BETA-MIG 2510 - Hobart Welders
Contents
1. OM 185 158 19 4 3 Unit Overload If unit is used beyond capacity excessive wire feed shorted output etc wire feeds but is not energized Release gun trigger to reset this condition 4 4 Aligning Drive Rolls and Wire Guide E 2 Ref ST 800 412 A A Turn Off power Correct Incorrect View is from top of drive rolls look ing down with pressure assembly open Allen Wrench Supplied Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire 6 Drive Gear Insert wrench and turn screw in or out until drive roll groove lines up with wire guide Tools Needed Close pressure roll assembly 3 16 in Close door BB 4 5 Troubleshooting poe Near 3 7 LS Trouble Remedy No weld output wire does not feed Be sure line disconnect switch is On see Section 2 12 Replace building line fuse or reset circuit breaker if open see Section 2 12 Reset circuit breaker CB1 see Section 4 2 Secure gun trigger connections see Section 2 5 Check and replace Power switch if necessary Have Factory Authorized Service Agent check all board connections and main control board No weld output wire feeds Thermostat TP1 open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 2 2 Connect work clamp to get good metal to metal contac2. 1 do 184 737 WHEEL Prior to KH400282 2 vase erates 090 693 WHEEL Eff w KH400282 2 A ne 184 745 PIN cotter Prior to KH431446 2 Pei Owe A sa E 121614 RETAING ring Eff wKH431446 2 ene Qt viata yee 184 664 2 PANEL side rene ee ee 1 28 SR1 173713 RECTIFIER SCR main consisting of 1 aO 166 667 CLAMP spring thyristor 1 30 TP2 154 244 THERMOSTAT NO 442 1 EEES is n pneus 143 818 THYRISTOR SCR 500A 300V 2 Nc 143852 FOOT mtg rectifier 2 PT 24154243 oire THERMOSTAT NG ee sais Pere bite pues 1 94 C3 4 031 689 CAPACITOR cer disc 01uf 1000VDC 2 pe D Seis inis 179 714 2 GEAMDP thyristor rc AS ee eee ERE i ROGO neuere d rd Re uas 1 PBC abel as 184736 4 CASTER sus rune RTS Gat aia as 146149 5 GABLE WOrk vw piu n aad SUO deerat 190 750 GLAMR WOFK reti oe DOR IER mor rt PEE 185 198 3 4 KIT driv toll 1 2 e een dd b
3. 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 MERCHANTABILITY AND FITNESS Within the warranty periods listed below manufacturer will repair or replace any warranted parts or components 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 P
4. 1 tae ae TP1 121497 THERMOSTAT NO 1 na dO cest ons ra Fig 6 2 CENTER BAFFLE w COMPONENTS 1 A 148809 BLADE fan 9 000 5wg 34 deg w mtg hardware 1 12 FM 148808 MOTOR fan 230V 50 60 2 1 APT Gig Aan cake 184671 WINDTUNNEL 0 I He mee 1 TE IP 184658 4 PANEL rear nn ans BE dere rear dud era eI durent fS RI ete 1 RER SEEN 1846605 v BRACKET glee eines nbe ehe nel 1 EK Rare 184 746 CHAIN safety 1 17 PLG20 144 085 CORD SET 250V 1 RAE LCS MEE 178 126 CONNECTOR clamp cable 1 sas 1955 GS acs 125785 s VALVES 2AVAGS rer ruth ne Dr de nace See aie E PRES ee 1 iss ae 134 464 LABEL warning general precautionary 1 C HRS 184 660 WRAPPER ASSEMBLY 1 Med e 184 715 BRACKET bottle retainer 1 BRE 184656 2 BASE an unten an AW A oe 1 sx euis REA 184 744 AXLE Prior to KH431446 1 NP TEE 186 879 AXLE Eff w KH431446
5. 1 22 VR1 144425 VARISTOR oooccccococccccc ue nennen nennen 1 moda bue Lt 494 613 TERMINAL pwr output black 2 24 C7 8 186014 CAPACITOR ASSEMBLY 2 25 RC1 184 734 BUSHING terminal 2 position 1 wi sesh uss C9 185013 LEAD ASSEMBLY elect 1 RE re C10 185012 LEAD ASSEMBLY elect 1 Fig 6 3 WIRE DRIVE ASSEMBLY 1 piis te deu re 134201 STAND OFF SUPPORT PC card 4 IZ a v 144 933 DOOR access changeover 1 i PEE 021469 LABEL danger high voltage 1 m PLG7 083526 CONNECTOR amp SOCKETS 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 185 158 27 6 3 Wire Drive Assembly Fig 6 2 Item 26 ST 801 793 x Hardware is common and not available unless listed 2 e 21 20 PA ltem Dia Part
