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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.com
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From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8-3. Holding And Positioning Welding Gun .
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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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding Ha
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection, ting of Containers
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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 vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux Identifie un message de sécurité particulier. PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et
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LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation. tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien ventiler les espaces confinés ou porter un
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2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. Ne pas placer l’appareil sur une surface inflam- Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à proximité d’elle. ventilateurs. Maintenir fermés et bien fixés les portes, Ne pas installer l’appareil à proximité de produits inflammables. panneaux, recouvrements et dispositifs de N
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2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org). tional.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection
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SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage KVA KW Output Range 115 V, 60 Hz, Single- W/ Gun Dimensions DC Phase Length: 18-7/8 in (479 mm) 90 A @ 19 Volts DC, 20 2.90 2.50 55 lb 20% Duty Cycle Width: 10-5/8 in (25 kg) 30 − 135 28 (270 mm) 63 A @ 21 Volts DC, 15* 2.20* 1.77* 20% Duty Cycle* Height: 12-3/8 in (314 mm) Solid/ Flux Cored/ Wire Feed Speed Range Stainless Alumin
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3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 115 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for 200 unit to cool. Reduce amperage or duty cycle before welding. 135 Exceeding duty cycle can 100 damage unit or gun and void warranty. 80 60 40 20 10 2 4168 80 40 600 100 1 20 Duty Cycle % 20% duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B.
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3-3. Volt-Ampere Curves The volt-ampere curves show the A. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 30.0 25.0 20.0 Range 4 15.0 Range 3 Range 2 10.0 Range 1 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 20.0 Range 4 Range 3 15.0 Range 2 Range 1 10.0 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 19
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SECTION 4 − INSTALLATION 4-1. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End 4 Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 Gun Trigger Leads 2 3 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. Installing Work Clamp 1 Nut 3 2 Work Cable From Unit 1 3 Work
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4-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output no shielding gas output terminal terminal 4-4. Changing Polarity 1 Lead Connections For Direct CHANGING Current Electrode Negative POLARITY
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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 1 Cap with CO shielding gas. See Parts List for optional 2 2 Cylinder Valve CO gas regulator/flowmeter. 2 Remove cap, stand to side of valve, 1 and open valve slightly. Gas flow 4 blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter 2 Install so face is vertical. 7 5 Regul
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4-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual 2 18 in 1 branch circuit protected by time-de- (460 mm) lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 3 50 up to 200 ft (61 m). Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 18 in (460 mm) 802 4
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4-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug (NEMA 6-50P) 3 Receptacle (NEMA 6-50R) Connect plug to receptacle. 4 Line Disconnect Device 18 in (457 mm) of space for airflow See Section 4-8. Special installation may be required where gasoline or volatile liquids are present − 4 see NEC Article 511 or CEC Section 20. L1 Always connect grounding conductor first. L2 = GND/PE 3 1 2 L1 L2 230 VAC, 1 Do not move or operat
