BETA-MIG 2250 - Hobart Welders
Contents
1. SC 192 433 Figure 5 1 Circuit Diagram For Welding Power Source OM 192 440 Page 22 Notes OM 192 440 Page 23 SECTION 6 PARTS LIST 5 Hardware is common and OX not available unless listed 10 Fig 6 3 20 Fig 6 5 ST 802 281 Figure 6 1 Main Assembly OM 192 440 Page 24 Item Dia Part No Mkgs No Description Quantity Figure 6 1 Main Assembly beady ED uus 146 165 PANEL side 1 TEN 089899 LATCH side flush 2 ubi ae 134 464 LABEL warning general precautionafy 1 e fert ore 192379 DOOR ASSEMBLY 4 1 iD odas 4192 382 WRAPPER ASSEMBLY 2 1 226 T1 192375 TRANSFORMER pwr main 200 230 1 f ag Zena MILITO x STABIMZER aaa edil pecuniae Barren 1 8 SR1 192 428 RECTIFIER consisting of 1 E 604 515 THERMOSTAT NC open 211F close 186F 1 SAJ a tes Fig 6 2 CENTER BAFFLE w components 1 TO ae Fig 6 3 PANEL rear w components2. 1 nho C ennt eer 177 302H Handle gun small pair 1 Load Rex 177 489H Support gun cable 1 env GLAMP Cable sans base po eni URGES EI ERATUM RR VE iC 2 pano kO tare varies MEER EUN CABLE gun assembly 1 ids e Leere 177 488H TRIGGER switch han 1 Mao p GONNEGTOR Butt 3 no esee temer ete eos ata m doen den 2 UNE I OEA E E A E WIRE lead assembly 1 EB shit ee Wiese TERMINAL quick connect 250 2 EAT eg 177 285H RING bayonet 1 ise itus dud eicere nia ea WRENCH allen 1 8in 1 O ida o sati be WRENCH allen 1 16 In rubo Rer ete EAR talar tar 1 sede lt deus 177 490H SUPPORT cable feeder 1 O Aree ONI 177 286H ADAPTER support 1 E ue ode W10904 014 O RING 1 2x5 8x1 16in 2 POLL MM E SET SCREW 6 32x1 8 in Ref Tuo 379 427 004 LINER spring assembly 030 045 1 Mcr 409 737 002 LINER spring assembly 024 035 1 edd en 177 50
3. 1 11 PLG1 188911 CORD SET 250V 1 e Etre 192891 BASE ote een e dari e e e init 1 PUB ani best 135 390 AXLE oe tee abla Sie ieee ees RC ie obeti P ble iA 1 A 190 759 o ni m te t tete T e Te A 2 vd LR reu 121614 RING retaining eI nn 2 AE HS 008 999 4 CASERA IR EE e ees 2 E eni ha ihe cras Fig 6 4 PANEL front w components 1 D EE 146 149 5 GABEE WOK era sen bad delis eau erbe Pepe ge ie der het dir ox ga 1 ATG ice 190 750 CLAMP Works anera nia nk emeret mes deni Red tede Pat RUE e cnrs 1 PREISE EEE Fig 6 5 GUN 20 A Piecemaker 12 ft 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 192 440 Page 25 Hardware is common and not available unless listed ST 802 284 A Figure 6 2 Center Baffle w Components OM 192 440 Page 26 Item Dia Part No Mkgs No Description Quantity Figure 6 2 Center Baffle w Components Fig 6 1 Item 9 Ld ER 058 427 RING retaining spool resti onm eti ee 085 980 NUT 625
4. 0 50 100 150 200 250 300 350 DC AMPERES va curvel 4 95 SB 192 436 2 4 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew Insert gun end through opening until it bottoms against drive assembly Tighten thumbscrew 4 Gun Trigger Leads Insert leads one at a time through small grommet on front panel Con nect female friction terminals to matching male terminals in unit Polarity is not important Close door Ref ST 801 875 OM 192 440 Page 10 2 5 Installing Work Clamp C KO 1 Work Cable Route cable out front panel opening from inside 2 Negative Black Output Terminal Connect cable to terminal 3 Hardware 4 Work Clamp Route cable through clamp handle and secure as shown Close door Tools Needed LL 1 2 3 4 in Ref ST 802 285 Ref ST 801 566 2 6 Setting Gun Polarity For Wire Type Her Shown As Shipped Set For Electrode Positive DCEP For Solid Steel Stainless Steel Aluminum or Flux Core with Gas Wires GMAW Process Wire Drive Assembly GUN Lead To Positive POLARITY Output Terminal CHANGEOVER Work Clamp Lead CONNECTIONS To Negative AN
5. 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 A LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit se STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards ZOR N 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 not point gun toward any part of the body other people or any metal when threading welding wire 43 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practic
