OM-929 196 903B February 2000 Specifications Covered by this Manual: 500 438 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder BETA-MIG 1800 And M-15 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 WARNING This product, when used for welding or cutting, 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.) The following terms are used interchangeably throughout this manual: Stick = SMAW OM-929B SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. 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. 1-2.
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. 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 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
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. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – INTRODUCTION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. Open Circuit Voltage 200 V 230 V KVA KW 150 A at 23 VDC, 60% Duty Cycle 33 30 1.6* 26 1.4* 6 0.27* 5 0.13* Wire Feed Speed Dimensions Weight 90–650 IPM (2.3–16.5 m/min) H: 29-7/8 in (759 mm) W: 15-1/8 in (384 mm) D: 33-3/8 in (848 mm) 195 lb (88 kg) Wire Type and Diameter Solid Steel/ Stainless Steel Aluminum Flux Cored .023 – .035 in (0.6 – 0.9 mm) .030 – .035 in (0.8 – 0.
2-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. va_curve1 4/95 – 180 824 2-4. Installing Welding Gun 1 2 3 Drive Assembly Gun Securing Knob Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 1 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 3 Close door. 2 4 Ref.
2-5. Setting Gun Polarity For Wire Type 1 2 3 4 Shown As Shipped – Set For Electrode Positive (DCEP) For Solid Steel Or Aluminum Wires (GMAW Process). Polarity Changeover Label Wire Drive Assembly Positive (+) Output Terminal Negative (–) Output Terminal Always read and follow wire manufacturer’s recommended polarity. 1 Close door.
2-6. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection Fitting has threads. 3 1 Argon Gas Flow Adjust CO2 Adapter Customer Supplied 5 2 right-hand Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate (see Section 3-2). This flow gauge can be adjusted between 5 and 25 cfh.
2-8. Changing Input Voltage From 230 Volts To 200 Volts Cut cable ties as necessary. 1 2 230 Volt Lead Tubing Locate lead marked 230 VAC. Slide tubing down and disconnect lead splice. Fold tubing over 230 volt lead stub and secure. 3 200 Volt Lead Locate lead marked 200 VAC. Slide tubing down, and connect 200 volt lead stub to top half of the former 230 volt lead, and secure with existing hardware. 2 3 Slide tubing over connection and secure. 1 Tools Needed: 5/16, 3/8 in Ref. 801 878-B 2-9.
2-10. Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power. 2 3 Y Do not move or operate unit where it could tip. Plug Receptacle Connect plug to receptacle. 4 18 in (457 mm) of space for airflow Input And Grounding Conductors Connect directly to line disconnect device if hard wiring is required. 5 Line Disconnect Device See Section 2-9.
2-11. Threading Welding Wire 1 2 3 4 5 6 7 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 7 Tools Needed: 1 2 3 5 Ref. 802 472 / 802 480 6 . 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. Tighten Close and tighten pressure assembly, and let go of wire.
SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Control The scale around the control is percent, not wire feed speed. 2 Voltage Control The higher the selected number, the thicker the material that can be welded (see welding guide and Section 3-2). 4 3 4 Welding Guide Power Switch 1 2 3 Ref.
3-2. Weld Parameters Material Thickness Wire Type, Shielding Gas, And Flow Rate Wire Diameter (inch) Operator Controls 3/8 in (9.5 mm) 1/4 in (6.4 mm) 3/16 in (4.8 mm) 1/8 in (3.
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. 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 Remove drive roll and apply light coat of oil or grease to drive motor shaft. 4-2. Circuit Breakers Y Turn Off unit. 1 Circuit Breaker CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails.
4-3. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner. Install and tighten wire outlet guide. Blow out gun casing. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Ref.
4-4. Replacing Switch And/Or Head Tube Y Disconnect gun first. 1 Remove handle locking nut. 3 2 4 Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure. Secure head tube in vice. 5 6 Loosen jam nut. Remove from vice and turn head tube out by hand.
4-5. Replacing Gun Contact Tip Y Turn Off unit. 1 2 Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Tools Needed: 2 Remove contact tip and install new contact tip. Reinstall nozzle. 1 Ref. 800 797-C 4-6. Changing Drive Roll And 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. 3 Drive Roll Install correct drive roll for wire size and type.
4-8. Wire Drive/Gun Troubleshooting Table Wire Drive/Gun Trouble Remedy Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section 4-3). welding. Adjust drive roll pressure (see Section 2-11). Readjust hub tension (see Section 2-7). Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2). Replace contact tip if blocked (see Section 4-5). Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-6).
SECTION 5 – ELECTRICAL DIAGRAM SC-186 683 Figure 5-1.
SECTION 6 – PARTS LIST . Hardware is common and not available unless listed. 801 873-C Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 1 . . . . . . . . . . 196 902 . . . 2 . . . . . . . . . . 184 670 . . . 3 . . . . . . . . . . 184 657 . . . 4 . . . . S1 . . 124 511 . . . 5 . . . . . . . . . . 184 733 . . . 6 . . . . R1 . . 035 897 . . . 7 . . . . . . . . . . 148 956 . . . 8 . . . . S2 . . 153 197 . . . 9 . . . . T1 . . 184 669 . . . 10 . . . . . . . . . . . Fig 6-2 . . . . . . . . . SR1 . . 184 674 . . . 11 . . . . . . . . . . 170 757 . . . 12 . . .
. Hardware is common and not available unless listed. ST-801 877-C Figure 6-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 10) . . . 1 . . . . . . . . . . . 170 201H . . . NUT, retaining w/warning label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 184 738 . . . SPACER, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 374 551 . . . WASHER, flat keyed . . . . . . . . . . . . . . . . .
. Hardware is common and 8 1 2 3 not available unless listed. 5 9 10 15 11 16 17 13 12 14 9 11 12 800 792-B Figure 6-3. M-15 Gun Item No. Part No. 169 589 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 2 2 2 3 5 8 9 10 11 12 13 14 15 15 15 16 17 . . . . . 169 715 . . . ♦087 299 . . . ♦000 067 . . . ♦000 068 . . . ♦000 069 . . . . . 169 716 . . . . . 170 470 . . . . . 169 718 . . . . . 169 738 . . . . . 194 524 . . . . . 169 737 . . . . . 169 741 . . . . .
Effective October 1, 1999 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.