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section 1 - Hobart Welders

1. The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of 30 FT the welding power source Curves of other settings fall between the curves shown 25 20 o o S 1 gt 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Amperage Ssb1 1 10 91 248 833 A SECTION 5 INSTALLATION 5 1 Installing Nozzle Contact Tip And Adapter A Turn off welding power ERE source 1 Nozzle 2 Contact Tip 3 3 Tip Adapter 2 Po hed Ms d Wire size stamped on tip check 1 Sot and match wire size Z od AD 8 mm Ng p Tools Needed C Se TE 8mm Ref 243 839 A OM 260 273 Page 13 FF A complete Parts List is available at www HobartWelders com 5 2 Installing Welding Gun Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew D 1 Drive Assemb
2. Amperes Input at Rated Welding Amperage ee Rated Load Output KVA KW Weight Overall Output Range DC 9 230 V 60 Hz W Gun Dimensions Single Phase Length 19 1 2 in 495 mm 130 A 21 5 Volts 68 Ib Width 10 5 8 in DC 30 Duty Cycle 25 190 31 20 5 4 7 3 88 81 kg 270 mm Height 12 3 8 in 314 mm SC S Flux Cored Aluminum Wire Feed Speed Range Wire Type And Diameter 023 035 in 030 045 in 030 035 in 50 740 IPM 1 3 18 8 m min At No Load 0 6 0 9 mm 0 8 1 2 mm 0 8 0 9 mm 40 700 IPM 1 0 17 8 m min Feeding Wire 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating H unit overheats thermostat s 200 opens output stops and cooling 175 fan runs Wait fifteen minutes for 3 130 unit to cool Reduce amperage or d i duty cycle before welding g 100 NOTICE Exceeding duty cycle 4 80 can damage unit or gun and void 60 warranty 2 O a 20 10 10 20 30 40 50 60 70 80 100 Duty Cycle 80 duty cycle at 130 amps Dao C 3 Minutes Welding 7 Minutes Resting Overheating de DECHE Reduce Duty Cycle Minutes duty1 4 95 248 832 A OM 260 273 Page 12 FF A complete Parts List is available at www HobartWelders com 4 4 Volt Ampere Curves
3. Warranty Questions Call 1 800 332 3281 7AM 5PMEST 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 Assistance Visit the Hobart website www HobartWelders com HOBART S31 WARRANTY Effective January 1 2013 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of MD or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Brothers Co Troy Ohio and Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobar
4. 12 72 lt ZIK RIBBED e E Z7 77 ALK CB1 2 7 lt e Oo lt N OR ZZ CR3 Tl Res m Lo pol p RC5 J Ps E E E 125 GAS VALVE GS1 52 23 l 26 BK BLK lt 2 lt 2 phe VS b dst 4 T POWER EM SWITCH KO 00060 24 VAC L ae lt 3 ae PT gt gt RC1 6 Me lt 4 lt gt RC1 14 15 gt gt RC1 15 CONTROL BOARD CONTROL CR PC1 CONTACTORU 3 12 gt gt RC1 12 RC1 8 lt K RC1 16 lt K ALK RC6 ke anaes DS RC1 7 lt lt OCA 2 lt S RC1 5 RC1 13 lt lt PLe7 IRc7 J SUD SE RC4 1 lt GUN 8 RC4 2 lt lt TRIGGER lo j 2 gt gt gt RC1 4 7 gt 3 gt aa gt gt RC1 17 RC1 18 lt lt SPOOL GUN RC1 10 lt lt MOTOR DM2 B gt 4 gt 20 gt gt RC1 20 SOT OM 260 273 Page 32 Figure 8 1 Circuit Diagram amp WARNING e Do not touch live electrical parts Disconnect input power or stop eg engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit n JO PRI 1 n x4 gt 14 3 4 PRI 2 XS I 7 p x2 x1 gt POSITIVE D s 12 JA PRI 3 SRE C1 TE1 d aul Ko 210 PRI 4 Z1
5. Fine Spatter Uniform Bead Moderate Crater During Welding Weld a 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 S 0052 B OM 260 273 Page 38 9 8 Troubleshooting Excessive Spatter So Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead e 6008 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal TD A Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts ne
6. 27 the ISO 9001 Quality 7 1 Routine Maintenance 27 System Standard 7 2 Overload Protection a EELER per Ree xp need oe eee aa tut ae fp tai d dise 27 7 3 Drive Motor Protection 27 7 4 Changing Drive Roll Or Wire Inlet Guide 28 7 5 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing 29 7 6 Replacing Switch And Or Head Tube 30 7 7 Troubleshooting Table 25 virun n ceed eae RENE Redon tapas dead oem Ate E 31 SECTION 8 ELECTRICAL DIAGRAM 32 TABLE OF CONTENTS SECTION 9 GMAW WELDING MIG GUIDELINES 34 9 1 Typical GMAW MIG Process Connections 34 9 2 Typical GMAW MIG Process Control Settings 35 9 3 Holding And Positioning Welding Gun 36 9 4 Conditions That Affect Weld Bead Shape 37 9 5 Gun Movement During Welding 38 9 6 Poor Weld Bead Characteristics 38 9 7 Good Weld Bead Characteristics 38 9 8 Troubleshooting Excessive Spatter 39 9 9 Troubleshooting Porosily see eI eie e rry YR e RR ria dues 39 9 10 Troub
7. Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 5 10 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 6 1 Reset welding power source supplementary protector see Section 7 2 No weld output wire does not feed fan motor continues to run Thermostat TP1 open overheating Allow fan to run with gun trigger switch off thermostat closes when unit has cooled see Section 4 3 Check Voltage range switch position Rotate knob until it clicks into detent at desired range setting Ensure Spool Gun MIG switch is in correct mode see Section 5 2 or 5 11 Secure gun trigger leads see Section 5 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 7 5 Check for proper polarity connections see Section 5 5 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Wire does not feed wire is not ener gized wire feeds unevenly Check contact tip Check for kinks in gun cable and liner Check gun trigger plug connection at welding power source wire feeder Check and if necessary replace gun trigger switch see Section 7 6 Check contact tip Check for kinks in gun cable Blow out liner and gun casing see Section 7 5 L
8. OM 260 273 Page 23 FF A complete Parts List is available at www HobartWelders com 5 12 Threading Welding Wire cS e Wire Spool wA D 3 ERI Welding Wire SRM Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight 1 2 3 4 5 6 Tools Needed EF Hold wire tightly to keep it from unraveling Gin 150 mm Open pressure assembly Make sure Pull and hold wire cut off end Push wire thru guides into gun feed roll is set to correct groove to continue to hold wire match wire size see Section 7 4 EF Use pressure indicator scale to set a desired drive roll pressure Tighten Pressure Indicator Scale Be sure that wire is positioned Remove gun nozzle Turn power on Be sure that Voltage range in proper feed roll groove and contact tip Switch is set to range 1 2 3 4 5 6 or 7 to Close and tighten pressure feed wire Rotate knob until it clicks into assembly and let go of wire detent Wire will not feed if range switch is set between ranges Tighten SE WOOD Press gun trigger until wire comes Be sure that tip matches wire diameter Feed wire to check drive roll pressure out of gun Reinstall contact tip and nozzle Tighten knob enoug
9. TV eb0 winujwiniy WNUIWNiy 4 N 2Q 10 suoneoriddy 0opInO Jo pulM 10 poo5 Aiuelod PS palnbad se BuIPI S ON 0 d490 10 ee e SSSIUIB1S SSaIUl 1S d390 40 Augiod 1S 9 S0Zd M PIOS uiui 670 GE0 ww g70 0 0 xxUoBJV 00L E E a e ww CU Sto ww 670 S 0 ww 670 S 0 709 9 2JV 9776H 06 ww 8 0 00 XIW HL ww 970 ken uu 670 S 0 09 001 uu 70 0 0 oo ww 970 reg eouejeeddy 10429 d320 404 Jayeds sso seanpoug Aelod les 00 9g u0BJV96G 9 S0ZH einxIW se9 SI PIOS ww 9 0 pesn upg y Mold UJ2 0 0c Bunnies Aluelod P9pIeA ul 20 Sau Jo sep 5ulpleluS pue Gus eB pz Jojoureiq peiseBBns ed M I uS1EMM sessed gIdIlIhU pue uoneaedaad jujof enbiuysa jodo d 5ulsn DSDISA oq ued sjenazew 9IU1 Delinbe se 1SnIDV eyewixoidde eg sBures eDexoed BUIPISM M HOA OEZ 10 9DInb BurpjeM 248 827 B OM 260 273 Page 26 FF A complete Parts List is available at www HobartWelders com SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7T 1 Routine Maintenance ay oum ef WC IS umo ET a rnm P CA SS before maintaining gt Maintain more often during severe conditions Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent x EH 2 O p ec
10. e Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 maintaine
11. masse une m me borne de sortie de soudage D brancher le c ble pour le proc d non utilis OM 260 273 Page 5 ll reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup 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 LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures 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 une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Trava
12. stance inflammable zs gt e LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 260 273 Page 7 Les PIECES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage L EXPLOSION DE LA BATTERIE peut provoquer des blessures e Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage Les PIECES MOBILES peuvent causer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispos
13. www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example restrict access for passers by or conduct individual risk as sessment for welders All welders should use the following procedures
14. 2 mm 770 183 5 per package 000 069 10 per package MIG Nozzle Standard 770 404 169 715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716 Replacement Liners 023 025 in 0 6 mm 196 139 194 010 030 035 in 0 8 0 9 mm 196 139 194 011 035 045 in 0 9 1 2 mm 196 140 194 012 Available at farm and tool supply retailers Ayailable at Hobart Miller welding distributors 10 3 Replacement Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PART NO INCHES mm 237 338 023 025 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 246 565 030 035 8 and 9 V VK Grooves 10 4 Regulator Flowmeter PART NO DESCRIPTION REMARKS For use with CO shielding gas 10 50 CFH Use 212 492 Regulator Flowmeter with gas hose 144 108 Available at Hobart Miller welding distributors CS A complete Parts List is available on line at www HobartWelders com 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 260 273 Page 44 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Notes
