Hobart Welding Products OM-947 manual

OM-947 212 149G 2010 − 05 Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW) W elding (Optional) Flux Cored (FCA W ) W elding Handler 125 A n d H - 9 B G u n R File: Flux Cored (FCA W)[...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

T ABLE OF CONTENTS SECTION 9 − WIRE WELDING GUIDELINES 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical FCA W Process Connections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Connections 32 [...]

OM-947 Page 1 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 [...]

OM-947 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. 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 , [...]

OM-947 Page 3 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. F A[...]

OM-947 Page 4 1-4. California Proposition 65 W arnings W elding 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[...]

OM-947 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2010 − 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. [...]

OM-947 Page 6 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[...]

OM-947 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les i[...]

OM-947 Page 8 Les PIÈCES MOBILES peuvent causer des blessures. 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 v[...]

OM-947 Page 9 2-5. P r inc ipa l es n or m es d e s éc ur it é Safety i n W elding, 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 W elding and Cutting, American Welding Society [...]

OM-947 Page 10[...]

OM-947 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMAW) Wire Feed Flux Cored Arc W elding (FCAW) SECTION 4 − SPECIFICA TIONS 4-1. Specifications Rated Weldi[...]

OM-947 Page 12 4-2. Duty Cycle And Overheating duty1 4/95 − 210 517-B Duty Cycle is percentage of 10 min- utes 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. NOTICE − Exceeding d[...]

OM-947 Page 13 SECTION 5 − INST ALLA TION 5-1. Installing W ork Clamp 1 Nut 2 W ork Cable From Unit 3 W ork Clamp 4 Screw 5 W ork Clamp T abs Bend tabs around work cable. 6 Insulator Grip Slide one insulating grip over work cable before connecting to clamp. Slide insulating grips over handles. Ref. 802 456 . Connection hardware must be tightened [...]

OM-947 Page 14 5-2. Process/Polarity T able Process Polarity Cable Connections Cable T o Gun Cable T o Work Clamp FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative ( − ) output terminal Connect to positive (+) output terminal GMA W* − Solid wire with shielding gas DCEP − Reverse polarity Connect [...]

OM-947 Page 15 5-4. Installing Gas Supply . This Section only applies to MIG units or units equipped with MIG kit. 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 V alve Remove cap, stand to side of valve, and open valve slightly . Gas flow blows dust an[...]

OM-947 Page 16 5-5. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in. T ools Needed: Ref. 802 971-C / 803 012 / 803 013 -B Installing 8 in. (203 mm) Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Retaining ring used with[...]

OM-947 Page 17 5-6. Serial Number And Rating Label Location Th e serial number and rating information for this product is located on 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. 5-7. Selecting A Location And Connecting Inpu[...]

OM-947 Page 18 5-8. Installing Contact T ip And Nozzle T ools Needed: Ref. 804 241-A ! T ur n off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. 1 2 3 Flux Nozzle MIG Nozzle Use with flux core[...]

OM-947 Page 19 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Cable Lay gun cable out straight. T ools Needed: 6 1 Pull and hold wire; cut off end. 4 in. (102 mm) Remove gun nozzle and contact tip. Open pressure assembly . Push wire thru guides into gun liner; continue to hol[...]

OM-947 Page 20 SECTION 6 − OPERATION 6-1. Controls 1 V oltage Switch Use control to select the weld voltage range. As the thickness of material increases, a higher voltage range must be selected (see weld setting label in welding power source or Section 6-3 as applicable). Do not switch under load. . Switch must “click” into detent position f[...]

OM-947 Page 21 Notes[...]

OM-947 Page 22 6-3. W eld Parameter Chart[...]

OM-947 Page 23 210 428[...]

OM-947 Page 24 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe condi- tions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked W e[...]

OM-947 Page 25 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Pressure Adjustment Knob 2 Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly up. 3 Pivot T ube Plate 4 Securing Screws 5 Pressure Arm Pivot T ube 6 Inlet Wire Guide Remove screws and pivot tube plate. Lift out pressure arm pivot tube, and slide inlet wire [...]

