIG Process Control Settings NOTE gt specifications 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 Material thickness determines weld parameters 1 8 or 0 125 in L 4 Convert Material Thickness to Amperage A 0 001 in 1 ampere 0 125in 125A y Wire Size Amperage Range 4 0 023 in 30 90 A a 0 030 in 40 145 A Select Wire Size 0 035 in 50 180 A Wire Wire Speed Select Wire
13. Be sure that wire is positioned Remove gun nozzle Turn power on Be sure that Voltage range in proper feed roll groove and contact tip switch is set to range 1 2 3 4 5 6 or 7 to Close and tighten pressure feed wire Rotate knob until it clicks into assembly and let go of wire detent Wire will not feed if range switch is set between ranges Re Tighten gt SE D WOOD 4 Press gun trigger until wire comes Be sure that tip matches wire diameter Feed wire to check drive roll pressure out of gun Reinstall contact tip and nozzle Tighten knob enough to prevent slipping Cut off wire Close door Ref 804 688 A OM 227 978 Page 18 SECTION 6 OPERATION 6 1 Controls E oo oo 1 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting increases wire speed range also increases see weld setting label in welding power source or Section 6 2 as applicable am H a 20 80 ob 100 WIRE FEED G DO NOT SWITCH WHILE WELDING 2 Power Switch 3 Voltage Switch The higher the selected number the thicker the material that can be welded see weld setting label in welding power source or Section 6 2 as applicable Do not switch under load OVER on Switch must position 4 Over Temperature Light Light illuminates overheats 5
14. SECTION 7 MAINTENANCE amp TROUBLESHOOTING 22 7 1 Routine Maint enance 54845e EE dace dad eee ENEE E IE EI dE 22 7 2 Overload Protection vie NEEN as tan ea er nn 22 723 Drive Motor Protection ceca Sieg Se oe oes eM De A Ye Es Se ee ge Ae ire ne Ye a he ees 22 7 4 Changing Drive Roll Or Wire Inlet Guide 23 7 5 Replacing Gun Contact Tip ooocccccccccccccc esse 23 7 6 Cleaning Or Replacing Gun Une 24 7 7 Replacing Switch And Or Head Tube 2 25 7 8 Troubleshooting Table 26 SECTION 8 ELECTRICAL DIAGRAM 0c cece ccc pente Erene e eee eee e eee 28 TABLE OF CONTENTS SECTION 9 MIG WELDING GMAW GUIDELINES 30 9 1 Typical MIG Process Connections 30 9 2 Typical MIG Process Control Settings 31 9 3 Holding And Positioning Welding Gun 32 9 4 Conditions That Affect Weld Bead Shape 33 9 5 Gun Movement During Welding 34 9 6 Poor Weld Bead Characteristics 34 9 7 Good Weld Bead Characteristics
15. see welding power source Owner s Manual Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriate setting 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual or door chart for appropriate setting 10 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed 804 695 A 804 696 A OM 227 978 Page 17 5 11 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight OO O1 P GO MM 0000 TO O AK Lei Fr Tools Needed gt gt 0000 O S amp Y es LA Open pressure assembly Make sure Pull and hold wire cut off end Push wire thru guides into gun feed roll is set to correct groove to continue to hold wire match wire size see Section 7 4 Use pressure indicator scale to set a desired drive roll pressure Tighten Pressure Indicator o Scale P
16. CHAUFFER L QUIPEMENT 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 nr nn nn 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 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 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californ
17. Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again OM 227 978 Page 22 7 4 Changing Drive Roll Or Wire Inlet Guide wur O Tools Needed E 030 035 Groove Stamped 024 N F 023 025 Groove Stamped 030 035 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Retaining Pin To remove drive roll push drive roll in and rotate it 1 4 turn to the open slot and slide it out over the retaining pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot 4 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll 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 see Section 5 11 Ref 803 714 A 7 5 Replacing Gun Contact Tip R gt wale Tools Needed EF gt A Turn Off power before 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 Re
18. 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 227 978 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 close together by twisting or taping them Arrange cables to one side and away from the operator Do not coi
19. 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 227 978 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 e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGN
