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Hobart Welding Products 175 Welder User Manual

1. 22 SECTION 6 MAINTENANCE 5 24 6 1 Routine Maintenance 24 6 2 Overload Protection 44 are sata date dade ferr xdi date gage duis 24 6 3 Drive Motor Protection 2555 sente faded ape te mx REX tes tex RAE Re als 24 6 4 Changing Drive Roll Or Wire Inlet Guide 25 6 5 Replacing G n Contact Tip A TA RE dent 25 6 6 Cleaning Or Replacing Gun 26 6 7 Replacing Switch And Or Head 27 6 8 Troubleshooting Table 2 3 sis oye tate tage pe PR RR DER dates te ERA be RES Agee be 28 SECTION 7 ELECTRICAL 29 TABLE OF CONTENTS SECTION 8 WELDING GMAW GUIDELINES 31 8 1 Typical MIG Process Connections 31 8 2 Typical MIG Process Control Settings 32 8 3 Holding And Positioning Welding Gun 33 8 4 Conditions That Affect Weld Bead Shape
2. 34 8 5 Gun Movement During Welding 35 8 6 Poor Weld Bead Characteristics 35 8 7 Good Weld Bead Characteristics 35 8 8 Troubleshooting Excessive 36 8 9 Troubleshooting Porosity 36 8 10 Troubleshooting Excessive Penetration 36 8 11 Troubleshooting Lack Of Penetration 37 8 12 Troubleshooting Incomplete 37 8 13 Troubleshooting 2 2 37 8 14 Troubleshooting Waviness Of Bead 38 8 15 Troubleshooting Distortion 38 8 16 Common MIG Shielding Gases 39 8 17 Troubleshooting Guide For Semiautomatic Welding Equipment 39 SECTION 9 PARTS LIST 225422420560 buse x EIER shan dere thie iceet kar 42 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 S
3. Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of 0 to 15 degrees 8 13 Troubleshooting Burn Through Burn Through weld metal melting c
4. Turn Off power before E replacing contact tip 1 Nozzle Tools Needed gt lt 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Ref 802 399 A Return To Table Of Contents OM 944 Page 25 6 6 Cleaning Or Replacing Gun Liner 2 Disconnect gun from unit Head Tube Remove nozzle contact tip adapter gas diffuser and wire outlet guide 20 22 Lay gun cable out straight before installing new liner lt Blow out gun casing A Tools Needed CX lt gt 2 8 mm 10mm 10 mm To Reassemble Gun Insert new liner Install wire outlet guide so that 1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tight en two full turns more Cut liner off so that 3 4 in 19 mm Sticks out of head tube Install gas diffuser adapter contact tip and nozzle Ref 802 446 OM 944 Page 26 Return To Table Of Contents 6 7 Replacing Switch Head Tube G D A Turn Off welding power source wire feeder and disconnect gun 1 Remove handle locking nut gt 3 Slide handle o 2 Remove switch housing Install new switch and connect leads polarity is not importan
5. 1 peu DOE pene 196 007 PANEL front black 1 99 010368 CLAMP work 1 196 619 CABLE work 1 196 575 SWITCH rocker SPST 115 VAC model 1 Return To Table Of Contents OM 944 Page 43 Dia Part No Mkgs No Description Quantity Figure 9 1 Main Assembly Continued E ET 196 574 SWITCH rocker DPST 230 VAC model 1 207 078 KNOB pointer 5 1 de 207 079 KNOB pointer voltage 1 202708 MOTORH gear REN EGCA RR 1 ES 193189 CONNECTOR 1 24440 rete cope 196 654 SCREW thumb 1 UR ee eee ee ee 196 009 FITTING gas barbed 1 ee 202 925 ROLL feed 024 030 035 in 1 5540 eats 194 508 HEAD feed 1 c 203025 GUIDE wire 1 ee eee ee me 209 228 LABEL weld cha
6. M N i x 5 9 o 9 8 g 2 g Y m 5 5 amp J H 41 R2 4 CR2 CRI AH 718 31 P22 3 RC22 3 801 1 5 Q 5 z P22 4 RC22 4 52 gg 1 2 RES 27 gt P21 2 RC21 2 5 gg RCI 6 cs 07 MOTOR Lx P21 1 RC21 1 A RC1 3 CONTROL RC2 4 24 gt gt lt CIRCUIT T 4 po J4 RC1 4 51 424 BUN 6 rer lt qo N SWITCH 35 RC1 5 es lt gt lt N RC14 e 1 lt Ret 1 194 325 Diagram 230 VAC Model Return To Table Of Contents Ircul Figure 7 2 C OM 944 Page 30 SECTION 8 MIG WELDING GMAW GUIDELINES noa rf 8 1 Typical MIG Process Connections Regulator Flowmeter Shielding Gas Gas Hose Wire Feeder Power Source 0000 0 Return To Table Of Contents Work Clamp Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Workpiece light mig 5 967 Ref 802 445 B OM 944 Page 31 8 2 Typical MIG Process Control Settings NOTE gt specifications These settings are guidelines only Material and wire type joint design fitu
7. 944 196 639G October 2003 HOBART Processes SO WELDER S Description Arc Welding Power Source Wire Feeder Handler 135 175 And H 10 Gun OWNER S MANUAL Visit our website at www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Ic M i you may need to fix the problem Warranty and from Hobart is backed by i i i the best warranty the System Standard service information for your particular model y business are also provided I0 9001 2000 QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local
8. OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them 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 Return To Table Of Contents SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles A identifie un message de s curit particulier Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole
9. 81 lt 7 XI Lyd pal POSITIVE y P a O Le tt 1 L EEI 1 m 9 CVV O x S _ i NEGATIVE 651 RI RC22 2 RC22 1 2 P22 20 2 20 1 P22 2 P22 1 N RC20 2 N RC20 1 Xx x x 8 of n 5 EY RER RAR lt a g 5 8 N T o g a d E 8 g o g R2 CR1 Te o V M N E g Nm x T O N 37 RC1 1 RC2 3 t lt 5 gt 42 gg RCI 2 ons 8 ou J6 6 E l RC2 4 b ALK MOTOR 47 gg RCI S CONTROL 4 CIRCUIT NS J4 RC1 4 l S oa 1 Q lt gt 5 fe RCI S Le f a RC14 1 lt RC 194 324 C t Diagram For 115 VAC Model Return To Table Of Contents Ircul Figure 7 1 C OM 944 Page 29 ALD lt RIBBED GRN m CB1 3l SR1 Ls Bu o D KI 52 NI P 21 POSITIVE O Eugen E ee L c1 4 TITI QO i NEGATIVE 651 R1 P20 2 P20 1 RC22 2 P22 2 N RC20 2 Rc20 1 X N N 3 5 5 S 1 ml oa
10. 1 we 169 738 locking handle 1 ee ee 169 719 lt s eR IHRE 1 079 975 O RING 187 ID x 103CS rbr 1 Tam 194010 LINER monocoil 023 025 wire x 15ft consisting of 1 TE EE 194011 LINER monocoil 030 035 wire x 15ft consisting of 1 mcm 194012 LINER monocoil 035 045 wire x 15ft consisting of 1 9 D do onde 194 014 LINER monocoil 4 64 AL wire x 10ft nyl consisting of 1 TEL 197 123 O RING 312 ID x 062 70 Dura BUNA N 2 acacia atts 196 255 SWITCH trigger 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 9 3 Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PART NO INCHES mm 202 925 024 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 9 4 Options PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 Ib 45 kg 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg 19
11. 1 Rating Label Supply correct input power 2 Plug NEMA 6 50P 3 Receptacle NEMA 6 50R Connect plug to receptacle 4 Line Disconnect Device See Section 4 8 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 457 mm of space for airflow Always connect grounding conductor first GND PE 230 VAC 1 v Do not move or operate unit where it could tip ssb2 2 1 94 802 443 A Ref 802 085 OM 944 Page 16 Return To Table Of Contents 4 8 Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In AWG Kcmil 14 Max Recommended Input Conductor Length In Feet Meters 66 20 Min Grounding Conductor Size In AWG Kcmil 12 Reference 1996 National Electrical Code NEC S 0092 J 4 9 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set T Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only with 8 in 203 mm spool only Tools Neede
12. 23 0 m min At No Load 030 035 in 150 850 IPM 3 9 22 1 m min Feeding Wire 0 8 0 9 mm Return To Table Of Contents OM 944 Page 9 3 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 A 115 VAC Model opens output stops and cooling fan runs Wait fifteen minutes for 200 unit to cool Reduce amperage or duty cycle before welding 135 Exceeding duty cycle 100 damage unit or gun and void 80 warranty o 5 60 40 lt 5 5 20 10 1 2 4 6 810 20 40 60 80 100 Duty Cycle 20 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B 230 VAC Model 200 130 100 5 80 60 40 5 5 O 20 10 10 20 30 40 50 60 70 80 100 Duty Cycle 80 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz N 3 Minutes Welding 7 Minutes Resting Overheating 0 Aor V M p OR Reduce Duty Cycle Minutes duty1 4 95 196 617 196 618 OM 944 Page 10 Return To Table Of Contents 3 3 Volt Ampere Curves A 115 VAC Model OUTPUT VOLTS 30 0 25 01 20 0 15 0 10 0 5 0 0 0 The volt ampere curves show the minimum a
13. OM 944 Page 40 Return To Table Of Contents Notes Return To Table Of Contents OM 944 Page 41 SECTION 9 PARTS LIST Hardware is common and not available unless listed 22 N 802 449 E Figure 9 1 Main Assembly OM 944 Page 42 Return To Table Of Contents Dia Part No Mkgs No Description Quantity Figure 9 1 Main Assembly sean Wl T 199566 DOOR 1 pane Sous eade ss 196 006 HINGE door as eee ee dae eed 2 211 987 clone 1 204 608 NUT RH ded REE RE RR ee eee eee eR 1 202998 SPRING Cprsn 1 fee OF EL ege oodd 203072 WASHER flat Er xe DURER EE DRE ER 1 pM To Tc 211 339 HUB SPOOL 1 202 726 ADAPTER spool hub 1 d Er 195886 CIRCUIT CARD ASSY control 115 VAC model 1 2900 perds 195 887 CIRCUIT CARD ASSY control 230 VAC model 1 195 999 BASE 1 1 d sirer e 210109 CIRCUIT BREAKER 25 amp 1 xp 196 467 TUBING PVC