15. Recommended Standard Fuse Rating In Amperes Time Delay Fuses 25 Normal Operating Fuses 30 Min Input Conductor Size In AWG 4 14 Max Recommended Input Conductor Length In Feet Meters 20 Min Grounding Conductor Size In AWG 4 14 Reference 2011 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 15 B 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 260 273 Page 20 FF A complete Parts List is available at www HobartWelders com 5 10 Connecting Input Power Pak Aire 230 VAC 1 v Tools Needed C input4 2012 05 Ref 803 766 C 260 711 B OM 260 273 Page 21 FF A complete Parts List is available at www HobartWelders com 5 10 Connecting 1 P
16. View of Gun Angle GROOVE WELDS 45 0 15 be 3 45 7 N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 260 273 Page 36 9 4 Conditions That Affect Weld Bead Shape LF Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT Ie Je Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT jpo O eS CO a Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 260 273 Page 37 9 5 Gun Movement During Welding EF 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 P3539 AAA EU AX DD 1 2 3 Stringer Bead Steady Movement Along Seam Weave Bead Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 9 6 Poor Weld Bead Characteristics O E OO Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S 0053 A 9 7 Good Weld Bead Characteristics
17. and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment T OVERUSE can cause OVERHEATING e 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 ee 7 FLYING SPARKS can injure y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards SN N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure 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 BATTERY EXPLOSION can injure
18. 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 compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 4 e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift
19. en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger A Kei Ne pas toucher aux Dieces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants F Indique des instructions sp cifiques o cal Ce groupe de symboles veut dire Av
20. i E P d E 1Q el Every Unreadable Labels Q Weld Terminals Damaged Gas Hose 1 Weld Cables 3 Months Cords X Gun Cables Every 6 Months Q Drive Rolls Q Inside Unit 7 2 Overload Protection N 1 Supplementary Protector CB1 e D D CB1 protects unit from overload If CB1 opens unit shuts down 1 Reset supplementary protector o e e SE SES 802 441 7 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 260 273 Page 27 FF A complete Parts List is available at www HobartWelders com 7 4 Changing Drive Roll Or Wire Inlet Guide GO 030 035 V Groove is used for Solid Wire Stamped 030 035 VK Grooved EF Be sure gun is fully inserted into drive housing Liner to drive roll distance should be within 1 8 in 3 2 mm of each other Example 030 035 VK Groove is used for Flux Core Gasless Wire Stamped 030 035 V 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen thumbscrew Slide tip as close to drive rolls as possible without touching Tighten thumbscrew 3 Drive Roll The drive roll consists of two different grooves The stamped markings on the end surface of the drive roll refers to the groove on the op
21. in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 260 273 Page 4 A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual
22. les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE LARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement 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 Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des
23. mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants OM 260 273 Page 8 A Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly
24. o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le 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 par s correctement conform ment AWS F4 1 et AWS A6 0 voir les Normes de S curit e Ne soudez pas si l air ambiant est charg de particules gaz OU va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la piece le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles 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 panta
25. servir d un respirateur d adduction d air homologu e uc D e Les CHAMPS ELECTROMAGNETIQUES CEM peuvent affecter les implants m dicaux e e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction e e LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz comprim contiennent du gaz sous haute pression Si une bouteille est endommag 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 des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support station naire 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 circuits lectriques Ne jam
26. An Illinois Tool Works Company 2200 Corporate Drive Troy OH 45373 USA For Assistance Call1 800 332 3281