20. ce souder ou le sol Dans ces conditions utiliser ve 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 aucun danger ANT 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
21. 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 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 levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu 43 2 4 A gt nn nn y E rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR
22. 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 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 Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and relat
23. travel speed OM 227 978 Page 36 9 14 Troubleshooting Waviness Of Bead sil Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal 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 9 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 9 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel an Aluminum Argon A Argon 25 CO X 80 or greater Argon X xi balance CO or Oxygen 100 CO2 X Tri Mix X 1 Limited sho
24. 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 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 larc 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 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 electrode 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 DES PIECES CHA
25. 1 E E 197 123 O RING 312 ID x 062 70 Dura BUNA N 2 NE A EE 196 255 v SWITCH trigger tan ans sans Ban anne Dakar ea 1 M2 cia nes mate en 180 433 CORD trigger assembly 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 227 978 Page 43 10 3 Optional Drive Rolls For All Feed Head Assemblies PART NO WIRE DIAMETER INCHES mm 202 925 023 025 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 10 4 Options PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 Ib 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg max 231 204 H 14 Replacement Gun 10 ft length 030 035 wire size 300 173 DP 3035 20 Spool Gun For push pull wire feeding 195 186 Protective Cover Weatherproof nylon 212 492 Regulator Flowmeter For use with CO shielding gas 10 50 CFH 144 108 Gas hose 5 ft For use with regulator flowmeter 212 492 10 5 Consumables ITEM HOBART PACKAGE NO MILLER PACKAGE NO Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 03
26. 20 30 40 60 70 80 100 Duty Cycle 30 duty cycle at 150 amps DRA D 3 Minutes Welding 7 Minutes Resting Overheating SS amp gt amp gt gt amp gt Reduce Duty Cycle Minutes duty1 4 95 227 953 A 4 3 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of Ko Gr AS the welding power source Curves of other settings fall between the D curves shown 5 7 6 gt gD 4 s 3 5 2 10 5 0 0 10 2 2 DO A amp DM 10 110 10 10 10 WH 160 10 180 10 AD 20 20 20 Amperage ssb1 1 10 91 227 954 A OM 227 978 Page 10 SECTION 5 INSTALLATION 5 1 Installing Welding Gun Her Spool Gun D fe 1 Drive Assembly 2 MIG Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew
27. 35 Aluminum ss 030 0 8mm Spoolgun Set Polarity 100 Argon 035 0 9mm for DCEP NERD EEN E Match feedroll groove to diameter of wire being used CAUTION Do not change Voltage switch position Set Tension Knob Setting to 3 at start while welding See owners manual for Adjust tension per instructions in the manual more information Multiple passes may be required depending on the application and joint design Aluminum wire settings are with the DP 3035 Spool Gun attached A push angle for the torch is normally recommended for aluminum OM 227 978 Page 20 25 210 Amp Wire Welding Package Recommended Voltage and Wire Speed Settings for thickness of metal being welded Number on left of slash is Voltage Setting Number on right of slash is Wire Feed Setting 18 gauge 14 gauge 048 inch 075 inch 11 gauge 1 8 inch 3 16 inch 1 4 inch 3 8 inch DCEP 1 2mm 2 0mm 3 2mm 4 8mm 6 4mm Ce 4 50 14 55 15 70 5 80 Eiectrode Positive ME A A Ze ee For Solid Wire 55 Be Ze CEA A AS AA A 3 35 4 40 5 60 5 70 E REH FO A 4 35 5 40 6 40 WE WE WE WE WE 4 20 5 30 6 30 6 35 a A KEE gt N gt oO a N ol a 3 35 Electrode Negative For Flux Cored Wire 3 2 172 1 15 50 30 a W W WI ao ja SE N N NS N W W gt jo o o a a oO jo a On N o 00 di O