14. 187 ID x 312 OD 24 000 1 116 996 VALVE gas 115 VAC model 1 128 751 VALVE gas 230 model 1 diese 197 198 CABLE TIE 700 799 bundle dia 2 147 545 CORD SET 125V 5 15P 14GA 3 C 78 SPT 3 jkt 115 VAC model 1 MEL a 152 118 CORD SET 250V 6 50P 12GA 3 C 7ft SPT 3 jkt 230 VAC model 1 111443 BUSHING strain 1 plc 605227 NUT gas vale EE RE UR CERO NER RE ODER 1 pix 196 063 MOTOR fan 115 VAC model 1 EL 196 064 MOTOR fan 230 VAC model 1 ze isis 409 953 001 BLADE fan cooling 1 monui ne 194 268 TRANSFORMER power assy 115 VAC model 1 ser 2 we 194 277 TRANSFORMER power assy 230 VAC model 1 MUERTO ER 208015 HANDLE 0 1 ER 196 005 lt WRAPPER ER RIDERE AER 1 E 204 036 LABEL warning 1 avid A E 203 491 CLAMP capacitor 1
15. 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 0 15 4 90 90 4 End View of Work Angle Side View of Gun Angle GROOVE WELDS 45 0 1 5 17 459 N N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A Return To Table Of Contents OM 944 Page 33 8 4 Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage 10 laeeem 0 3 Push ie gt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT Ae Le LE Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT nn Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 944 Page 34 Return To Table Of Contents 8 5 Gun Movement During Welding NOTE gt Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area one pass of the electrode 3 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side
16. AU MI 193 039 CAPACITOR 5300041 115 VAC model 1 uain ee 193 040 CAPACITOR electrit 100000uf 230 VAC model 1 203 868 REACTOR ASSY 115 VAC model 1 asd oh hl es 203 874 REACTOR ASSY 230 VAC model 1 peopel EP 193 191 RECTIFIER ASSY 115 VAC model 1 ex 193 316 RECTIFIER ASSY 230 VAC model 1 EE 198 585 PLATE support 230 VAC model only 1 193 193 BUS BAR positive 1 CUTE 196000 BAFFLE 1 pat Al res 405 576 001 BUSHING 1 mp 193 144 INSULATOR output 1 ad obe cepe bal Be 193 194 BUS BAR negative 1 199 824 LABEL warning 1 E Em 194201 STAND OFF e see ne 1 Let gap RES 409 477 SWITCH rotary 25A 5 position 1 Of otiose tni 194513 POTENTIOMETER Rib LER Red eden 1 Gu d pe ERES 196 129 PANEL front purple
17. The most commonly used shielding gases are listed in the following table Application Spray Arc Steel Short Circuiting Steel 2 Aluminum Argon X Argon 25 X 80 or greater Argon X balance CO or Oxygen 100 X Tri Mix X 1 Limited short circuiting use 2 90 HE 7 1 2 2 1 2 CO 8 17 Troubleshooting Guide Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure on wire feed rolls Increase pressure setting on wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch
18. And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric 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 944 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org
19. EX D S 0054 A 8 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration BB ND S 0053 A 8 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 1 3 Moderate Crater During mM Welding Weld new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 NoOverlap 5 Good Penetration into Base Metal B 5 S 0052 B Return To Table Of Contents OM 944 Page 35 8 8 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that DERNIERS cool to solid form near weld bead 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner 8 9 Troubl
20. Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL US
21. Material Wire Type Suggested Diameter and Shielding Gas of Wire Polarity Setting 20 30 cfh Flow Rate Being Used Being Welded Steel Flux Core No Shielding Gas Required 030 0 8 mm E71T 11 Good for Windy or DCEN Outdoor Applications 035 0 9 mm Solid Wire C25 Gas Mixture 024 0 6 mm ER70S 6 75 Argon 25 CO2 DCEP Produces less Spatter 030 0 8 mm Better Appearance Solid Wire 024 0 6 mm ER70S 6 100 CO2 DCEP 030 0 8 mm Stainless Steel Stainless 024 0 6 mm Steel Tri Mix DCEP 90 He 7 5 Ar 2 5 2 030 0 8 mm Aluminum Aluminum 100 Argon 030 0 8 mm DCEP Match feedroll groove to diameter of wire being used CAUTION Set Tension Knob Setting to 3 at Start Do not change Voltage Switch Adjust tension per instructions the manual Knob position while welding Aluminum wire is relatively soft so feedability is not as good Make sure that hub tension is not too tight and OM 944 Page 20 Return To Table Of Contents for 115 Volt Wire Welding Package Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded CHANGING Number Left of Slash 15 Voltage Setting Number on Right of Slash 15 Wire Feed Setting POLARITY 22 gauge 1 8 inch 3 16 inch Electrode Negative 8 mm 3 2 mm 5 For Flux Core Wire ppp Positive For Sold we Wire Sp
22. below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e 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 gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use 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 cons
23. faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apr s ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants 5523 LES DECHARGES ELECTRIQUES peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension 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 Tout mat riel mal install ou mal mis la terre pr sente un danger Ne jamais toucher aux pi ces lectriques sous tension Porter des gants et des v tements de protection secs et exempts de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre e Ne pas se servir d une source de courant
24. 5 957 H 10 Replacement Gun 10 ft length 030 035 wire size NOTE If individual parts are required see Parts List chapter of this manual for part number to order Return To Table Of Contents OM 944 Page 45 Notes Warranty Questions Call 1 877 1 for your local Hobart distributor Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way HOBART gt WELDERS HOBART EL WARRANTY Effective January 1 2003 5 311 WARRANTY applies to all Handler 125 135 and 175 models Airforce 250 250A 375 400 and 625 models and Champion 4500 and 10 000 models Beta Mig 1800 Champ 1435 2060 8500 models Ironman 210 and 250 models Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial No KK200262 and newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobar
25. AFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 4 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 Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away re ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from wo
26. ERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPL
27. Hobart distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 877 Hobart1 6a THO Hob_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 113 2SYMbOUVWSAGE s oe E e oe PE ERE E ne ms 1 T2 Are Welding Hazatds on hee vut er ce ae ee edt TE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 150 JEME Intormaltions ten Ent e M ost dul sec n 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 SPECIFICATIONS c est ets dink em
28. IED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province hobart retail 8 03 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For techn
29. R L EQUIPEMENT lt e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage Ne pas obstruer les orifices ou filtrer l alimentation en air du poste soe LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s gt lt ASS e Mettre un bracelet antistatique AVANT de mani puler 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 imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage PAL Revenez la table des mati res LES ORGANES MOBILES peuvent causer des blessures CE e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences Le rayonnement haute fr quence peut causer des interf rences av
30. alternatif dans les zones des les endroits confin s ou l o on risque de tomber Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige e Sil tilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux 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 Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre in
31. arity connections see Section 4 4 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 5 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 4 10 Change to proper drive roll groove see Section 6 4 Readjust hub tension see Section 4 9 Replace contact tip if blocked see Section 6 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 6 4 or Section 6 6 Replace drive roll or pressure bearing if worn or slipping see Section 6 4 Secure gun trigger leads or repair leads see Section 4 1 Check and clear any restrictions at drive assembly and liner see Section 4 10 or Section 6 6 Release gun trigger and allow gun and motor protection circuitry to reset Have nearest Factory Authorized Service Agent check drive motor OM 944 Page 28 Return To Table Of Contents SECTION 7 ELECTRICAL DIAGRAM BLK RIBBED NEUTRAL GRN er m cat
32. ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement 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 prot ger les tiers de la projection d tincelles et de m tal chaud Ne pas souder un endroit des tincelles peuvent tomber sur des substances inflammables e 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 agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in ce