27. Cc Cc oc 8 C e C C C M P Pressure Assembly Pressure Assembly Open Closed Tools Needed J 5 8 or 11 16 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 supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate After flow is set close pressure assembly 260 460 B OM 260 273 Page 17 FF A complete Parts List is available at www HobartWelders com 5 7 Selecting A Location va RES P LAS EA Location And Airflow Do not move or operate unit where it could tip 18 in 460 mm 1 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasolin
28. HUTE DE L QUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds y L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage p Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub
29. MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Regulators Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Water Coolant Systems 4 Engines batteries except Trek 180 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 contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where a
30. OM 260 273B 2013 03 Processes pm MIG GMAW Welding Flux Cored FCAW Welding FC Description EC Arc Welding Power Source And Wire Feeder Handler 190 And H100S4 10 Gun OWNER S MANUAL Find us on Facebook Yu File MIG GMAW ES www HobartWelders com TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage iis sesta EO ERE EORR UEENRE IR MEDUME TAE EUR Tq River CE ES 1 1 2 Arc Welding Hazards scis dE eir ce gne m Ex RR E EIERE a doe dob acr bee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards s dd be xav n XR as ok na ede LR 4 1 6 EMF Information 2 xc ERE RU ERGO RE ADORA EE e den Mare db DARE e EA 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Syimboles utilis s rer Eee PY sere dis Es 5 2 2 Dangers relatifs au soudage Alan 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM Liu 9 SECTIONS DEFINITIONS cimi RE ERREUR E ERE AS RE EE SEN SEN 11 3 1 Additional Safety Symb
31. Q COM xd 1 8 308 PRI 5 NEGATIVE 11 VOLTAGE RANGE TEE J06 PRI 6 SELECT H SWITCH S2 a 1 4 JO4 PRI 7 Um 2 JO PRI 8 NOTE DENOTES SWITCH TERMINAL MARKINGS amp 16 BK MIG GUN fu uem S3 SPOOL 13 GUN ALD WIRE DRIVE DM1 MOTOR BLK PLG8 RC8 18 35 23 10 WFS gt 2 gt t MIG SPOOL GUN 19 CONTROL 1 gt 248 830 A OM 260 273 Page 33 SECTION 9 GMAW WELDING MIG GUIDELINES 9 1 Typical GMAW MIG Process Connections A Weld current can damage EC electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter Wire Feeder Power Source E _ Gun Shielding Gas TET ms OS ng Gas ec t Workpiece UC UC z d Work Clamp GMAW1 2011 03 GMAW Only Ref 801 909 A Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 260 273 Page 34 9 2 Typical GMAW MIG Process Control Settings IS These settings are guidelines only Material and wire type joint design fitup position shielding gas etc affect settings Test welds to be sure they comply to specifications Material thickness determines weld parameters e 1 8 or 0 125 in Conve
32. The most commonly used shielding gases are listed in the following table Application Gas Short Circuiting Spray Arc Short Circuiting Spray Arc Short Circuiting Spray Arc Steel Steel Stainless Steel Stainless Steel Aluminum Aluminum Argon All Positions All Positions Flat amp Horizontal Flat amp Horizontal Argon 1 Qu Fillet Fillet Flat amp Horizontal Flat amp Horizontal O Argon 2 O2 Fillet Fillet Flat amp Horizontal Argon 5 Oo Fillet Flat amp Horizontal Argon 8 CO2 n All Positions Fillet Al 259 Flat amp Horizontal moe SE All Positions All Positions CO Fillet Argon 50 2 CO All Positions Flat amp Horizontal CO it All Positions Fillet Helium All Positions Argon Helium All Positions Tri Mix4 All Positions akon Globular Transfer Heavy Thicknesses Single Pass Welding Only 90 HE 7 1 2 AR 2 1 2 COs Also for GMAW P All Positions 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy wire does not feed Wire feed motor operates but 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 Restri
33. VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM a certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises Limiter par exemple tout acc s aux passants ou proc der a une valuation des risques individuels pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phon
34. Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual FF A complete Parts List is available at www HobartWelders com 5 11 Connecting Optional Spool Gun N e Ge 1 Drive Assembly EX CAU 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew Spool Gun Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position 7 Polarity Changeover Terminal Block To make proper polarity connection see welding power source Owner s Manual 6 MIG Gun Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriate setting 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s es oe e cause Manual or door chart for shielding gas leakage i i Incorrect a a Correct pris sening rigger Gun Not Seated Gun Fully Seated s Press trigger to energize welding power source Contactor start shielding gas flow and begin wire feed 260 573 A