28. 5 in 0 9 mm 770 180 5 per package 000 068 10 per package 770 177 5 per package 000 067 10 per package 045 in 1 2 mm 770 183 5 per package 000 069 10 per package MIG Nozzle Standard 770 404 169 715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716 Replacement Liners 023 025 in 0 6 mm 196 139 194 010 030 035 in 0 8 0 9 mm 196 139 194 011 035 045 in 0 9 1 2 mm 196 140 194 012 Available at farm and tool Available at Hobart Miller supply retailers welding distributors NOTE If individual parts are required see Parts List chapter of this manual for part number to order OM 227 978 Page 44 Notes DECIMAL EQUIVALENTS 015625 di Bes Se 9 8 se Bei Se 99 ve Bag 96 32 Dez ve Be se ee Ze Be ve 9 0 0 3 Ber ve CS 9 Bk Se Se ve 0 0 0 3 Qo Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Warranty Questions Call 1 800 332 3281 7 AM 6PMEST Service You always get the fast reliable response you need Most replacement parts can be in your hand
29. Definitions A Amperage Voltage Z Hertz Negative Positive y 1 ENS Single Phase Input gt Output y Voltage Input O Off On Q k Do Not Switch G Gas Metal Arc ojo Wire Feed A Wee ce ae While Welding Welding GMAW SECTION 4 SPECIFICATIONS 4 1 Specifications Maximum Open Amperes Input at Rated Welding Amperage FRE Rated Load Output Weight Overall Output Range Ee etc 230 V 60 Hz KVA KW W Gun Dimensions Single Phase Length 19 1 2 in 495 mm 150 A 23 Volts 76 lb Width 10 5 8 in DC 30 Duty Cycle 25 210 34 24 5 33 4 60 34 kg 270 mm Height 12 3 8 in 314 mm Zeie Flux Cored Aluminum Wire Feed Speed Range Wire Type ainless And Diameter 023 035 in 030 045 in 030 035 in 60 770 IPM 1 5 19 6 m min At No Load 0 6 0 9 mm 0 8 1 2 mm 0 8 0 9 mm 40 680 IPM 1 0 17 3 m min Feeding Wire OM 227 978 Page 9 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s 200 opens output stops and cooling 175 fan runs Wait fifteen minutes for 130 unit to cool Reduce amperage or Y duty cycle before welding o 100 A Exceeding duty cycle can a 80 damage unit or gun and void E 60 warranty lt 5 40 o KE 5 O 20 10 10
30. ETIC FIELDS can affect pacemakers e Pacemaker wearers keep away 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 connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and mov
31. Gun Trigger Re Ref 227 950 A click into detent if main transformer ceptacle OM 227 978 Page 19 6 2 Weld Parameter Chart For 230 VAC Model Welding Guide for 230 Volt Settings are approximate Adjust as required Thicker materials can be welded using proper technique joint preparation and multiple passes Material Wire Type Suggested Diameter Being and Shielding Gas of Wire 24gauge 22 gauge Welded Polarity Setting 20 30 cfh Flow Rate Being Used 024 inch 030 inch 0 6mm 0 8mm 024 0 6mm 7 20 2 25 Solid Wire C Gas Mixture BEER ES PRE ER70S 6 75 Argon 25 CO 030 0 8mm 2 22 Set Polarity Produces less spatter JJ for DcePy Better Appearance 935 omm eae A A 024 0 6mm 3 30 Solid Wire DP CE ME ER70S 6 ES 850 am Set Polarity SS WEE EEN DEER for DCER 035 0 9mm 024 0 6mm 2 30 Stainless Kram Stainless et Cu Tri Mix 030 0 8mm 2 20 Steel DCE Py 90 He 7 5 A1 2 5 CO LE y ead 035 0 9mm AA Pl eee 030 0 8mm Flux Core ea SA A E71T 11 na 2055 o Imm E EN set Polarity Outdoor Applications BEZ Br BE for DCEN 045 10mm ARTO ME EA Aluminum 030 0 8mm Aluminum Set Polarity 100 Argon 035 0 9mm With Optional for DCEP ESAS Er EEE DP 30
32. NGE door edel d ANE cians iti dead alias 2 shale d en dita ats et 211 887 crc HUB WUE are rates ra a ra ara da dite 1 ANR adelaide lay Ge patton 204 608 NUT sis asta eA arms lack cua aang durite fat ace a a ra As 1 De ans ace at Sea seek aoe 202 998 SPRING open 1 whe Bi Masai 203 072 4 WASHER AE a ee te Pd hi A An 1 o rl dea 211339 HUB SDO0 acs cae cee ran na 1 el Bin eue A 2027 26 ADAPTER Spol NUD en release 1 A A a 225828 CIRCUIT CARD ASSY control 1 TO ars 228 045 BASE IOWE lt a a id ee ee wads air ats 1 eh ME 210 109 SUPPLEMENTARY PROTECTOR 25 amp 1 ee AE EEES 196 467 TUBING PVC 187 ID x 312 OD x 23 00 1 EGI E see mn 216 398 in VALVE DAS ARKAA na AARAA NA EUA DAAE een ern des 1 STE are des 197 198 CABLE TIE 700 799 bundle dia 2 SAD ee aan 227939 CORD SET 250V 6 50P 12GA 3 C 7ft SPT 3 jkt 1 ae Oele 010916 CONNECTOR clamp cable 750 1 ar aa A st eee 137 761 NUT gas valve 1 MONA RE 196 064 MOTOR fan ococococ ttn een e enn eens 1 nee ae 409 953 001 BLADE fan cooling 1 Ms 20 Narren 225 937 TRANSFORMER power assy 1 ed Lai da ts 208 015 HANDLE carrying
33. O gt a gt o o OH SE Tal N NS N noi IN Jol o al lo aon a a O O a O ol N Ei EI o o N N S 3 a 3 rs A E W N S SI IS 8 a le ER n rol inf fal fa SI N NS N 00 a o bm N N W W o ojo al oj ja ol Io Jl N N N N O No W a gt ol 00 JO OO o a al o a Wire Speed listed is a starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleanliness of metal etc A spool gun eliminates many feedability issues associated with the soft Aluminum wire 227949B 227 949 B OM 227 978 Page 21 SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance e X Ge ar E A Disconnect power Maintain more often before maintaining during severe conditions ne 14 Check Change Q Clean Replace Reference ELA To be done by Factory Authorized Service Agent Every Unreadable Labels Q Weld Terminals Damaged Gas Hose Lk Weld Cables 3 Months 1 Cords vr Gun Cables Every Ph 6 Le Months be os My Q Drive Rolls Q Inside Unit 7 2 Overload Protection 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down 4 Reset supplementary protector o e e D 802 441 7 3 Drive Motor Protection