6. CIRCUIT BREAKER man reset 1P 4A 250VAC 1 dd i ae 184667 BAFFLE 1 12 C5 161930 CAPACITOR ASSEMBLY consisting of 1 ud grasses 092 186 STRIP mtg capacitor 2 vxo dA bes iet 082902 STRIP mtg center capacitor 1 HMS VON ee nee 156517 CAPACITOR elctit 15000uf 8 EET 083 147 GROMMET scr No 8 10 6 16 PC1 184316 CIRCUIT CARD control 1 nr 115 094 CONNECTOR amp SOCKETS Included w rectifier 1 T PLG4 131052 CONNECTOR amp SOCKETS 1 Rates PLG5 131 056 CONNECTOR amp SOCKETS 1 e Kennel PLG6 115092 CONNECTOR 8 SOCKETS 1 17 R1 119998 RESISTOR WW fxd 300W 5 ohm 1 038 618 LINK jumper 2 19 TE1 158 406 TERMINAL ASSEMBLY pri 1ph 3V 1 0110199 TUBING e tee vehe ieu re mee meters oe ere ne 2 21 CR1 006 393 RELAY 24VAC DPDT
7. HOBART WELDING PRODUCTS OM 185 158A May 1997 Eff w Serial Number KH438994 Specifications Covered by this Manual 903 533 903 562 903 563 Processes Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding an Description El EN Arc Welding Power Source and Wire Feeder BETA MIG 2510 OWNERS MANUAL 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 Een 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 i
8. le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya 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 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 morte
9. 185 158 17 3 3 Installing Receptacle Module for use with a Spool Gun Optional PA 1 Knockout Panel Pierce front panel label at corners of knockout and follow groves in front panel The knockout is held in place by a thin metal section half way down each side Be sure to cut label across metal sections before removing knockout to avoid tear ing the label 2 Module 3 Plug PLG9 4 Receptacle RC2 Locate receptacle RC2 in unit wir ing harness Connect plug PLG9 to RC2 Slide module in and secure with supplied screws 18 ST 801 869 Tools Needed J OM 185 158 4 Maintenance and Troubleshooting 4 1 Routine Maintenance e E A Disconnect power before maintaining 3 Months Replace unreadable labels WARNIN y Repair or replace cracked weld cable CF Il Clean and tighten weld terminals A vi EA Blow out or vacuum inside During heavy service clean monthly 6 Months 4 2 Circuit Breaker CB1 gt m 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or Lar om kinks 3 Wire Drive Assembly 9 Check for jammed wire binding 2 drive gear or misaligned drive rolls Allow cooling period and reset HO breaker Close door NI H T Y E o Ref ST 801 789
10. 19 0 18 0 17 0 045 Feed Speed 33 30 28 26 24 21 19 12 10 Mild Steel Volts 29 5 290 290 285 265 98 Ar 2 O2 035 20 cfh Feed Speed 65 64 64 60 54 Volts 24 0 23 5 23 5 22 5 22 5 22 5 22 0 20 5 030 EP Feed Speed 63 56 47 42 38 34 28 23 bi Volts 26 0 25 0 24 0 24 0 22 5 21 5 21 5 21 5 20 0 19 5 035 Feed Speed 67 60 53 45 39 32 26 20 14 12 Stainless Steel Volts 285 275 265 255 250 98 Ar 2 O2 035 20 cfh Feed Speed 64 60 56 50 48 Volts 16 0 15 0 14 0 13 0 12 5 12 5 12 5 030 Feed Speed 30 26 20 12 11 9 9 Flux Cored Volts 16 0 14 5 13 5 13 0 12 5 12 5 12 5 E71T GS 035 No Gas Feed Speed 20 12 10 7 5 2 0 Volts 19 0 18 5 18 0 16 5 15 5 14 5 14 0 13 5 045 Feed Speed 22 20 16 12 10 9 7 0 035 Feed Speed 58 50 41 36 33 33 i Flux Cored Lo Volts 26 0 25 5 255 250 245 240 E 20 cfh 045 Feed Speed 33 28 26 21 20 19 Volts 25 5 24 5 24 0 21 5 20 0 19 5 035 Flux Cored CET Feed Speed 73 65 46 36 33 30 75 Ar 25 CO2 Volts 25 5 25 5 24 5 24 0 23 5 23 5 20 cfh 045 Feed Speed 33 28 26 21 20 19 Volts 26 0 25 0 24 0 22 5 21 0 16 0 15 5 ES Aluminum 5356 Argon 3 64 9 Feed Speed 70 64 58 50 36 34 31 OM
11. 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 OM 185 158 X MOVING PARTS can cause injury e Keep away from moving parts such as fans a 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 The user is 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 compatible e To reduce possible interference keep weld cables as short
12. 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 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 1 5 Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is no