35. ais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz comprim r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service G N LA C
36. ar welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 9 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 260 273 Page 39 9 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and T m A base metal Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groo
37. are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 ground and operate this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions TK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 drounded receptacle outlet e When making input con
38. coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection WELDING can cause fire or explosion des C 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 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover the
39. ction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner OM 260 273 Page 42 Problem Probable Cause Remedy 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 p
40. d Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment Such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 260 273 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website
41. e 212 642 4900 web site www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc t
42. e or volatile liquids are present see NEC Article 511 or CEC Section 20 260 711 B ST 139 445 E OM 260 273 Page 18 FF A complete Parts List is available at www HobartWelders com 5 8 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool SE When a slight force is needed to turn spool tension is set G Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only When a slight force is needed to turn spool tension is set Retaining ring used with 8 in 203 mm spool only Tools Needed LES J 1 2 in 803 012 803 013 B Ref 802 971 C OM 260 273 Page 19 FF A complete Parts List is available at www HobartWelders com 5 9 Electrical Service Guide Elec Serv 2011 08 A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source In dedicated circuit installations the National Electrical Code NEC allows the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 60 Hz Single Phase Input Voltage V 230 Input Amperes A At Rated Output 20 5 Max
43. ertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installez mettez la terre et utilisez correctement cet quipement conform ment son Manuel d Utilisation et aux r glementations nationales gouvernementales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les con
44. for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION fre_som_2011 10 A Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu s r ces consignes relatives aux pr cautions de s curit et au mode op ratoire 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont mo
45. ge et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des matieres resistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 260 273 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds 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 D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l
46. h to prevent slipping Cut off wire Close door 260 587 A OM 260 273 Page 24 FF A complete Parts List is available at www HobartWelders com SECTION 6 OPERATION 6 1 Controls ES 2 SA 2 o V Qi 1e DO NOT SWITCH WHILE WELDING 4 3 Ref 248 840 A Ref 246 668 A 1 Wire Speed Control 3 Voltage Switch 4 Gun Trigger Receptacle The higher the selected number the 5 Trigger Switch Use control to select a wire feed speed As thicker the material that can be welded i Voltage switch setting increases wire see weld setting label in welding power When pressed energized wire feeds and speed range also increases see weld source or Section 6 2 as applicable Do shielding gas flows setting label in welding power source or not switch under load Section 6 2 as applicable Switch must click into detent 2 Power Switch position OM 260 273 Page 25 FF A complete Parts List is available at www HobartWelders com Weld Parameter Chart For 230 VAC Model 6 2 Z88 91IM PIIOS 104 eAnisod epoaj29 3 doa 9JIM p3J02 XN 4 104 eAneBeN 2P0119911 N oOq 1IHV1Od SNISNVHO UunuIUJnI 40 PSPUSUUUIO28 llBUIJOU S 4240 34 40 SI5ue usnd v asm UIhUIUnI yos y YUM pejeroosse senssi Ayliqepos ueui So16UIUII9 unf joods y peuoepe ung joods 00L 9uundIoodS eui u