34. OM 227 978B 2007 04 Processes MIG GMAW Welding Flux Cored FCAW Welding HOBARI fs Description e KI Arc Welding Power Source And Wire Feeder Handler 210 Online Forum www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years 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 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 dis
35. Speed Size Recommendation Arosa Amperage 0 023 in 3 5 in per ampere 3 5x 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 y Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage Select Voltage Wire speed amperage controls weld penetration wire speed burn off rate Ref 804 685 A OM 227 978 Page 31 9 3 Holding And Positioning Welding Gun NOTE es 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 Es 1 4 to 1 2 in 6 To 13 mm Hold a shorter stickout when welding with solid wire and using a 5 shielding gas 5 Cradle Gun and Rest Hand on Workpiece nee 0 15 Vad A 90 90 35 End View of Work Angle Side View of Gun Angle GROOVE WELDS 45 0 15 N A ASIN End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 227 978 Page 32 9 4 Conditions That Affect Weld Bead Shape NOTE Eg Weld bead shape depends on gun angle direction of travel electr
36. UDES 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 des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester 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 danger ee D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilite 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 clencher un incendie de l autre c t Ne pas effectuer le soudage su
37. 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 HS
38. Welding 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 MIG Gun position Tools Needed i 7 16 in IB I nein Close door 6 MIG Gun Be sure that gun end is tight against drive assembly 3 Oe j d Q a Z II De Exposed O rings will cause shielding Incorrect gas leakage Correct Gun Not Seated Gun Fully Seated 804 686 A 5 2 Installing Work Clamp E Connection hardware must be tightened with proper tools Do not just 1 Nut hand tighten hardware A loose electrical connection will cause poor 2 Work Cable From Unit weld performance and excessive heating of the work clamp 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp Slide insulating sleeves over handles 802 456 A OM 227 978 Page 11 5 3 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW Solid wire with shield DCEP Reverse polarity Connect to positive out Connect to negative output ing gas put terminal terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal 5 4 Changing Polarity
39. and install switch housing Secure with handle locking nut Y Clm Tools Needed y o t Y IC 19mm Ref ST 800 795 C OM 227 978 Page 25 7 8 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 5 6 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 6 1 Reset welding power source supplementary protector see Section 7 2 No weld output wire does not feed fan motor continues to run Thermostat TP1 open overheating Allow fan to run with gun trigger switch off thermostat closes when unit has cooled see Section 4 2 Check Voltage range switch position Rotate knob until it clicks into detent at desired range setting Secure gun trigger leads see Section 5 1 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 7 5 Check for proper polarity connections see Section 5 4 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Ele
40. andard 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 L accumulation 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 227 978 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 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 Standa
41. ce switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Receptacle NEMA 6 50R Connect receptacle as shown 9 Over Current Protection Select type and size of over current protection using Section 5 7 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 10 Plug NEMA 6 50P Connect plug to receptacle ssb2 2 1 94 804 687 A OM 227 978 Page 14 5 7 Electrical Service Guide Input Voltage 230 Input Amperes At Rated Output 24 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 Time Delay 2 25 Normal Operating 3 35 Min Input Conductor Size In AWG 14 Max Recommended Input Conductor Length In Feet Meters SCH Min Grounding Conductor Size In AWG 14 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 Conducto