13. er M Er M DET 1 an Bert 182 788 HOUSING adapter gun feeder 1 124 778 x KNOB aet a at x De aca x io 1 ren 173619 CARRIER drive roll w comp 1 zelus 174609 SCREW 4 7 x 12 soc hd 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 28 OM 185 158 Options and Accessories BETA MIG 2510 Olympic 30A Spool Gun 130 831 01 9 Ideal for aluminum welding jobs 200 Amp 100 duty cycle air cooled 1 Ib spool gun with 30 ft 9 1 m cable assembly Use with Spool Gun Module 043 084 Spool Gun Module 043084 Required if welding with spool gun Provides a convenient way for you to plug in an Olympic 30A spool gun Spool Shaft for Use with 1 and 2 Ib 4 in 102 mm Welding Wire Spools 204 550 15 ft 4 6 m Gas Hose 205 382 Double Gas Bottle Rack Kit 205156 001 OM 185 158 29 Notes Notes Notes
14. le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage 2 3 185 158 DES ORGANES MOBILES peuvent provoquer des blessures 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 Le rayonnement 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 lectroniq
15. ou un cran facial LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces 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 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 Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des
16. 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 ee 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 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 approved ear protection if noise level is high CYLINDERS can explode if damaged Shieldin
17. 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 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 FO
18. 23 lt lt RC6 7 RC3 15 gt gt 22_ COMMAND COMMON 29 1 E 24 RC4 2 5 M TER IN STD 0 lt RC6 3 MAN CONTROL RC4 n Scc E ee g RCS G Roa GAS CONT OUT R3 gt 4 lt lt RC6 8 RC4 PLC E B ES RC4 1 gt gt GAS CONTIN 5 cw PLG1 PLG2 A 8 lt RC6 2 Po eus RC3 2 55 22 EM REF OUT 5 op RC3 4 gt gt EM REF COMVON 83 c c 1 1 19 2 RCI BAL AED lt 2 lt y og IREGR t 1 ce co lt OM 1308 22 Notes OM 185 158 23 6 Parts List 6 1 Main Assembly ST 801 783 24 OM 185 158 Item Dia Part No Mkgs No Description Quantity AMICOS 185 321 LABEL set nameplate side decals 1 D ics sce acus 184670 RANDLE a lo E RE een els presea 1 ngog ns PET ss 167958 c ee na ee PE IE 1 4 81 124 511 SWITCH tgl DPST 40A 600VAC On Off 1 5 R23 035897 POTENTIOMETER CP 1 T 2W 1K linear Voltage Control Wire Feed Speed 2 Guise 194 733 KNOB ei sue ipee ate dni bated nde ede nes need e ied 2 di iet mene 184 894 PANEL front see ehe en beep pres ete pale UN ep 1 8 7012 143 892 STABILIZER i Reis bes EFL ee nae ad ines 1 9 11 174553 TRANSFORMER pwr main 200 230 460 consisting of 1 2 9 T1 174554 TRANSFORMER pwr main 230 460 575 consisting of
19. 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 693 2 1 1 8 5 8 in 2 8 Installing Drive Roll and Wire Inlet Guide wu 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touch ing Tighten screw 3 Anti Wear Guide Install guide as shown 4 Drive Roll Install correct drive roll for wire size and type 5 Drive Roll Securing Nut ST 150 227 C Tools Needed 5 64 in IT 7 16 in Et Turn nut one click to secure drive roll 12 OM 185 158 2 9 Installing Wire Spool and Adjusting Hub Tension DD ST 801 790 Small Spool Adapter ce A 9 16 in CB 2 10 Positioning Jumper Links i gt Ref ST 801 789 gt gt EST 200 VOLTS 230 VOLTS men MR When a slight force is needed to turn spool tension is set Check input voltage available at site 230 VOLTS 460 VOLTS 1 Jumper Links Access Door ARAR AM o Oro Open door 2 Jumper Link Label 460 VOLTS 575 VOLTS 3 Input Voltage Jumper Links P 9 5 A o of Move jum