6. MES Ji Le N Ss xA lip 5 Hardware is common and not available unless listed ST 802 282 Figure 6 4 Front Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 6 4 Front Panel w Components Fig 6 1 Item 17 Dat X4 bises 143974 HANDEE ans ti ea a re ead rt 1 lO dd 192378 PANEL TONE s var esse E eet ds 1 BE EA EOM 494 845 HANDLE switch RII 1 A DUO ee ate 184733 200 KNOB sa a a a aceite doce eda D TES Bee 1 I ed 035 897 POTENTIOMETER CP 1 T 2W 1K linear wire feed speed 1 ot Ors os S2 192373 SWITCH selector 7 position 1 ud dtes S1 128755 SWITCH tgl DPST 40A 600 VAC 1 Ey Dp REESE 192 969 COVER module access 1 i Os e 193 280 LABEL spoolmodule access 1 PAO tect RR 170 647 BUSHING snap in nV anaa aa aaee 1 as 204 413 BUSHING snap in nV annaa 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 192 440 Page 29 CS Hardware is common and 18 not available unless listed E 20 Scan Figure 6 5 Gun And Cable Assembly Piecemaker 20 A Item Part No No Description Quantity Figure 6 5 Gun And Cable Assem
7. Output Terminal dee E o 8 c Reverse Lead Connections Set for Electrode Negative DCEN For Gasless Flux Cored Wires FCAW Process Drive Assembly Becomes Negative Ref ST 192 432 Tools Needed 2 3 4 in 1 Polarity Changeover Label 2 Positive Red Output Terminal 3 Negative Black Output Terminal Always read and follow wire manufacturers recommended polarity Close door je L Ref ST 801 875 OM 192 440 Page 11 2 7 Installing Gas Supply Chain gas cylinder to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Regulator Flow Gauge Install so face is vertical 2 Gas Hose Connection Fitting has 5 8 18 right hand threads 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturers recommended flow rate see Section 3 2 This flow gauge can be adjusted between 5 and 25 cfh 4 CO Adapter Customer Supplied 5 O Ring Install adapter with O ring between regulator flow gauge and CO cylinder Tools Needed IZ 1 1 8 5 8 in Ref ST 801 789 Ref ST 149 827 B Ref ST 158 697 A 2 8 Installing Wire Spool And Adjusting Hub Tension ESP Use compression spring with 8 in 200 mm spools
8. 4 6 Welding Troubleshooting Table Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 2 11 Check and replace power switch if necessary Check circuit breakers CB1 and or CB2 and reset if necessary see Section 4 2 Replace building line fuse or reset circuit breaker if open see Section 2 11 Secure gun trigger leads in receptacle or repair leads or replace trigger switch see Sections 2 4 and or Parts List Thermostat open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 2 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 4 4 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 11 Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct size drive roll see Section 4 3 Readjust drive roll pressure see Section 2 12 Replace inlet guide contact tip and or liner if necessary see Sections 4 3 4 4 and or 4 5 4 7 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 4 5 Adjust drive roll pressure see Section 2 12 Rea
9. When a slight force is needed to turn spool tension is set d e Tools Needed C ee gt IL 15 16 in ST 072573 B OM 192 440 Page 12 2 9 Changing Input Voltage From 230 Volts To 200 Volts Tools Needed EF 3 5 16 3 8 in Cut cable ties as necessary 1 230 Volt Transformer Lead Fan Lead 2 Black Switch Lead 3 Tubing Locate lead marked 230 VAC Slide tubing down and disconnect black switch lead from splice Be sure 230 volt transformer lead and white fan lead remain spliced Fold tubing over 230 volt transform er fan lead splice and secure 4 200 Volt Lead Locate lead marked 200 VAC Slide tubing down and connect 200 volt lead stub to black switch lead that was just disconnected from the 230 volt lead and secure with exist ing hardware Slide tubing over connection and secure Ref ST 802 287 2 10 Electrical Service Guide Input Voltage 200 230 Input Amperes At Rated Output 40 35 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 60 50 Min Input Conductor Size In AWG Kcmil 8 10 Max Recommended Input Conductor Length In Feet Meters 108 33 94 29 Min Grounding Conductor Size In AWG Kcmil 10 10 Reference 1996 National Electrical Code NEC S 0092J OM 192 440 Page 13 2 11 Selecting A Location And Connecting Input Power H 4 e ul Aap
10. d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 192 440 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur 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 provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de pro
11. quipement de la zone de soudage soit com patible 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 quipement lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 192 440 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and