OM-947 Page 26 7-5. Replacing Gun Contact Tip T ools Needed: Ref. 804 241-A ! T urn Off power before replacing contact tip. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter , and install new contact tip. Reinstall nozzle. 1 2 3[...]

OM-947 Page 27 7-6. Cleaning Gun Liner 804 241-A / 803 838-A ! T urn Off welding power source. 1 Nozzle 2 Contact T ip 3 Adapter Head T ube T ools Needed: 8 mm La y gun cable out straight, and blow out liner . Remove nozzle. Cut of f wire at contact tip, and remove contact tip and tip adapter . . Thread wire according to Section 5-9. Reassemble dri[...]

OM-947 Page 28 7-7. Replacing Gun Liner Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A T ools Needed: 8 mm / 10 mm Remove nozzle. Cut of f wire at contact tip, and remove contact tip and tip adapter . Open pressure assembly. Retract wire from liner onto spool. . Hold wire tightly to keep it from unraveling. Secure end of wire at spool. T wist t[...]

OM-947 Page 29 7-7. Replacing Gun Liner (Continued) When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. Slide locking rings over top and bottom of handle, and secure by twisting rings clockwise 1/4 turn. Place other half of handle over head tube and cable. Be sure that cable is s[...]

OM-947 Page 30 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-7). 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 if open. No wel[...]

OM-947 Page 31 SECTION 8 − ELECTRICAL DIAGRAM 230 950-A Figure 7-1. Circuit Diagram[...]

OM-947 Page 32 SECTION 9 − WIRE WELDING GUIDELINES 9-1. T ypical FCA W Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce w or k cl am p as close to the weld as possible. Wire Feeder/ Power Source fcaw 1/2003 / Ref. 803 444-A Self-Shielding Flux Core Wire[...]

OM-947 Page 33 9-3. T ypical Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A Convert Material [...]

OM-947 Page 34 9-4. Holding And Positioning Welding Gun . W elding 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 e nd o f noz zle, and tip o f wir e is posi tion ed c orre ctly on s eam. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 El[...]

OM-947 Page 35 9-5. Conditions That Affect Weld Bead Shape . 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. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFILES[...]

OM-947 Page 36 9-6. Gun Movement During Welding . Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along Se[...]

OM-947 Page 37 9-9. T roubleshooting − 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use sh[...]

OM-947 Page 38 9-12. T roubleshooting − 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 [...]

OM-947 Page 39 9-15. T roubleshooting − W aviness Of Bead W aviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding 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 o[...]

OM-947 Page 40 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 803 446-B 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 42 20 21 22 23 24 25 26 27 28 29 32 30 31 33 34 35 36 37 38 39 40 41 43 Figure 9-1. Main Assembly[...]

OM-947 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 210 432 CASE SECTION, front/bottom/rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 530 BLANK, snap-in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-947 Page 42 1 804 243-A 2 3 5 − See T able 9-1 4 6 7 7 Figure 9-2. H-9B Gun Description Part No. 195 157R Item No. Figure 9-2. H-9B Gun Quantity 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 226 190 NOZZLE, flux cored slip type 1 . . . [...]

OM-947 Page 43 803 442-B 4 5 1 6 7 8 9 2 3 Figure 9-3. Wire Drive Assembly Quantity Description Part No. 209 532 Item No. Figure 9-3. Wire Drive Assembly 1 212 377 BEARING, idler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212 379 ROLL, drive .024-.030/.[...]

Notes W o r k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

Notes[...]

Notes[...]

Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 2010 − 01 Service Y o u 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 Hoba[...]

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Hobart Welding Products. 2010 − 01 Hoba rt We lding Product s An Illinois T ool W or ks Comp an y 600 W est Main Stree t Tr oy , OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Liter atur e Or Nea re s t Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Dat[...]