47. hase Input Power Continued Jes Installation must meet all National and Local Codes have only qualified per sons make this installation Disconnect and lockout tagout input power before connecting input con ductors from unit Follow established procedures regarding the installation and removal of lockout tagout devices A Always connect green or green yellow conductor to supply grounding termi nal first and never to a line terminal See rating label on unit and check input volt age available at site A 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals Black And White Input Conductor L1 And L2 6 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to dis connect device line terminals 7 Over Current Protection Select type and size of over current protec tion using Section 5 9 fused disconnect switch shown 8 Receptacle NEMA 6 50R Connect receptacle as shown Close and secure door on disconnect device Follow established lockout tagout proced ures to put unit in service 9 Plug NEMA 6 50P Connect plug to receptacle input4 2012 05 803 766 C 260 711 A Notes OM 260 273 Page 22
48. holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 260 273 Page 40 9 14 Troubleshooting Waviness Of Bead ii e 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 18 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 9 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds Notes OM 260 273 Page 41 9 16 Common GMAW MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years
49. i Je sBuiyes oa UInUIUUnIV yy 919 rejeuu jo sseuijueejo eue Dau peeds 9AB Ino YIS se uons so qeueA J910 uo spuedep osje paads SI Buipjo 9IIUA peunj aui eq ues Dumes peedg m Aug anjena Bunes e SI pars PeedS aM 0679 s s 00179 ap 94 9 oss sg 9 os s sm SE 0 CT Bed ees 00L Z 9E 9 SEIS 09 2 09 9 0v 9 08 4 09 Z 30V 4 0g 06 4 0S 2 04 9 wu 0 8 ww 79 wu gp ug youl 9UG youl PL uout 9L E You 8 L eB LL aS Pe ai SI USEIS Jo 1461 uo Jaqwnn Bunies BLOA SI SBIS Jo Je uo JjaquinN pepjeM Bujeq jejeu jo sseuyolu 10 sus peedg ai pue ebeyoA pepueuiuoaag oss ose oe en on EE a EN 0v 5 09 t DIS 0p 1 SE 1 oz os very se sure 05 9 se s og 7 e CE 02 2 09 9 EA 0 E DIE ov 9 os serv se 05 9 0s 8S 0v S Ob v 08 9 09 9 0v S SE 05 9 06 5 0v S Or vt Ov 09 9 09 5 ose Le om 06 9 08 8 09 v 0S ov z 0 L uBisep Julo pue uonesiydde au uo Buipuedep pauinbaa aq Aew sessed ejdniniy UOIBUUJOJUI 210W 10 enuew SJ9UAO 99g BUIDISA aM uonisod uoyws eBeyoA eBueuo jou oq iNOILnVO Jenueui y ui suononysu Jed uolsue1 jsn py uis je o 5Ull9S qouy uolsue 195 pesn Bulag M jo 919UJBID 0 9AOOJ5 01P88 EE TEE 5 und joods xxuoBJ 00L TV 9S S 00L uunuluunIV oo PPPHioodS Auelod S IPUondO uu
50. iller 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 fumees et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer 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 for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et 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 provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visa
51. ion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 260 273 Page 9 OM 260 273 Page 10 SECTION 3 DEFINITIONS 3 1 Additional Safety Symbols And Definitions Warning Watch Out There are possible hazards as shown by the symbols Drive rolls can injure fingers 3 2 Miscellaneous Symbols And Definitions Safe1 2012 05 Safe32 2012 05 A Amperage V Voltage H Z Hertz Negative Positive n c 1 Au Single Phase Input e Output y Voltage Input O Off On Do Not Switch G Gas Metal Arc 7 f Flux Cored Arc KN sS While Welding ab olo vire heed T Welding GMAW Welding FCAW Line Connection U Conventional Load Primary Voltage U 2 Voltage No Percent R QE e U Rated No Load l Rated Supply Cur Rated Welding Rectifier 0 Voltage Average 1 rent 2 Current X Duty Cycle S Suitable For Welding In An Environment With Increased Risk Of Electric Shock Notes OM 260 273 Page 11 FF A complete Parts List is available at www HobartWelders com SECTION 4 SPECIFICATIONS 4 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 2 Specifications
52. itifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section E e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s
53. leshooting Excessive Penetration 39 9 11 Troubleshooting Lack Of Penetration 40 9 12 Troubleshooting Incomplete Fusion 40 9 13 Troubleshooting Burn Through 40 9 14 Troubleshooting Waviness Of Bead 41 9 15 Troubleshooting Distortion 41 9 16 Common GMAW MIG Shielding Gases 42 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment 42 SECTION 10 WARRANTY ACCESSORIES CONSUMABLES 0 00 cece ese eee 44 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2011 10 A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call atte
54. lons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES OW SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermerl alimentation du gaz comprim en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se
55. ly X LA 2 MIG Gun 3 Welding gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in MIG Gun position Close door gt Be sure that gun end is tight against drive assembly ei o bet Ojo DON o bebe OW D Incorrect Exposed O rings Correct will cause shielding Gun Fully Seated Gun Not Seated gas leakage y 260 458 A OM 260 273 Page 14 5 3 Installi FF A complete Parts List is available at www HobartWelders com ng Work Clamp CP Tools Needed IE 10m Connection hardware must be tightened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and excessive heating of the work clamp un 2 m Work Clamp Work Cable From Unit Screw Flat Washer Lock Washer Nut Route work cable through hole in clamp handle Secure cable with hardware as shown O1 PS Co ND 258 550 A OM 260 273 Page 15 5 4 Process Polarity Table CS A complete Parts List is available at www HobartWelders com Process Polarity Cable Connections Cable To Gun Cable To Work GMAW Solid wire with shield DCEP Reverse polarity ing gas C