33. cracked E RD terminals weld cable lt wn 6 Months Blow out or vacuum inside During heavy service clean monthly 6 2 Overload Protection gt 1 Circuit Breaker CB1 CB1 protects unit from overload If CB1 opens unit shuts down 1 Reset breaker o S 802 441 6 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again OM 944 Page 24 Return To Table Of Contents 6 4 Changing Drive Roll Or Wire Inlet Guide C 992 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 The drive roll consists of two differ ent sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 4 10 4 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot 030 035 Groove 024 Stamped 024 Stamped 030 035 Ref 802 444 6 5 Replacing Gun Contact
34. d TS LOB When slight force is needed to turn spool tension is set 803 012 803 013 B Ref 802 971 C Return To Table Of Contents OM 944 Page 17 4 10 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight O1 ND Tools Needed gt Ce Hold wire tightly to keep it from unraveling 0000 O ids 7l PC C i UK 150 mm lt Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Use pressure indicator Tighten scale to set a desired CI drive roll pressure EXE Pressure ON 2S Indicator z3 Scale 4 M OF gt INPUT Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn power on wo Tighten E 5 Press gun trigger until wire comes Be sure that tip matches wire diameter Feed wire to check drive roll pressure out of gu
35. d clare aptes il leur est recom mand de respecter les consignes ci dessus Revenez la table des mati res SECTION 3 SPECIFICATIONS 3 1 A 115 VAC Model Specifications Maximum Open Amperes Input at Rated Welding Amperage ARP Rated Load Output Weight Overall Output Range ud 115 V 60 Hz Single KW W Gun Dimensions Phase Length 18 7 8 in 90 19 Volts DC 479 mm 20 Duty Cycle 20 2 90 2 50 556 width 10 5 8 in 30 135 28 25 kg 270 63 A Q 21 Volts DC 15 220 177 70 mm 20 Duty Cycle Height 12 3 8 in 314 mm Solid Flux Cored Stainless Aluminum Wire Feed Speed Range Wire Type 024 030 in 030 035 in And Dia 0 6 0 8mm 0 8 0 9 mmy 370 840 IPM 9 2 21 8 m min At No Load 030 190 800 IPM 4 9 20 8 m min Feeding Wire 0 8 mm CSA Rating B 230 VAC Model Amperes Input at Rated Welding Amperage Rated Load Output KVA KW Weight Overall Output Range Dc 9 230 V 50 60 Hz W Gun Dimensions Single Phase Length 18 7 8 in 130 20 Volts 479 mm DC 3095 Duty Cycle hh AN R O 1 At 60 Hz Input 20 30 175 30 19 5 4 60 3 75 NUR aon Duty Cycle At 50 Hz 270 Input Height 12 3 8 in 314 mm Solid Flux Cored Stainless Aluminum Wire Feed Speed Range Wire Type 024 035 in 030 045 in And Dia 0 6 0 9 mm 0 8 1 2 mm 350 900 IPM 9 0
36. d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUMEES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont inhalation peut tre dangereuse pour la sant e Se tenir distance des fum es et pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e travailler dans un espace clos que s il est bien ventil ou porter un respirateur adduction d air Demander toujours un surveillant ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble Ne pas souder 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 irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moin
37. ec les quipements de radio navigation et de communication les services de S curit et les ordinateurs e Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation e Sila Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil e Faire r guli rement contr ler et entretenir l installation e Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique e Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que le poste de s
38. eed listed is starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleanliness of metal etc keep torch as straight as possible A push angle for the torch is normally recommended 209 228 Return To Table Of Contents OM 944 Page 21 5 3 Weld Parameter Chart For 230 VAC Model Welding Guide Settings approximate Adjust as required Thicker materials be welded using proper technique joint preparation and multiple passes Material Wire Type Suggested Diameter and Shielding Gas of Wire Polarity Setting 20 30 cfh Flow Rate Being Used Being Welded Steel Flux Core No Shielding Gas Required 030 0 8 mm Evam Good for Windy 035 0 9 mm DCEN Outdoor Applications 045 1 2 mm Solid Wire C25 Gas Mixture 024 0 6 mm ER70S 6 75 Argon 25 CO2 030 0 8 mm DCEP Produces less Spatter 035 0 9 mm Better Appearance Solid Wire 024 0 6 mm ER70S 6 100 CO2 030 0 8 mm DCEP 035 0 9 mm Stainless Stainless 024 0 6 mm Steel Steel Tri Mix 030 0 8 mm DCEP 90 7 5 2 5 CO2 035 0 9 Aluminum P Aluminum 100 Argon 035 0 9 Match feedroll groove to diameter of wire being used CAUTION Set Tension Knob Setting to 3 at Start Do not change Voltage Switch Adjust tension per instr
