OM-226 857B 2010−04 Processes MIG (GMAW) Welding Description Wire Feeder Spool Gun Spool Guns 3035-20 And 3545-20 File: Wire Feeder
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.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 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.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. 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. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
OM-226 857 Page 10
SECTION 3 − INSTALLATION 3-1. Specifications For Spool Gun 3035-20 Wire Diameter Range .030 Thru .035 in. (0.8 Thru 0.9 mm) Aluminum Wire .023 Thru 035 in. (0.6 Thru 0.9 mm) Hard Or Cored Wire Approximate Wire Feed Range 115 To 715 ipm (4.1 To 20.4 mpm) Cooling Method Air Cooled Maximum Spool Size Weld Circuit Rating Overall Dimensions Weight 4 in. (102 mm) Diameter 100 Volts, 150 Amperes, 60% Duty Cycle Using Argon Shielding Gas Length: 11-1/2 in. (291 mm) Width: 2-1/4 in. (57 mm) Height: 8 in.
3-4. Installing Optional Spool Gun Switch In Welding Power Source 2 ! Turn off and disconnect input power. 1 Welding Power Source Center Baffle Switch Location Switch Mounting Plate 2 3 1 Remove 2 screws securing switch mounting plate to center baffle. Pull switch mounting plate to pull wiring harness through center baffle hole. 4 Plastic Plug Remove and discard plastic plug from center hole in switch mounting plate panel. 5 Nylon Cable Tie Cut and discard nylon cable tie.
3-5. Connecting Spool Gun To Welding Power Source 5 2 3 5 4 7 1 6 6 Tools Needed: 8 Ref. 802 582-A 3/4 in. ! Turn off and disconnect input power. Disconnect and remove MIG (GMAW) welding gun, if applicable. 1 Front Panel Opening 2 Spool Gun Weld Cable Route weld cable through front panel opening. 3 Positive (+) Output Terminal Connect spool gun weld cable to positive (+) output terminal. 4 Work Clamp Lead Work clamp lead should be connected to negative (−) output terminal.
3-6. Installing Wire Spool And Threading Welding Wire 7 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover. Tools Needed: 6 1 8 3 4 5 Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool. 4 2 1 3 9 10 Hub Tension Nut Wire Spool 5 Push Roll/Lower Drive Roll 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever (Red) 8 Wire Inlet Guide 9 Contact Tip 10 Nozzle Remove nozzle and contact tip.
3-7. Removing Existing Barrel And Installing Contact Adapter 1 Base Nut Location Remove base nut from handle. 2 4 Handle Section Remove handle section from gun. 3 Drive Roll Assemblies Remove drive roll assemblies. 4 3 5 Nut Remove nut from barrel. 5 2 Barrel Remove barrel from gun. Disconnect gas hose from gas nipple. 6 7 Antirotation Pin Contact Adapter Remove antirotation contact adapter. 1 pin from Install contact adapter into gun, and secure with nut.
SECTION 4 − OPERATION 4-1. Controls . Spool Gun On/Off switch in Millermatic 185 Hobart IronMan 210 or IronMan 250 must be in On position for spool gun operation (see Field Kit 207 642 instructions). 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 2 1 Open valve on cylinder just before welding. 3 Valve Trigger Press trigger to energize welding power source contactor, start shielding gas flow, and begin wire feed.
5-2. Changing Drive Rolls ! Turn off and disconnect input power. 1 Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer, and lift out drive roll. To install drive roll: 4 3 Slide drive roll onto shaft and secure with washer and screw. Changing Lower Drive Roll: 2 1 It may be necessary to remove drive roll side of gun case to change lower drive roll.
5-3. Changing Liner ! Turn off and disconnect input power. 1 2 3 Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. 3 2 1 Tools Needed: Ref. 801 891-A 5-4. Troubleshooting Trouble Gun tube assembly loose. Remedy Tighten nut at base of gun tube assembly. No weld output; gun/feeder does not Place Power switch on welding power source in the On position (see welding power source Owner’s work. Manual). Erratic weld output. Tighten and clean all connections.
5-5. GMAW (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires different techniques than MIG welding mild steel. A. Before You Start Welding S Material thickness that can be welded with MIG process or aluminum are 14 ga. [0.074 in. (1.9 mm)] or heavier. (How heavy depends on the output capacity of the welder being used.) To MIG weld aluminum thinner than 14 ga.
S Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2. Gas Nozzle Contact Tube Recessed 1/8 in. (3.2 mm) Inside The Nozzle ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÉÉÉ ÉÉÉ Contact Tip To Work Distance 3/4 in. (19 mm) Figure 5-2. Contact Tube Position And Tip-To-Work Distance S Avoid large weave beads on aluminum.
SECTION 6 − ELECTRICAL DIAGRAMS 186 451 Figure 6-1.
SECTION 7 − PARTS LIST . Hardware is common and not 13 12 24 25 18 39 41 40 32 38 37 36 35 34 33 31 30 29 27 26 28 15 1 22 2 21 20 16 17 19 2 23 4 5 6 7 8 14 11 9 3 4 10 available unless listed. 801 900-D Figure 7-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Complete Assembly for Spool Gun 3035-20 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 40 41 . . . PB1 . . . . . 186 416 . . TRIGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and 14 13 25 23 41 40 39 32 38 37 36 35 34 33 31 30 29 27 26 28 15 1 2 22 21 20 16 17 18 19 24 2 4 5 6 7 12 8 11 9 3 4 10 not available unless listed. 802 577-A Figure 7-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-2. Complete Assembly For Spool Gun 3545-20 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 40 41 . . . PB1 . . . . . 186 416 . . TRIGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
Effective January 1, 2010 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MA or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST 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.
Owner’s Record Please complete and retain with your personal records. Model Name Protect Your Investment! Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Call 1-877-Hobart1 or visit our website at www.HobartWelders.