56. m taking it apart Install Liner e a Liner uw sun Stickout Thread wire according to welding power source wire feeder manual Tools Needed COP C Xe 8mm 10 mm 243 839 A OM 260 273 Page 29 FF A complete Parts List is available at www HobartWelders com 7 6 Replacing Switch And Or Head Tube e ar A Turn Off welding power source D wire feeder and disconnect gun 1 Remove screws 5 2 Remove handle halves and nuts 4 SS 2 Bs Remove screw on 3 Remove switch housing Install new ita ei switch and connect leads polarity is opposite side d not important Reassemble in reverse order If replacing head tube continue to end of figure 4 Secure head tube in vice 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 H 9 Reinstall screws 8 Remove from vice Reposition handle halves and and nuts install switch housing A gE Bs Reinstall screw on opposite side SH CRAN AN Tools Needed lt mm phillips 243 840 A OM 260 273 Page 30 FF A complete Parts List is available at www HobartWelders com 7 7 Troubleshooting Table
57. m with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes OM 260 273 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuse
58. nect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 260 273 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the
59. nections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical 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 Disconnect cable for process not in use SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter discon
60. ntion 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 Additionalsafety precautions
61. ntr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit A Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues
62. ols And Definitions 11 3 2 Miscellaneous Symbols And Definitions 11 SECTION 4 SPECIFICATIONS ee EEN SE Rex EX RR EE EEN eR anne 12 4 1 Serial Number And Rating Label Location 12 4 2 Sp ciications versets cei v ER EDUPRYDRNCPRSEURU RE E UR e S WRSUATR UL SUP APR UHRUP SUE sss 12 4 3 Duty Cycle And Overheating sa na tte es e EH RER E UU PEE RET 12 4 4 Volt Ampere CUIVes OO 13 SECTION 5 INSTALLATION EE rmt a rarum n RR nna e m RR 13 5 1 Installing Nozzle Contact Tip And Adapter 13 5 2 Installing Welding GUM ies c erra EN ER SEENEN Erbe EIER d NIE See e b e EROR Se e 14 5 3 Installing Work Clamp 15 5 4 Proeesg BolarityTaBI8EES eR ER ERR DR RR RS EIN 8 dee age 16 5 5 Changing Polarity 5 rk iE sa RE Ro ER ONU REESE DEDERE AA We dug 16 5 6 Installing Gas ele EE EE 17 5 7 Selecting A Location SE RR EE EE EE EEE 18 5 8 Installing Wire Spool And Adjusting Hub Tension 19 NII 9001 5 9 Electrical Service Guide eos o teeth b eU EP E Ra ne ann dudas 20 5 10 Connecting Input Power 21 QUALITY SYSTEM 5 11 Connecting Optional Spool Gun 23 v 5 12 Threading Welding Wie 24 SECTION 6 OPERATION SEE 25 6 1 eni c P DERE 25 6 2 Weld Parameter Chart For 230 VAC Model 26 Hobart is registered to SECTION 7 MAINTENANCE amp TROUBLESHOOTING
63. onnect to positive 4 out put terminal Connect to negative output terminal FCAW Self shielding wire DCEN Straight Polarity no shielding gas Connect to negative output terminal Connect to positive output terminal 5 5 Changing Polarity 3 RPS CHANGING POLARITY DCEN Electrode negative for flux cored wire ele oooo C4 o DCEP Electrode positive for solid wire exeXeXe steen OOOO A Turn off welding power source 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturers recommended polarity and see Section 5 4 Close door 260 459 A OM 260 273 Page 16 FF A complete Parts List is available at www HobartWelders com 5 6 Installing Gas Supply DO NOT use Argon Mixed gas regulator flowmeter with CO shielding gas See Parts List for optional 1 CO gas regulator flowmeter T d 2 0 DE SN ow 5 E Argon Gas Or e Mixed Gas 6 O C e C C C CH Cc
64. ow weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 5 12 Change to proper drive roll groove see Section 7 4 Readjust hub tension see Section 5 8 Replace contact tip if blocked see Section 7 5 Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 or Section 7 5 Replace drive roll or pressure bearing if worn or slipping see Section 7 4 Secure gun trigger leads or repair leads see Section 5 2 Check and clear any restrictions at drive assembly and liner see Section 5 12 or Section 7 5 Gun is not secured to feed head Check thumbscrew securing gun end to feed head adapter and tighten if necessary Have nearest Factory Authorized Service Agent check drive motor Weld porosity Remove weld spatter buildup in nozzle Check O rings on gun connector and replace if damaged Make sure inner head tube is tight in cable connector Check gun connector to be sure it is fully inserted into drive assembly Check shielding gas flow supply OM 260 273 Page 31 SECTION 8 ELECTRICAL DIAGRAM