12. 3 y DES ORGANES MOBILES peuvent provoquer des blessures C e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication 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 installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil 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 et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l
13. avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces b LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit
14. limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart warr 3 97 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment 1998 Hobart Welding Products 1 00 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hob
15. 0 V KVA KW 200 A at 24 VDC 40 35 8 6 8 60 Duty Cycle 35 1 1 1 3 0 31 0 18 No Load Wire Feed Wire Type and Diameter Speed Dimensions Weight Solid Steel 90 750 IPM H 31 1 4 in 794 mm 185 Ib Stainless Steel Aluminum Flux Cored 2 3 19 m min W 18 7 8 in 479 mm 84 kg D 36 1 2 in 927 mm 023 045 in 030 035 in 030 045 in 0 6 1 2 mm 0 8 0 9 mm 0 8 1 2 mm While idling 2 2 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 300 opens output stops and cooling HI 950 fan runs Wait fifteen minutes for EH unit to cool Reduce amperage or LI 200 voltage or duty cycle before welding 150 A Exceeding duty cycle can O damage unit and void m warranty 100 50 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE 60 Duty Cycle At 150 Amperes 20 068 6 Minutes Welding 4 Minutes Resting Overheating T 0 Aor V 2o gt Reduce Duty Cycle Minutes duty1 4 95 SB 192 435 OM 192 440 Page 9 2 3 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown 40 D DC VOLTS 10
16. 1 Rating Label 4 A PY Supply correct input power LU 2 Plug A Do not move 3 Receptacle or operate unit d Connect plug to receptacle where it could tip 4 Input And Grounding 18 in 457 mm of Conductors space for airflow Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 2 10 A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Always connect grounding conductor first GND PE LAA ST 802 286 OM 192 440 Page 14 2 12 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight NOV ND Tools Needed gt gt Ref ST 802 285 Hold wire tightly to keep it o from unraveling 9 og ET zaje E 8 in Je din e 150 mm 102 mm Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Tighten d ai m SEI VA gt A INPUT
17. 11 94 hiex cores des Le nie ter err DT EROR T ed acc PEE 6059413 WASHER flat uvis ne a kk ae N ad cci al B anten tus 186 437 SPRING cprsn 84500 x 110W A Die te T ae 057 971 WASHER flat 632 ID x 1 500 OD x 12 Oasis 057 745 SPRING cprsn 2 430 OD x 90 wire x 2 500 Ju EEGEN 186 435 HUB SPOO u tr adesse rei Khe Lope tein IS Ue eor ae REG A E m CET 186 436 WASHER brake plastic D ME 192 377 2 BAFFLE center ale E LA statut 0831472 GROMMET EE lise C6 186 998 CAPACITOR ASSEMBLY KIT consisting of ain ie 185 643 BUSS BAR capacitor greet mare 082 902 STRIP MTG CENTER CAPACITOR 14 184 584 CAPACITOR elctlt 15000uf 45VDC 15 R2 45 5 091 685 RESISTOR cuco sees a aaa URNEM Pe DER me oe Ja eS 16 W 188634 CONTACTOR DEF PRP 60a 3p consisting 0f mus vies D ET ede dt 114 786 LINKS connecting contactor terminal 17 CR1 072817 RELAY enci 24VAC DPDT an 18 CB2 180912 CIRCUIT BREAKER man reset 1P 5A 250V 19 CB1 183492 CIRCUIT BREAKER man reset 1P 10A 250V 20 PC1 171986 CIR
18. 3H KIT plug quick connect Hobart feed includes Items 28 amp 29 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 192 440 Page 31 Notes Notes Notes Warranty Questions Call 1 800 332 6619 WELDING PRODUCTS Hobart Warranty Effective January 1 1997 This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory 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 manufacturer will repair or replace any warranted parts or components
19. CUIT CARD ASSEMBLY control 1 usa ais 097 416 TERMINAL pwr output black 1 22 93 60 075 820 128750 GAPACITOR ASSEMBEY sus tribal ai qaa 2 23 C9 10 193205 CAPACITOR ASSEMBLY 2 24 RC2 184734 BUSHING terminal 2 position 2 QO bai di ET eats 184 692 DRIVE ASSEMBLY wire consisting 0f 1 C26 st itr S 204 368 MOTOR gear eh rn 1 sil OU an RTE 203 081 SCREW feedroll 1 ni 1 euo 079 633 FITTING hose brs barbed nipple 1 DI ee reine 186 021 BLOCK connector gun 1 PAS 1O ONE 184 735 GUIDE wire adapter 1 x dus TE 184 741 HEAD feed 1 tods dp ete 203 025 GUIDE wire met 1 n OO obs OR etia 184 742 ROLL drive V gr oVe eus naines Geez bee o rete eese Rs 1 DC Leni nn 134 201 STAND OFF SUPPORT PC card 4 e CR Reid 097 421 TERMINAL pwr output red 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 fro
20. Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Regles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage 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 ex amin 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 Re searc
21. ON 2 INTRODUCTION n nnn nennen nn nn n n nnn 2 15 SpecifiCations sese OR DUREE ERREUR EM EN e 2 2 Duty Cycle And Overheating n s a anunua nenn r nennen 2 3 Volt Ampere Curves 2 4 Installing Welding Gun mm n 2 57 Installing Work Clamp ele RR RE ERE IU EI ERES EN eb eds 2 6 Setting Gun Polarity For Wire Type 2 7 Installing Gas Supply ars stets A Basar Hs ae 2 8 Installing Wire Spool And Adjusting Hub Tension 2 9 Changing Input Voltage From 230 Volts To 200 Volts 2 10 Electrical Service Guide 2 11 Selecting A Location And Connecting Input Power 2 12 Threading Welding Wire nannaa nananana SECTION 3 OPERATION 4 nie ER eu DSS en Bala COMO ii tage VAM NA NA NAAR RA NN a Mate kla 3 2 Weld Parameters sereine Rex x c x Y ere E xx RR een RENT uka SECTION A MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance ui ost us E spedito Re eR A ad 4 2 Circuit Breakers a rnst panana A e ERE E ee Pbi eia Edd 4 3 Replacing Drive Roll And Wire Inlet Guide 4 4 Replacing Gun Contact Tip 4 5 Cleaning Or Replacing P
22. POWER Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire TUN ETE E N WOOD 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 192 440 Page 15 SECTION 3 OPERATION 3 1 Controls 1 Wire Speed Control 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 3 2 3 Power Switch WIRE FEED SPEED olo BETA MIG 9950 i n amp WV THe XII o RATED OUTPUT GS KA vous 24 DO NOT SWITCH 200 UNDER LOAD VO LTAG NTROL DUTY CYCLE 60 MAX OCV 36 AMP RANGE 30 220 INPUT POWER OFF Ref ST 192 372 OM 192 440 Page 16 3 2 Weld Parameters WIRE TYPE WIRE MACHINE MATERIAL THICKNESS GAS SIZE SETTINGS 3 8 5 16 1 4 3 16 12GA 14GA 16GA 18GA 20GA 22GA FLOW RATE ms S je vor im je cam _ WRESBEED ios he rs In fo fe Ir Is 030 VOLTAGE p p p p p p p p BJ osmm WIRESPEED fes fes fse fo e fs Jz fe e p oss voma p e p p k p kb p k M osmm WIRESPEED o fes fse fso fa fo jo fo jo jo oa Woner
23. UTE DE L APPAREIL peut blesser e Utiliser anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn Y i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT T e Pr voir une p riode de refroidissement respec ius ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste se LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s 7 E e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes 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 pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage
24. WELDING PRODUCTS OM 192440A November 1998 Specifications Covered by this Manual 903 702 Processes Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding an Description mm Arc Welding Power Source and Wire Feeder BETA MIG 2250 OWNER S MANUAL 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 REGISTERED QUALITY SYSTEM b 4 worksite We ve made 77 installation and operation quick and easy With Hobart you can count on years of reliable service with proper WARRANTY maintenance And if for some reason the unit Working as hard as you E i do every power source Hobart is registered to the needs repair there s a Troubleshooting section from Hobart is backed by Ge Penn Quality System that will help you figure out what the problem SE warranty in the is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided Hobart Welders manufactures a full line of welders and welding related equipment For information on other
25. art1 WELDING PRODUCTS
26. at an authorized service facility as determined by manufacturer 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 MANUFACTURER 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 MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MANUFACTURER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the
27. bly Piecemaker 20 A iud des NJE 379 300 NOZZLE slip on assembly 1 oi IAS Ier Ed 379 587 TIPS contact 023 vit e e Re e p Ph Roe a e 1 E et 379 304 TIP contact 030 1 Era Renae 379 314 TIP contact 035 1 EE 4379 313 TIP contact Dina Ee AER Dan 1 RE MERE rt 379 596 DIFFUSER gas 1 Nr ne RE SEISCREW 6 32 1 8 nee einen brisa 2 zn D debi SAN 3793301 INSULATOR nozzle z i iiieiensc etes ele i mie nb ee T hee iere 1 seno ed ewe 177 483H TUBE gun assembly 1 e EE W10904 012 O RING LLLLL esse nennen 2 OM 192 440 Page 30 Item Part No No Description Quantity Figure 6 5 Gun And Cable Assembly Piecemaker 20 A Continued Lid Bate niet 177 480H FITTING cable 2 DE atenta teu utenti asi SETSGREW 1 4 20 1 4 sou etat area le yeh OG EG eR na 2 px 1 9 C 177504 cet GLAM ANO sunt hn ee ne tetas MEER S ede e 1 pind West 172481H NU cable ii ina whe en ENE Aa BE ces JE PH HS 2 Abad aet tn 177 272H NUT square 4 lO RAN 203 296 005 SCREW handle 4 vot AAA 177 275H HOOK gun suspension
