OM-944 196 639G October 2003 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 135 / 175 And H-10 Gun Visit our website at www.HobartWelders.
From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Holding And Positioning Welding Gun . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Y Marks a special safety message. . Means “Note”; not safety related. 1-2.
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. 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. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES.
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLOSION LES ORGANES MOBILES peuvent causer des blessures. D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle. D Se tenir à l’écart des organes mobiles comme les ventilateurs. D Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection. D Ne pas installer l’appareil à proximité de produits inflammables.
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.
SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Rated Welding Output Amperage Range Maximum OpenCircuit Voltage DC KVA KW Weight W/ Gun Overall Dimensions Length: 18-7/8 in (479 mm) 90 A @ 19 Volts DC, 20% Duty Cycle 30 − 135 20 2.90 2.50 15* 2.20* 1.
3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. A. 115 VAC Model 200 Output Amperes 135 Y Exceeding duty cycle can damage unit or gun and void warranty.
3-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. A. 115 VAC Model 30.0 OUTPUT VOLTS 25.0 20.0 Range 4 15.0 Range 3 Range 2 Range 1 10.0 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 LOAD AMPS B. 230 VAC Model 30.0 25.0 Range 4 OUTPUT VOLTS 20.0 Range 3 15.0 Range 2 Range 1 10.0 5.0 0.
SECTION 4 − INSTALLATION 4-1. Installing Welding Gun 1 2 3 4 Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 2 Drive Assembly Gun Securing Thumbscrew Gun End 3 Gun Trigger Leads Insert leads, one at a time, through gun opening on front panel. Connect female friction terminals to matching male terminals in unit. Polarity is not important. Close door. 1 Ref. 802 440-A 4-2.
4-3. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) output terminal Connect to negative (−) output terminal FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative (−) output terminal Connect to positive (+) output terminal 4-4.
4-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. . DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 1 4 2 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.
4-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 2 1 18 in (460 mm) Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. 2 3 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.
4-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 3 Plug (NEMA 6-50P) Receptacle (NEMA 6-50R) Connect plug to receptacle. 4 18 in (457 mm) of space for airflow Line Disconnect Device See Section 4-8. 4 Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. L1 Y Always connect grounding conductor first.
4-8. Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In AWG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil 12 Reference: 1996 National Electrical Code (NEC) S-0092-J 4-9.
4-10. Threading Welding Wire 1 2 3 4 5 6 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. 6 Tools Needed: 1 3 2 5 . Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. . Use pressure indicator Tighten scale to set a desired drive roll pressure.
SECTION 5 − OPERATION 5-1. Controls 1 Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 5-2 and 5-3, as applicable). Do not switch under load. . Switch must “click” into detent position 1, 2, 3, 4, or purge for proper contact. 2 Voltage Switch - Purge “0” Position In purge position, fan runs but there is no weld output. 3 Wire Speed Control Use control to select a wire feed speed.
5-2. Weld Parameter Chart For 115 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials using proper technique, joint preparation, and multiple passes. Material Wire T ype, Being Welded and Polarity Setting Steel Flux Core E71T Suggested Shielding Gas 20−30 cfh Flow Rate No Shielding −1 1 can be welded Gas Required Good for Windy Diameter of Wire Being Used .030” (0.8 mm) or Applications .035” (0.9 mm) Solid Wire C25 Gas Mixture .024” (0.
for 115 Volt Wire Welding Package Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded. Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. 22 gauge (.8 mm) −−− 18 gauge (1.2 mm) 16 gauge (1.6 mm) 1/8 inch (3.2 mm) 3/16 inch (4.
5-3. Weld Parameter Chart For 230 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials using proper technique, joint preparation, and multiple passes. Material Wire T ype, Being Welded and Polarity Setting Steel Flux Core E71T Suggested Shielding Gas 20−30 cfh Flow Rate No Shielding −1 1 can be welded Gas Required Good for Windy Diameter of Wire Being Used .030” (0.8 mm) .035” (0.9 mm) or Applications .045” (1.2 mm) Solid Wire C25 Gas Mixture .024” (0.
for 230 Volt Wire Welding Package Recommended V oltage and Wire Speed Settings for Thickness of Metal Being Welded. Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. 22 gauge (.8 mm) 18 gauge (1.2 mm) 16 gauge (1.6 mm) 1/8 inch (3.2 mm) 3/16 inch (4.8 mm) 1/4 inch (6.