65. ower source for correct voltage Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 260 273 Page 43 SECTION 10 ACCESSORIES CONSUMABLES 10 1 Accessories PART NO DESCRIPTION REMARKS 770 187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 Ib 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 Ib 34 kg max 195 186 Protective Cover Weatherproof nylon 245 926 H100S4 10 Replacement Gun 10 ft length 030 035 wire size 300 796 SpoolRunner 100 Spool Gun For push pull wire feeding 10 2 Consumables ITEM HOBART PACKAGE NO MILLER PACKAGE NO Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 770 177 5 per package 000 067 10 per package 035 in 0 9 mm 770 180 5 per package 000 068 10 per package 045 in 1
66. posite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 12 EF VK Knurled groove is used for flux cored wire and V groove is used for solid wire 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 5 Drive Roll Tension Knob Using flux core wire with VK groove tension should be set between 1 1 2 to 2 Higher setting may cause welding wire to deform and not allow proper feeding Flux Core Wire Recommended stickout is 1 2 in 12 7 mm from gun tip Solid Wire Recommended stickout is 3 8 in 9 5 mm from gun tip Actual drive roll may differ from that shown See Section 10 3 for additional drive roll configurations 258 380 B OM 260 273 Page 28 FF A complete Parts List is available at www HobartWelders com 7 5 Changing Nozzle Contact Tip Adapter And Liner And Cleaning Gun Casing D A Turn off welding power 1 Nozzle 2 2 Contact Tip 4 3 Tip Adapter Head P e EN Tube E Wire size stamped on tip check 1 lg AD d and match wire size Cut off wire and disconnect gun from feeder 8 mm Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out gun casing e straight before e installing new liner Reassemble gun in reverse order fro
67. rt Material Thickness to y Amperage A 0 001 in 1 ampere 0 125 in 125A d Wire Size Amperage Range M D 0 023 in 30 90A 0 030 in 40 145 A Select Wire Size 0 035 in 50 180A Wire R Wire Speed Select Wire Speed Size ecommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6x 125 A 200 ipm ipm inches per minute d Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate OM 260 273 Page 35 9 3 Holding And Positioning Welding Gun 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 Y EN D eo U Z Ge 12 P A SANCTUS 1 Hold Gun and Control Gun Trigger T 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout Solid Wire 3 8 to 1 2 in 3 9 to 18 mm 2 5 Cradle Gun and Rest Hand on Workpiece 5 4 GRR 0 15 Vod 90 90 nr End View of Work Angle Side
68. s or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT 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 compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating 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 Compressed gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install
69. t 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 delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Reactors Stabilizers Transformers 2 3 Years Parts and Labor Drive Systems ldle Module PC Boards Rotors Stators and Brushes Solenoid Valves Spot Welder Transformer Switches and Controls 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Accessories Batteries Trek 180 Only Contactors 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 Flowgauge and Flowmeter Regulators No Labor HF Units
70. tre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort e L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Ne pas raccorder plus d une lectrode ou plus d un c ble de
71. uthorized 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 WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied
72. ve 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 Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of 0 to 15 degrees 9 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in
73. 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 2013 01 Thank you for purchasing Hobart Our trained technical support team is dedicated to your satisfaction For questions regarding performance op eration or service contact us Resources Available Always provide Model Name and Serial Style Number To locate a Service Center Call 1 800 332 3281 or visit our website at www HobartWelders com wheretobuy For Technical Assistance Call 1 800 332 3281 7 AM to 5 PM EST Monday through Friday Find us on E Facebook Yu 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 ORIGINAL INSTRUCTIONS PRINTED IN USA 2013 Hobart Brothers Co 2013 01 Hobart Brothers Co

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