39. eeded 5 8 1 1 8 in Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturers recommended flow rate Ref 802 028 A 802 441 OM 944 Page 14 Return To Table Of Contents 4 6 Selecting Location And Connecting Input Power 115 VAC Model A amp 1 Rating Label 2 Grounded Receptacle A 115 volt 20 ampere individual branch circuit protected by time de lay fuses or circuit breaker is re quired 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft 15 m or 12 AWG for 50 up to 200 ft 61 m Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 802 442 A Return To Table Of Contents OM 944 Page 15 4 7 Selecting Location And Connecting Input Power For 230 Model
40. entente entente 9 3 1 Specifications oes LEY AR HET CURE X 9 3 2 Duty Cycle And Overheating 2 10 3 3 Volt Ampere Curves eique e ades 11 SECTION 4 INSTALLATION 12 4 1 Installing Welding Gun 2 12 4 2 Installing Work Clamp zu cie ene vase vada eese Yaw cate E RR DR et 12 4 3 Process Polarity Table exor e a b De e Y ERE PE S 18 4 4 Changing Polarity 3e etr RYE RE BUR RIAM E IN 18 4 5 Installing Gas SUpply h sve xe IER E ER NUR S 14 4 6 Selecting A Location And Connecting Input Power For 115 VAC Model 15 4 7 Selecting A Location And Connecting Input Power For 230 VAC Model 16 4 8 Electrical Service Guide For 230 VAC Model 17 4 9 Installing Wire Spool And Adjusting Hub Tension 17 4 10 Threading Welding Wire insi EP RD RP RU RE 18 SECTION 5 OPERATION oie circ ete eases Vise ek eds ee ee eee eae ee 19 5 1 COTOS 19 5 2 Weld Parameter Chart For 115 Model 20 5 3 Weld Parameter Chart For 230 VAC Model
41. eshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal COIN 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 8 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 944 Page 36 Return To Table Of Contents 8 11 Troubleshooting Lack Of Penetration
42. 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 Return To Table Of Contents 1 3 Additional Symbols For Installation Operation And Maintenance FIRE EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to mo
43. hielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 944 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P D Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding
44. ical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 9 2003 Hobart Welding Products 1 03 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se ZN HOBART HS
45. leather and wool and foot protection WELDING can cause fire or explosion p 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 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 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 ti
46. n Reinstall contact tip and nozzle Tighten knob enough to prevent slipping Cut off wire Close door Ref 802 444 C OM 944 Page 18 Return To Table Of Contents SECTION 5 OPERATION 5 1 Controls pe gt e 1 Voltage Switch Wy RE 42m The higher the selected number gk the thicker the material that can welded see weld setting label in welding power source or Sections 5 2 and 5 3 as applicable Do not switch under load x Switch must click into detent position 1 2 3 4 or purge for proper contact 2 Voltage Switch Purge 0 Position In purge position fan runs but there is no weld output 3 Wire Speed Control Use control to select a wire feed Speed As Voltage switch setting in creases wire speed range also in creases see weld setting label in welding power source or Sections 5 2 or 5 3 as applicable 1 2 4 Power Switch 9 3 4 DO NOT SWITCH UNDER LOAD 3 x 1 PURGE 4 VOLTAGE 40 90 60 30 20 10 00 OFF WIRE FEED POWER Ref 196 082 Return To Table Of Contents OM 944 Page 19 5 2 Weld Parameter Chart For 115 VAC Model Welding Guide Settings approximate Adjust as required Thicker materials can be welded using proper technique joint preparation and multiple passes
47. nd maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown 0 10 20 30 40 50 60 70 80 90 LOAD AMPS 100 110 120 130 140 150 160 B 230 VAC Model OUTPUT VOLTS 30 0 25 0 20 0 15 0 10 0 5 0 0 0 Range 4 Range 3 Range Rahge 1 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 LOAD AMPS ssb1 1 10 91 196 608 196 609 Return To Table Of Contents OM 944 Page 11 SECTION 4 INSTALLATION 4 1 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew GunEnd 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 gun opening on front panel Connect female friction terminals to gt 2 matching male terminals in unit Polarity is not impor