28. ccording 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 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 Eq 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 192 440 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 MAGNETIC 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 a
29. djust hub tension see Section 2 8 Check circuit breakers CB1 and or CB2 and reset if necessary see Section 4 2 Replace contact tip if blocked see Section 4 4 Clean or replace wire inlet guide or liner if dirty or plugged see Sections 4 3 and or 4 5 Replace drive roll if worn or slipping see Section 4 3 Secure gun trigger leads in receptacle or repair leads or replace trigger switch see Section 2 4 and or see Parts List Check and clear any restrictions at drive assembly and liner see Section 4 5 Have nearest Factory Authorized Service Agent check drive motor OM 192 440 Page 21 SECTION 5 ELECTRICAL DIAGRAM E NND SIN s es EZ Nn9100ds 1 NOILdO NND OM Nn9 1004S SE F7 YOC OldWAJO Tu E 75 T Oe i dAY12 AYOM 897 AS de de de ve x gt WM Brs Ro Ro qu 3AUVO3N V V OV V 914 e o gs 5 Y ALSO ge si cou 029 glo S s r gt Z e E Fes jar MM E ios vod T NUS z o o Lod Y gt CH we Km E zio SPD zz O0 a 3 ES Gm z ZE lt 180 D a gt ze SITO GER lt 9 104 gt Ka 6 TS i 1 105 z u _ a 12 92 GS lt ZOU gp Bo LR s avis ZAL aag Ld po 8 2 4 K 7 798 5 z OS 77 T v ER V E i mez NOD Le 5 Tad 2 oo gt i P D 282 LU tr I ff vo 915 Luo 96 cou T 69 Z
30. earch 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 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 192 440 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 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 first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles identifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif a la s curit 1 2 Dangers relatifs au soudage l arc A Les s
31. es for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keepaway from moving parts such as fans gt e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors 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 compatib
32. es ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer 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 LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent 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 affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser 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 excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support
33. etal etc OM 192 440 Page 17 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance e gt gt ESSO A Disconnect power before maintaining 3 Months Replace unreadable labels 6 Months Blow out or vacuum inside During heavy service clean monthly WARNIN N E I Clean and tighten weld terminals A vit Repair or replace cracked weld cable e Remove drive roll and apply light coat of oil or grease to drive motor shaft OV 39 AE Y 4 2 Circuit Breakers 2d A Turn Off unit 1 Circuit Breaker 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 Circuit Breaker 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 circuit breaker Close door Ref ST 802 285 OM 192 440 Page 18 4 3 Replacing Drive Roll And Wire Inlet Guide a Tools Needed 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 Drive Roll Install c
34. h 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 lectriques 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 con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 192 440 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INTRODUCTION 2 1 Specifications Max Open Amps Input at Rated Output 50 or 60 Hz Single Phase Circuit Rated Output Voltage 200 V 23
35. iecemaker 20 A Gun Liner 4 6 Welding Troubleshooting Table 4 7 Wire Drive Gun Troubleshooting Table SECTION 5 ELECTRICAL DIAGRAM sus SECTION G PARTS LIST ee Re a ias WARRANTY WOW A au ua oon SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 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 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 4 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 a 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 I
36. lacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles uses endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour som nd fre 5 97 AEN Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact
37. le 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 If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 192 440 Page 3 1 5 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 res
38. m your local distributor OM 192 440 Page 27 5 Hardware is common and not available unless listed Y d Q KR E Ai A ST 802 283 Figure 6 3 Rear Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 6 3 Rear Panel w Components Fig 6 1 Item 10 is li eite rete 049 399 NUT 312 18 push on 1 Dmm 148809 FAN 9 in 5wg 34 deg 1 iO inm M 188706 MOTOR fan 230V 50 60 Hz 1 Ur 188 709 WINDTUNNEL Qin 2 1 E Up MO 125 785 VALVE 24VAC 2way custom port 1 E ve sip EI V REN 143 810 s PANEL reaf nee een eb E as ace EE RS 1 EE EE 193 063 BRACKET support tank 1 E rinde laur 188 441 CHAIN safety 1 Eee 605 227 NUT 750 14 knurled 1 CIO ster Res 178 126 CONN clamp cable 1 To maintain the factory original performance of your eguipment use only Manufacturer s Suggested Replacement Parts Model and serial number reguired when ordering parts from your local distributor OM 192 440 Page 28 m 11 8 Bee o E O A Ba We un
39. ment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 5 97 e A PF i 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 e f earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine 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 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 after removal of input power on inverters 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 ga
40. n 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 Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit 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 e Turn off all equip
41. orrect drive roll for wire size and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Ref ST 801 875 4 4 Replacing Gun Contact Tip AE Tools Needed EF C ee 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 Reinstall nozzle Ref ST 801 987 OM 192 440 Page 19 4 5 Cleaning Or Replacing Piecemaker 20 A Gun Liner de Contact Tip p gt Insulator Nozzle hae Adapter a x Head Tube S Remove nozzle contact tip and adapter 7 16 in Y Lay gun cable out straight E before installing new liner A Disconnect gun from unit Tools Needed Se IL 7 16 in ie 1 16 in Loosen setscrew in quick connect plug It may also be necessary to loosen setscrew in adapter Quick connect Plug Remove liner Blow out gun casing To Reassemble Gun Inspect o rings for chips or cuts be fore inserting new liner A light lu brication on the o rings will make liner installation easier Insert new liner Push liner against quick connect plug and tighten setscrew s Cut liner off so that 7 16 in 11 mm 1 32 in 8 mm sticks out of head tube Install adapter contact tip insula tor and nozzle Ref ST 802 290 OM 192 440 Page 20
42. placement Parts Limited Warranty shall not apply to 1 Items furnished by manufacturer but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 2 Consumable components such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 3 Equipment that has been modified by any party other than manufacturer 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 MANUFACTURER S 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 manufacturers option 1 repair or 2 replacement or where authorized in writing by manufacturer in appropriate cases 3 the reasonable cost of repair or replacement at an authorized 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 manufacturer s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B
43. pproved 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 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 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A k FIRE OR EXPLOSION hazard 4 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