20. No Mkgs No Description Quantity br le isos 172075 CARRIER drive roll w comp 1 ARA 166 072 SPACER g at ruca ii tee een ee el 1 RS RER Tere 174610 SCREW M 6 1 0 x 20 soc hd 3 173 620 BUSHING motor mtg 3 oa DP adit PI RS 010 224 2 PIN Spring cures a teeta eter LE UN awe Pre NEN ae ees 1 See eh 085 242 FASTENER pinned 4 2 1 mE 085 244 WASHER cupped 4 44 1 n MO10 23 SPRINGS OS sius ri geal ge tcx n RR Rt p Rr eh cx d at ara natin ge RACE 1 A e ae 085 243 KNOB adjust tension 1 im 166071 LEVER mtg pressure 1 up 079 634 PIN hingen ae MR IRR RODEO MCI CR ste asta MS 1 daos restes 151 828 PIN COENS ea crac ena i tnn dna ic tace P aci ar aa 2 dico En 184 234 HOUSING drive motor 1 Lusd4o PM 21 8435 MOTOR gear aca tec en ae EU aca a ec ed oid LR ec Ra Ig 1 iii 079 633 FITTING hose brs barbed nipple 1 Sex DOS edi i 184 235 INSULATOR drive assembly 1 Seed ec ste 145234 S STOB 6OVOI adus euet ee ELLAS EE
21. Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and 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 R gles 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 L extrait suivant est tir des conclusions g n rales du document intitul Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publi p
22. R 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 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 Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Eg Resources Available Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or
23. ar le Office of Technology Assessment du Congr s am ricain il existe maintenant d abon dantes donn es scientifiques compil es la suite d exp riences sur la cellule ou d tudes sur des animaux et des humains qui montrent clai rement que les champs lectromagn tiques basse fr quence peuvent avoir des effets sur l organisme et m me y produire des transforma tions M me s il s agit de travaux de tr s grande qualit les r sultats sont complexes Cette d marche scientifique ne nous permet pas d tablirun tableau d ensemble coh rent Pire encore elle ne nous per met pas de tirer des conclusions finales concernant les risques ventuels ni d offrir des conseils sur les mesures prendre pour r dui re sinon liminer les risques ventuels Traduction libre 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 vous 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 consignes mentionn es pr c demment font partie de celles desti n es aux personnes ayant recours un stimu
24. arts 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 Qrids 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 Replacement 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
25. dle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders 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 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 ee 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 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 Practices for the Preparation for Welding and Cut ting of Containers That Have Held
26. door for weld param 4 3 eters chart 3 Pilot Light 4 Power Switch ON INPUT POWER 1 40 19 21 24 2 30 70 16 26 20 80 14 28 10 90 12 31 0 100 10 32 WIRE FEED SPEED VOLTAGE CONTROL 16 OM 185 158 3 2 Weld Parameters S 185 221 Wire Type Wire Material Thickness Shielding Gas Diameter M usn And Flow Rate inch 9 3 8in 5 16in 1 4in 3 16 10ga 12ga 14ga 16ga 18ga 20ga 22ga 24ga Volts 20 0 19 5 19 0 18 0 18 0 18 0 17 5 17 0 17 0 023 Feed Speed 38 34 32 24 19 15 14 12 12 Volts 21 5 20 5 19 0 19 0 19 0 19 0 18 5 18 5 18 0 17 5 030 Mild Steel Feed Speed 45 36 27 26 19 15 13 11 10 9 ER70S 6 Am Volts 225 220 205 200 200 19 5 190 190 185 18 5 035 Feed Speed 40 33 30 27 21 21 16 12 10 8 B Volts 24 5 23 5 23 5 23 0 22 0 21 0 20 0 20 0 19 5 045 Feed Speed 27 25 22 19 18 17 15 11 10 Volts 19 5 19 5 19 0 18 5 18 0 18 0 16 5 16 5 16 5 023 Feed Speed 55 49 49 42 35 26 21 19 15 Volts 21 0 20 5 20 0 18 5 18 0 17 0 16 5 16 5 16 0 15 5 030 Mild Steel ER70S 6 Feed Speed 58 43 41 33 28 22 21 15 13 10 7596 Ar 25 CO2 Volts 21 5 21 5 20 5 20 0 19 5 19 0 18 5 17 5 17 5 16 5 20 cfh 035 Feed Speed 55 50 44 38 36 28 27 23 16 12 Volts 21 5 21 0 20 5 20 5 19 5 19 5