48. ndie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque e Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu s P vent blesser les yeux Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 944 Page 6 a LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort Couper l alimentation en gaz protecteur en cas de non utilisation Veiller toujours bien ventiler les espaces confin s ou porter un respira teur a adduction d air agr LES PIECES CHAUDES peuvent cau ser des br lures graves e pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu la
49. ompletely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed Return To Table Of Contents OM 944 Page 37 8 14 Troubleshooting Waviness Of Bead o Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 944 Page 38 Return To Table Of Contents 8 16 Common Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years
50. oudage soit pos et mis la terre confor m ment au pr sent manuel e Encasd interf rences apr s ex cution des directives 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 utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques 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 944 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compres
51. p position shielding gas etc affect settings Test welds to be sure they comply to parameters Material thickness determines weld 1 8 or 0 125 in p 4 Convert Material Thickness to Amperage A 0 001 in 1 ampere 0 125 125 Wire Size Amperage Range 0 023 in 30 90 A 0 030 in 40 145A Select Wire Size 0 035 in 50 180 A Wire Wire Speed Select Wire Speed Size Recommendation Amperage 0 023 in 3 5 in per 3 5 x 125 A 437 125 based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage Select Voltage weld bead Wire speed amperage controls weld pe netration wire speed burn off rate Ref 802 439 A OM 944 Page 32 Return To Table Of Contents 8 3 Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in
52. p 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 Su 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 944 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 Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open
53. 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 equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or s
54. rk and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process 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 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 equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body Return To Table Of Contents som 8 03 i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions
55. rt 115 VAC model 1 ON ec ern een ES 209 229 LABEL weld chart 230 VAC model 1 DIM 204 711 1 212 492 REGULATOR FLOWMETER 10 50 CO 1 OPTIONAL 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 Br er 1 9 Y 802 447 Figure 9 2 10 Gun 944 44 Return Table Of Contents Description Quantity 195 957 Figure 9 2 H 10 Gun IM re eee 169 715 NOZZLE slip type 500 orf flush 1 uu 087 299 contact scr 023 wire x 1 125 I RUE 000 067 contact scr 030 wire x 1 125 TID 000 068 TIP contact scr 035 wire x 1 125 000 069 TIP contact scr 045 wire 1 125 169 716 ADAPTER contact tip 1 she 170 470 RING retaining 1 p D Mies abe adhe 169718 T BE head occa ate cite bel Oe ake ARR ARR
56. s que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 944 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage e Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit A LE SOUDAGE peut causer un incen 2 die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de de soudure La projection d tincelles les pi
57. sed Gases in Cylinders brochure CGA 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI 787 1 de l American National Standards Institute 11 West 42nd Street New York 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique e
58. suffisant ou mal piss s pas s enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine Revenez la table des mati res som fre 8 03 APA Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de les me sures prendre pour viter tout danger e N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Ne pas connecter plus d une lectrode ou plus d un c ble de masse un m me terminal de sortie subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimentation lectrique Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs
59. t Reas semble in reverse order If replacing head tube continue to end of figure 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 7 Place head tube in vice and tighten until 6 Hand tighten head tube into cable connector nuts are tight ZH 8 Remove from vice Reposition handle and install switch housing Secure with handle locking nut JI CC Tools Needed o 19mm Ref ST 800 795 C Return To Table Of Contents OM 944 Page 27 6 8 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 4 6 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 5 1 Reset welding power source circuit breaker if open No weld output wire does not feed fan motor continues to run Thermostat TP1 open overheating Allow fan to run with gun trigger switch off thermostat closes when unit has cooled see Section 3 2 Secure gun trigger leads see Section 4 1 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 6 5 Check for proper pol
60. t equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG
61. t les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiques pendant le soudage ou le coupage OM 944 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les
62. tant Close door Ref 802 440 A 4 2 Installing Work Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable Tools Needed C e J 308 7 16 in 802 456 OM 944 Page 12 Return To Table Of Contents 4 3 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW Solid wire with shield DCEP Reverse polarity Connect to positive out Connect to negative output ing gas put terminal terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal 4 4 Changing Polarity 2 1 Lead Connections For Direct E CHANGING Current Electrode Negative POLARITY DCEN 2 Lead Connections For Direct DCEN Current Electrode Positive Electrode Negative DCEP For Flux Core Wire Always read and follow wire manufacturers recommended po larity and see Section 4 3 Close door Electrode Positive For Solid Wire Ref 209 228 Ref 209 229 Return To Table Of Contents OM 944 Page 13 4 5 Installing Gas Supply DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional gas regulator flowmeter Argon Gas Or Mixed Gas Tools N
63. teurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e 15 doivent consulter leur m decin avant de s appro cher d un lieu on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme 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 de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuya
64. uctions the manual Knob position while welding Aluminum wire is relatively soft so feedability is not as good Make sure that hub tension is not too tight and OM 944 Page 22 Return To Table Of Contents for 230 Volt Wire Welding Package Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded CHANGING Number on Left of Slash 15 Voltage Setting Number Right of Slash 15 Wire Feed Setting POLARITY DCEN Electrode Negative For Flux Core Wire 22 gauge 18 gauge 16 gauge 1 8 inch 3 16 inch 8 mm 1 2 mm 1 6 mm 3 2 mm 4 8 mm 1 10 1 30 3 50 3 60 4 80 va 3 40 3 50 4 60 2 450 1 20 1 45 2 85 3 90 4 100 1 10 1 30 2 40 3 80 4 85 4 100 Electrode Positive For Solid Wire 1 00 Wire Speed listed is a starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleanliness of metal etc keep torch as straight as possible push angle for the torch is normally recommended 209 229 Return To Table Of Contents OM 944 Page 23 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance ESSE Disconnect power before maintaining 3 Months Replace Repair or Clean unreadable replace NS 50 tighten weld labels
65. umables 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 944 Page 1 RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a 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 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet 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
66. ux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes e D tourner la t te lorsqu on ouvre la soupape d une bouteille e Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit Revenez la table des mati res 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que l anneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil nw t i L EMPLOI EXCESSIF peut FAIRE SURCHAUFFE
67. ve unit be sure forks are long enough to extend beyond opposite side of unit UM OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn an e 7 STATIC ESD can damage PC boards gt 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 22 MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do 0 e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Return To Table Of Contents MOVING PARTS cause injury Keep away from moving parts such as fans C Keep all doors
68. wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas solenoid valve not operating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage Return To Table Of Contents OM 944 Page 39 Problem Probable Cause Remedy Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary

Hobart Welding Products 175 Welder User Manual

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