44. quality Hobart products contact your local Hobart distributor Med d bera anual contact your local to receive the latest full line catalog or E ECH ve can also su iti individual catalog sheets To locate your nearest Welding SE E distributor or service agency call 1 877 Hobart1 Hobart offers a Technical Manual which provides more detailed service and parts information for your such as SMAW GTAW GMAW and GMAW P WELDING PRODUCTS TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 SymbolUsage 0 os ceeds uuum desserte audi 444 aa xk gu PA da 1 2 Arc Welding Hazards eee mn nn 1 3 Additional Symbols for Installation Operation and Maintenance 1 4 Principal Safety Standards 1 5 EMF lntormatjOHi 3 ead ai NE z NA ae lage SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles 5 SN Rx nr en 1 2 Dangers relatifs au soudage l arc 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 4 22 ee Dem pes emnes m e ERI ERE RR Pee EET Ke dre 1 4 Principales normes de s curit 1 5 Information sur les champs lectromagn tiques SECTI
45. ses 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 exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers 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 if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 192 440 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 Weara welding helmet fitted with a proper shade of filter to protect yo
46. stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres cir cuits 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 cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Z Risgue D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CH
47. t de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer 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 e V rifier f quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remp
48. tection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un PS 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 tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l au
49. that fail due to such defects in material or workmanship Manufacturer must be notified in writing within thirty 30 days of such defect or failure at which time manufacturer will provide instructions on the warranty claim procedures to be followed Manufacturer 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 the distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Robots Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Motor Driven Guns Process Controllers Water Coolant Systems HFUnits Grids Spot Welders Load Banks SDX Transformers Running Gear Trailers Field Options NOTE Field options are covered under the limited warranty for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6Months Batteries 5 90 Days Parts and Labor MIG Guns TIG Torches Plasma Cutting Torches Remote Controls Accessory Kits Re
50. tre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancherle c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser les yeux e Lesoudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage gen rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 192 440 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessur
51. ur 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 and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection Z 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 Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material 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 e 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 are properly prepared a
52. y e b ja ja b kb 12MM WIRESPEED eo oo jo se fa fo fs fo o pome B p bp p BET P UH fo fes s fo fo ja jas z E 708 6 oo Wome p e p ja p p p p h rop osmm _ WIRESPEED roo fes fr o feo j fe je jo je co2 fos voma v e ja je b k p p 20CFH au WinEsPEED sz 70 fo fs jas jo je fo jo o ms VOLTAGE y e p p p p 2 pP 12MM WIRESPEED jeo ss RR fe Ja fo jpa _ os Wome 5 p p p p I p osmm WRESPEED fso fse fso fo Jo fo p erir os os VOTAGE e p p p p p I FLUXCORE oomm _ WIRESPEED so fao fe fo jo fo jo jo ms VOTAGE 5 6 p p p p PT 12MM _ WIRESPEED je Ja jo Ja jo p TP _ enas os omae 7 p p e b p JJ FLUXCORE Wa WRESPEED so ze z fe fo js _ 7SARI2SCO2 045 voumce 7 7 7 Je 5 je aen Ja WIRESPEED ro fe fo 5o je 8 eo os vou PF fe po e STAINLESS oswu WIRESPEED fpo fo fo Ja 90 HE ox VOLTAGE le 5 Ja b b z em ap osmm WIRESPEED jeo 72 60 88 fo fe 25 002 fos VOTAGE p je p p p p p z 20cFH Ja wRESPEED fs fo fo fe fe fs fo p LT 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 m
53. ymboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants pum UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce e
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