27. e At 250 Amperes 20 038 4 Minutes Welding 6 Minutes Resting Overheating ua hs Minutes OM 185 158 9 3 gt OL Reduce Duty Cycle 2 3 Volt Ampere Curves 1 Normal Volt Ampere Curves The volt ampere curves show the normal minimum and maximum voltage and amperage output capa bilities of the welding power source Curves of other settings fall be tween the curves shown 2 Overload Volt Ampere Curves When unit is used beyond capacity circuitry senses the overload and shuts down unit output Release trigger and lower weld voltage set ting before trying to weld This shut down circuitry protects internal circuits and parts from overload damage Approximate shutdown voltage amperage points shown for reference only 60 ssb1 1 10 91 SB 144 925 A S 0700 A 50 r 30 F DC VOLTS 20 F 10 50 100 150 DC AMPER ES DC VOLTS 2 4 Installing Running Gear QA Install running gear as shown 10 Tools Needed BS 200 DC AMPER ES 250 ST 801 856 A OM 185 158 2 5 Installing Welding Gun ar 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Ref ST 801 789 Loosen securing knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Leads Insert leads one at a time through small
28. e tme rtt nn ates din ADI een 185199 consumable Is ad 182137 REGULATOR FLOWMETER 000 cece eee eee nn A aa 144108 2 HOSE GAS 22 A Racer act seers eR a d er eae ate 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 185 158 25 6 2 Center Baffle w Components Fig 6 1 Item 10 Hardware is common and not available unless listed 22 21 20 26 ST 801 786 OM 185 158 Item Dia Part No Mkgs No Description Quantity bul xd net kcu 170 201 NUT retaining w warning label HOBART 1 Du idc 184 788 SPAGCEHB SDO0l crass packs ara E AES 1 il 374551 WASHER flat keyed 1 N S 184 739 SPRING cprsn cent nee 1 MES 405 448 WASHER friction 1 x mm 1984703 BRACKET uu Rn nie MER ais 1 ARR 405976 S HUBS sre mU Ima 1 i08 usse bs 374546 SHAFT spool support 1 184 666 REEL SUPPORT sssssssssssses es dues 1 10 CB1 123745
29. ead 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 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 your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 list
30. ed 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 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 according to AWS F4 1 see Safety Standards e Connect work cable to
31. en tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l 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 a e Pr voir une p riode de refroidissement respec v ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s y amp e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes 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
32. equipment manufacturers Transportation Department PRINTED IN USA Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams File a claim for loss or damage during ship ment
33. g 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 OM 185 158 1 3 Additional Symbols for Installation Operation and Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to han
34. grommet on front panel Con nect female friction terminals to matching male terminals in unit Polarity is not important Close door 2 6 Setting Gun Polarity for Wire Type gt CL Polarity Changeover Label Wire Drive Assembly Positive Output Terminal Negative Output Terminal hx Always read and follow wire manufacturers recommended polarity Close door Pop Ref ST 801 789 Shown As Shipped Set For Electrode Positive DCEP For Solid Steel Or Aluminum Wires GMAW Process Wire Drive Assembly Work Clamp Lead To Lead To Positive Negative Output Output Terminal Terminal GUN POLARITY CHANGEOVER CONNECTIONS Reverse Lead Connections For Electrode Negative DCEN For Flux Cored Wires FCAW Process Drive Assembly Becomes Negative S 185 249 Tools Needed IS 3 4 in OM 185 158 11 2 7 Installing Gas Supply i E Ref ST 801 789 Ref ST 149 827 B Ref ST 158 697 A 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