42. components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Mil
43. ctrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 5 11 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 8 Replace contact tip if blocked see Section 7 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 or Section 7 6 Replace drive roll or pressure bearing if worn or slipping see Section 7 4 Secure gun trigger leads or repair leads see Section 5 1 Check and clear any restrictions at drive assembly and liner see Section 5 11 or Section 7 6 Gun is not secured to feed head Check thumbscrew securing gun end to feed head adapter and tighten if necessary Have nearest Factory Authorized Service Agent check drive motor OM 227 978 Page 26 Notes OM 227 978 Page 27 SECTION 8 ELECTRICAL DIAGRAM 4 WARNING nt TR ELECTRIC SHOCK HAZARD e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install Use or service this unit 12 T2 Mm A r BK CB1 27 17 77 lt K em CR3 aici ak a ni RC5 TUE 25 GAS VALVE lt 2 lt E o 23 l 6s1 26 e
44. 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 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 227 978 Page 38 Notes OM 227 978 Page 39 SECTION 10 PARTS LIST 22 E Hardware is common and not available unless listed 804 691 A Figure 10 1 Main Assembly OM 227 978 Page 40 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly LN pate tosh akc et 199566 DOOR ACCESS i nun Ae Ae a an BEEN eg 1 see Maine anges 196 006 f HI
45. e 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 FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit 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 If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit nn d t OVERUSE can cause OVERHEATING Allow cooling 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 as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do n
46. ed 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place e 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 type welding power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to yo
47. 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 polarity at welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of O to 15 degrees 9 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady
48. em 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 cause cancer birth defects and other reproductive harm OM 227 978 Page 3 1 5 Principal Safety Standards Sa
49. ervir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si utilisation d une source lectrique courant lectrique s avere 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 Palimentation 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 Ton 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 amp chafaudages en position coinc e comme assise ge l arc 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 Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi
50. fety 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 The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric
51. ie 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 Proposition californienne 65 Avertissements Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection 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 TE 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 PER RAYONNEMENT HAUTE FREQUENCE 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 fa
52. install nozzle Ref 802 399 A OM 227 978 Page 23 7 6 Cleaning Or Replacing Gun Liner Tools Needed A Disconnect gun from unit p Ts 22 8 mm 10mm Head Tube Remove nozzle contact tip adapter and gas diffuser 10 mm ae Remove liner 2 AE To Reassemble Gun PA Insert new liner Lay gun cable out straight Install wire outlet guide so that 1 8 g before installing new liner in 3 mm of liner sticks out Hand tighten outlet guide and then tighten two full turns more ao Cut liner off so that 3 4 in 19 mm ei A E sticks out of head tube ow out gun casing 9 9 Install gas diffuser adapter contact tip and nozzle Ref 804 692 A OM 227 978 Page 24 7 7 Replacing Switch And Or Head Tube Y Fr A Turn Off welding power source wire feeder and disconnect gun 1 Remove handle o aa C iiia 3 Slide handle o 2 Remove switch housing Install new switch and connect leads polarity is not important Reassemble in reverse order If replacing head tube continue to end of figure 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 7 Place head tube in vice and tighten until 6 Hand tighten head tube into cable connector nuts are tight PONE 8 Remove from vice Reposition handle