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Or 6-2. Overload Protection 1 Circuit Breaker CB1 CB1 protects unit from overload. If CB1 opens, unit shuts down. 1 Reset breaker. 802 441 6-3.
6-4. Changing Drive Roll Or Wire Inlet Guide 1 2 Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 1 3 3 2 4 Tools Needed: Stamped .024 Retaining Pin To secure drive roll, locate open slot and push drive roll completely over retaining pin, then rotate drive roll (1/4 turn) to closed slot. 4 .030/.035 Groove Drive Roll The drive roll consists of two different sized grooves.
6-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 8 mm / 10mm Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. Head Tube 8 mm 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner. Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more. Blow out gun casing.
6-7. Replacing Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. 1 Remove handle locking nut. 3 2 Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. 4 Secure head tube in vice. 5 6 Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector.
6-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 4-6). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1). Reset welding power source circuit breaker if open. No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when motor continues to run.
SECTION 7 − ELECTRICAL DIAGRAM 194 324-C Figure 7-1.
194 325-A Figure 7-2.
SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/ Power Source Shielding Gas Gas Hose Gun Work Clamp Workpiece light mig 5/967 / Ref.
8-2. Typical MIG Process Control Settings NOTE 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. 1/8 or 0.125 in Convert Material Thickness to Amperage (A) (0.001 in = 1 ampere) 0.125 in = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in 30 − 90 A 0.030 in 40 − 145 A 0.
8-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.
8-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
8-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 1 2 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. 3 S-0054-A 8-6.
8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand on solid surface or use two hands. 8-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move.
8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters. welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.
Notes Return To Table Of Contents OM-944 Page 41
SECTION 9 − PARTS LIST . Hardware is common and 19 15 24 31 41 42 43 45 47 46 52 51 48 1 44 49 39 34 40 33 2 50 32 36 38 37 35 3 4 30 5 6 7 8 28 29 9 10 11 27 12 13 26 25 17 23 16 14 18 20 21 22 not available unless listed. 802 449-E Figure 9-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 9 10 11 12 13 13 14 15 15 16 17 18 18 19 20 20 21 22 23 24 25 25 26 26 27 27 28 29 30 31 32 33 34 35 36 37 38 38 39 40 41 . . . . . . . . . . . . . . . 199 566 . . . . . . . . . . . . . . . 196 006 . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly (Continued) . . . 41 . . . . . . . . . . . . . . . 196 574 . . . 42 . . . . . . . . . . . . . . . 207 078 . . . 43 . . . . . . . . . . . . . . . 207 079 . . . 44 . . . . . . . . . . . . . . . 202 708 . . . 45 . . . . . . . . . . . . . . . 193 189 . . . 46 . . . . . . . . . . . . . . . 196 654 . . . 47 . . . . . . . . . . . . . . . 196 009 . . . 48 . . . . . . . . . . . . . . . 202 925 . . . 49 . . . . . . . . . . . . . . .
Item No. Part No. 195 957 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 2 2 2 3 4 5 6 7 8 9 9 9 9 10 11 . . . . . . . . . . . . . . . 169 715 . . . . . . . . . . . . . ♦087 299 . . . . . . . . . . . . . ♦000 067 . . . . . . . . . . . . . ♦000 068 . . . . . . . . . . . . . ♦000 069 . . . . . . . . . . . . . . . 169 716 . . . . . . . . . . . . . . . 170 470 . . . . . . . . . . . . . . . 169 718 . . . . . . . . . . . . . . . 169 738 . . . . . . . . . . . . . . . 169 719 . . . . .
Notes
Effective January 1, 2003 Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Contact your Distributor for: Welding Supplies and Consumables Call 1-877-Hobart1 or visit our website at www.HobartWelders.