35. ire Spool 5 5 di NC 2 Welding Wire 4 3 Inlet Wire Guide e 4 Pressure Adjustment Knob 5 6 7 Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight Drive Roll gt f gt Tools Needed a Hold wire tightly to keep it from unraveling V 6in 4in 150 mm CIRE Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire A gt HH OFF ON INPUT POWER LI Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire A gt x 2 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 185 158 15 3 Operation 3 4 Controls ABW dhe 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The scale around the control is actual voltage See Section 3 2 or inside welding power source
36. irectives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles 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 5 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 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
37. issement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protection 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 Le
38. lateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails OM 185 158 2 Installation 2 1 Specifications Amps Input at Rated Output 60 Hz Single Phase Max OpenCir Rated Output cuit Voltage 200 V 230 V 460 V 575 V KVA KW 250 A at 28 VDC 200 A at 28 VDC 32 50 44 22 18 10 7 7 40 60 2 3 2 1 0 8 0 46 0 13 Wire Type and Diameter Wire Feed Speed Dimensions Weight Solid Steel Stainless Steel Flux Cored 50 670 IPM H 37 in 940 mm 198 lb 1 2 1 7 m min W 19 in 483 mm 89 kg 023 045 in 023 035 in 030 045 in D 30 1 4 in 768 mm 0 6 1 2 mm 0 6 0 9 mm 0 8 1 2 mm While idling 2 2 Duty Cycle and Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding Exceeding duty cycle can damage unit void warranty WELD AMPERES 20 so 40 50 60 6096 Duty Cycle At 200 Amperes 1 08 6 Minutes Welding 4 Minutes Resting duty1 4 95 SB 150 215 py eg L CORRE II mg EE EXE IT pps pr qp pps S OOS A D HE Pen el p d opp ns quse 70 80 90 100 DUTY CYCLE 40 Duty Cycl
39. ll equipment when not in use Do not use worn damaged undersized or poorly spliced cables OM 185 158 OM 185 158A 5 97 safety som 4 97 APA 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 Do not drape cables over your body 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 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 gases can be hazardous to your health Keep your h
40. ls S assu rer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants 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 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 e 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 blou
41. mment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble 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 us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps OM 185 158 lire avant safety som fre 4 97 APA 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 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 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 Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail
42. per links to match input voltage S 144 918 C S 144 916 A Close and secure access door Close door Tools Needed St Ce O 3 8in OM 185 158 13 2 11 Electrical Service Guide S 0092J Input Voltage 200 230 460 575 Input Amperes At Rated Output 50 44 22 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Am 80 70 35 25 peres Min Input Conductor Size In AWG Kcmil 8 8 10 12 Max Recommended Input Conductor Length In Feet Meters 93 28 124 38 329 100 313 95 Min Grounding Conductor Size In AWG Kcmil 8 8 10 12 Reference 1996 National Electrical Code NEC 2 12 Selecting a Location and Connecting Input Power ST 801 788 Fa Have only qualified persons make this installation 1 Rating Label Supply correct input power A 14 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 457 mm for airflow GND PE Connect First L1 L2 GND PE Size and ratings must comply with ap plicable codes Install conductors in conduit or equivalent into a deener gized line disconnect device see Section 2 11 OM 185 158 2 13 Threading Welding Wire a T Ref ST 801 789 S 0627 A 1 W