53. ire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile 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 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 interference 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
54. it si l on doit travailler au dessus du sol graves Le circuit de l lectrode et de la pi ce est S assurer que tous les panneaux et couvercles sont correctement en sous tension lorsque le courant est d livr la places ets y sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal 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 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 Siisoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce a 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 s
55. l BLK e AMA 4 i POWER SWITCH TUT 24 vac L J RC5 PLCS we 3 lt f 7 gt gt RC1 6 Se lt 4 lt gt gt RC1 14 2 RC1 15 CONTROL CR CONTROL BOARD pci 72 RC1 12 4 KRC1 1 THERMAL OVERLOAD O 2 KRCI 9 BLUE Reel bo 2 Eis W zu 5 IX K2 lt RC1 5 PLG7 RC7 3 RC1 PLG1 GUN ie ud RC4 PLG4 TRIGGER o 7 gt 2 gt gt gt RC1 4 gt 3 Ze gt gt RC1 17 SPOOL GUN MOTOR gt 4 gt 0 gt gt RC1 20 OM 227 978 Page 28 Figure 8 1 Circuit Diagram WARNING e Do not touch live electrical parts S e Disconnect input power or stop b NW engine before servicing 7 e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit et y J01 PRI 1 T 71 211 l l 7 so 314 PRI 2 I POSITIVE D Be 3 512 PRI3 C1 u TE1 10 D Z1 5e 370 PRI 4 n El COM yea J08 PRIS x5 NEGATIVE 11 VOLTAGE RANCE aga 306 PRI 6 SELECT P SWITCH S2 ds 4 304 _ PRI 7 X6 1 2 302 __PRI 8 NOTE DENOTES SWITCH TERMINAL MARKINGS RC2 lt lt 102 RC3 lt lt 103 RC1 8 lt lt RC1 16 K 16 GLE GUN RC1 7 lt Z o s3 SPOOL RC1 13 lt lt 13 GUN FED e Kees oui WIRE DRIVE MOTOR RC4
56. l or drape cables around your body Bi DIN 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 A 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 LE Indi scurit iculi Ce groupe de symboles signifie Avertissement Attention Risques A Indique message de s curite particulier d LECTROCUTION 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 qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces
57. 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 certai
58. n 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 2 hobart_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor 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 PRINTED IN USA 2007 Hobart Welding Products 2007 01 Protect Your Investment Register your product at HobartWelders com Hobart
59. nationales graissage de nettoyage ou de pulv 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 DES u 4 BR y ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Nepas 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 227 978 Page 5 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons
60. ntain 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 227 978 Page 42 804 692 A Figure 10 2 H 14 Gun Item Part No No Description Quantity 231 204 Figure 10 2 H 14 Gun mati em OLIS pre NOZZLE slip type 500 orf flush see Section 10 5 D Me nat RIVA RR FAR REIS cana NOZZLE flux cored slip type see Section 10 5 e VIREN RER EB na REN TIP contact scr 023 wire x 1 125 see Section 10 5 D EE TIP contact scr 030 wire x 1 125 see Section 10 5 e human Men eur TIP contact scr 035 wire x 1 125 see Section 10 5 RARE AAA TIP contact scr 045 wire x 1 125 see Section 10 5 RC EN EEE hs taht st TUE ADAPTER contact tip see Section 10 5 ic EE 170470 RING relaining zu nen nen 1 EHE EEE Ee 1697182 TUBE Neal mess are Leg tens eek 1 erben 169 738 NUT locking handle 1 A sadism SENT 169 719 NUT am 1 O WEE E 079 975 O RING 28 IDxv10 C gr nennen 1 E mage Da te Den Ai ESTER LINER monocoil 023 025 wire x 15ft including see Section 10 5 ous Qi a LINER monocoil 030 035 wire x 15ft including see Section 10 5 RS PE ER Rane RER FES nen LINER monocoil 035 045 wire x 15ft including see Section 10 5 wiih saunas 194 014 LINER monocoil 4 64 AL wire x 10ft nyl including
61. ode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage len 2 aml ES Usea Drag Technique KS e with self shielding flux Perpendicular Drag Caled wire GUN ANGLES AND WELD BEAD PROFILES a Short Normal Long ELECTRODE EXTENSIONS STICKOUT kk Lv Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT er fae Van Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 227 978 Page 33 9 5 Gun Movement During Welding NOTE gt 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 gt area in one pass of the electrode 3 GE DM S 0054 A 9 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration OD BR ND S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal
62. ot point gun toward any part ofthe body other people or any metal when threading welding wire 453 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 8 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 a 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 Owner s 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 F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference probl
63. r 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 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 5 8 Installing Wire Spool And Adjusting Hub Tension ESP Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set er Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only When a slight force is needed to turn spool tension is set Ey Retaining ring used with 8 in 203 mm spool only Tools Needed IE i LS D 1 2 in 803 012 803 013 B Ref 802 971 C OM 227 978 Page 15 5 9 Installing Contact Tip And Nozzle CH Ev ASS Flux Nozzle Use with flux cored wire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Push nozzle over contact tip and adapter until it is seated onto adapter Contact tip will be exposed approximately 7 16 in 11 3 mm when installed properly Tools Needed
64. r des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient 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 electrode 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 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 VOLANTES e Porter des lunettes de s curit avec crans lat raux ou un cran
65. rds 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 3 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 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 DEFINITIONS 3 1 Symbols And
66. rt circuiting use 2 90 HE 7 1 2 AR 2 1 2 CO OM 227 978 Page 37 9 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 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
67. s 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 2007 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LH 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 provide instruc
68. s 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 Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they
69. structions 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 KSC ELECTRIC SHOCK can kill _e Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp
70. symboles prendre garde et suivre les n est 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 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 Nepas 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 ee ur Je chante dans la Section 2 5 Lireet e Me pas enrouler les c bles autour du corps sa Seed 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 cable distinct ner entretenir et r parer cet appareil W e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendant le fonctionnement maintenir a distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en z 3 m me temps cause de la pr sence d une tension a vide doubl e UNE DECHARGE ELECTRIQUE peut e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le 0 entra ner la mort champ les pi ces endommag es Entretenir l appareil conform ment amer ce manuel ue c organes gl EE e Porter un harnais de s cur
71. tions 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 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 HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable
72. tributor 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 2005 06 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 AC PAU hi D TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 13 25ymbol Wsager ER 1 1 2 Are Welding Hazatds EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 150 EMEF Information ze stent she a She ota SN Re Que A cee Shed al ns NN 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 21 SYMPOISS ulises daten rd ad E ac ete Ts Se id ada Cn a nt 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 7 2 5 Principales normes de s curit
73. ur health Keep your head out of the fumes Do not breathe the fumes e f inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 227 978 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 skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lense

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