43. s 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 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 a
44. soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le 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 En cas 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 R TE 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 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
45. t Replace contact tip see Gun Owner s Manual An overload condition occurred Release gun trigger see Section 4 3 Have Factory Authorized Service Agent check main control board and main rectifier Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 12 Check input voltage jumper links and correct position if necessary see Section 2 10 Have Factory Authorized Service Agent check main control board Fan motor does not run NOTE Fan only Have Factory Authorized Service Agent check fan on demand circuit runs when cooling is necessary Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct size drive rolls see Section 2 8 20 OM 185 158 Trouble Remedy Readjust drive roll pressure see Section 2 13 Replace inlet guide contact tip and or liner if necessary see Gun Owner s Manual Check position of input jumper links see Section 2 10 Have Factory Authorized Service Agent check main control board No wire feed Reset circuit breaker CB1 see Section 4 2 Turn Wire Speed control to higher setting see Section 3 1 Clear obstruction in gun contact tip or liner see Gun Owner s Manual Readjust drive roll pressure see Section 2 13 Change to correct size drive rolls see Section 2 8 Rethread welding wire see Section 2 13 Check g
46. tements de protection secs ne comportant pas de trous e S isoler de la pi ce et 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 on risque de tomber e servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation 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 fr que
47. tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres 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 OM 185 158 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 5 Risque 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 alim
48. ue sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit 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 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
49. un trigger and leads Repair or replace gun if necessary Have Factory Authorized Service Agent check main control board Poor weld bead or welding wire is noodle welding OM 185 158 Check polarity setting for type of welding wire being used see Section 2 6 21 5 Electrical Diagram 5 1 Circuit Diagram for Welding Power Source SC 184 944 SIA TE 200V Sat oe em e 230V 450V Y 200v TP2 RECT y 9 24NAC 15 EN EON PLG7 VI 2 2 z lt REMOTE 10 OPTION TCU SPOOL GUN Res SS lt A POSITIVE DUTPUT STUD 4 lt a 2 2 lt 3 s 4 e DRIVE PLGS RC2 Y D 22222 I OHOUSNG El RCI x I Sa CB NEGATIVE 1 24VAC TCR E a 25 E d m PEN EDD RS ES RC2 LE E BE WORK 0 2 erc 3 5 CLAMP 8 RC2 825 2 lt F C4 y y C7 PC4 RC2 gt gt G a 0 o RC1 PLEN B RC2 P Go 2 1 fi lt H lt RC3 1 2 M cer lt lt lt RC3 12 9 F 1 1 AED lt rc2 3 RC4 5 gt i lt 02 T 1 gt gt OV REF OUT 32 i i AD lt lt RC2 4 RC3 16 gt gt VOLT COMMAND IN tn a D gt 1 gt MT lt 2 1 RC3 3 E FM COMMAND N um
50. w a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 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 the 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 The above procedures are also recommended for pacemaker wearers Consult your doctor for complete information OM 185 158 1 Consignes de s curit utilisation 1 1 Signification des symboles 4 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 d
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