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Hobart Welding Products 120 manual

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Table of contents for the manual

  • Page 1

    Processes OM-210 088D November 1999 H a n d l e r 1 2 0 / 1 5 0 A n d Piecemaker 14A Gun Arc W elding Power Source And Wire Feeder Description MIG (GMA W) W elding Flux Cored (FCA W) W elding[...]

  • Page 2

    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 catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: MIG=GMA W T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-210 088 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch 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 W arning! Wat[...]

  • Page 6

    OM-210 088 Page 2 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. ARC RA YS can burn eyes and skin. 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[...]

  • Page 7

    OM-210 088 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.[...]

  • Page 8

    OM-210 088 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 yea[...]

  • Page 9

    OM-210 088 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-210 088 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-210 088 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-210 088 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding 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 Of fice, Washington, D.C. 20402. Recommended Safe Practice for[...]

  • Page 13

    OM-210 088 Page 9 SECTION 2 – SPECIFICA TIONS 2-1. Specifications A. 120 V AC Model Rated W elding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 120 V , 6 0 Hz, Single-Phase KV A KW W eight W/ Gun Overall Dimensions 90 A @ 19 V ol ts DC , 30% Duty Cycle 75 A @ 19 V ol ts DC , 20% Duty Cycle * 30 – 13[...]

  • Page 14

    OM-210 088 Page 10 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n - 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. Y Exceeding duty cycle can damage unit or[...]

  • Page 15

    OM-210 088 Page 1 1 2-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 – ST-802 082 / ST -802 089 A. 120 V AC Model B. 230 V AC Model[...]

  • Page 16

    OM-210 088 Page 12 SECTION 3 – INST ALLA TION 3-1. Installing Welding Gun Ref. ST-802 024 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert gun en d through opening until it bottoms against drive assembly . Tighten thumbscrew . 4 Gun Trigger Leads Insert leads, one at a time, through small grommet on front panel. Con[...]

  • Page 17

    OM-210 088 Page 13 3-4. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other station- ary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter [...]

  • Page 18

    OM-210 088 Page 14 3-5. Selecting A Location And Connecting Input Power For 120 V AC Model 1 Rating Label 2 Grounded Receptacle A 120 volt, 20 ampere individual branch circuit protected by time -de - lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 A WG fo r up to 50 ft (15 m) or 12 A WG for 50 up to 200 ft ([...]

  • Page 19

    OM-210 088 Page 15 3-6. Selecting A Location And Connecting Input Power For 230 V AC Model 1 Rating Label Supply correct input power . 2 Plug 3 Receptacle Connect plug to receptacle. 4 Line Disconnect Device See Section 3-7. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 51 1 or CEC Section[...]

  • Page 20

    OM-210 088 Page 16 3-7. Electrical Service Guide For 230 V AC Model Input V oltage 230 Input Amperes At Rated Output 19.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30 Min Input Conductor Size In A WG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 6 6 (20) Min Grounding Conductor Size In A WG/Kcmil 14 Refer[...]

  • Page 21

    OM-210 088 Page 17 3-9. Threading W elding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 7 6 1 3 4 5 6 in (150 mm) Pull and hold wire; cut off end. 4 in (102 mm) T ighten Remove gun nozzle and contact tip. Open pressure a[...]

  • Page 22

    OM-210 088 Page 18 SECTION 4 – OPERATION 4-1. Controls 1 V oltage Switch The higher the selected number , the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. 2 V oltage Switch - Purge “ 0 ” Position In purge position, fan runs but there [...]

  • Page 23

    OM-210 088 Page 19 4-2. W eld Parameters For 120 V AC Model 205 406-A Brackets and Rims Basketball Farm Equipment Frames, Frames, ” A ” Axles, Brackets, 5356 (.035) 1/4 1/2 5/16 3/4 1/2 1/2 1/2 1/2 3/4 1/4 1/2 1/2 5/16 1/2 1/4 5/16 5/16 5/16 5/16 1/4 1/4 1/4 3 – 4 3 – 4 2 – 3 2 – 3 3 – 4 2 – 3 3 – 4 2 – 3 2 4 – 5 3 – 4 3 –[...]

  • Page 24

    OM-210 088 Page 20 4-3. W eld Parameters For 230 V AC Model 205 424-A W elding Guide Settings are approximate. Adjust as required. WIRE TYPESIZE T O WELD: (Inches/ Gauge) GAS FLOW POLARITY WELDING VOL T AGE WIRE SPEED WIRE STICKOUT (Inches) (Cubic Ft/Hr) THICKNESS Auto Body Lawnmower Handles, W agons, T ricycles, Duct T ailpipes, Bicycles Wheelbar[...]

  • Page 25

    OM-210 088 Page 21 SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. 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 5-2. Overload Protection Ref. ST-80[...]

  • Page 26

    OM-210 088 Page 22 5-3. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. Tighten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stamped markings on the end surface of the drive ro[...]

  • Page 27

    OM-210 088 Page 23 5-5. Cleaning Or Replacing Piecemaker 14-A Gun Liner Ref. ST-801 995 1/16 in T o Reassemble Gun: Insert new liner . Push liner against quick-connect plug, and tighten set screw . Cut liner of f so that 3/4 in (19.05 mm) sticks out of head tube. Install adapter , contact tip, and nozzle. Lay gun cable out straight before installin[...]

  • Page 28

    OM-210 088 Page 24 5-6. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Check circuit breaker CB (CSA model), and reset if necessary ([...]

  • Page 29

    OM-210 088 Page 25 Notes[...]

  • Page 30

    OM-187 926 Page 26 SECTION 6 – ELECTRICAL DIAGRAM ST-205 400 53 Figure 6-1. Circuit Diagram For 120 V AC Model[...]

  • Page 31

    OM-210 088 Page 27 ST-210 01 1-C 53 Overload Feed Motor Figure 6-2. Circuit Diagram For 120 V AC CSA Model[...]

  • Page 32

    OM-187 926 Page 28 ST-205 423-B 53 53 Figure 6-3. Circuit Diagram For 230 V AC Model[...]

  • Page 33

    OM-210 088 Page 29 SECTION 7 – MIG WELDING (GMA W) GUIDELINES 7-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close to the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shie[...]

  • Page 34

    OM-210 088 Page 30 7-2. T ypical MIG Process 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. NOTE 1/8 or .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere) [...]

  • Page 35

    OM-210 088 Page 31 7-3. Holding And Positioning Welding Gun 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electr[...]

  • Page 36

    OM-210 088 Page 32 7-4. 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. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STI[...]

  • Page 37

    OM-210 088 Page 33 7-5. 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 across gaps, a weave bead or multiple stringer beads works better . NOTE 1 Stringer Bead – Steady Movement Along Seam 2 Weave Bead – Side T o Side Movement Al[...]

  • Page 38

    OM-210 088 Page 34 7-8. T roubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool t o 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. U[...]

  • Page 39

    OM-210 088 Page 35 7-1 1. 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 maintai[...]

  • Page 40

    OM-210 088 Page 36 7-14. T roubleshooting – W aviness Of Bead W aviness O f 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 h[...]

  • Page 41

    OM-210 088 Page 37 7-16. 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Cir[...]

  • Page 42

    OM-210 088 Page 38 SECTION 8 – P ARTS LIST . Hardware is common and not available unless listed. ST-802 066 Figure 8-1. Main Assembly[...]

  • Page 43

    OM-210 088 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 +203 563-1 P ANEL, top (gray) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 +203 563-BA P ANEL, top (Mac red) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 44

    OM-210 088 Page 40 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 49 129 696 CONT ACTOR, input (120 V AC model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 409 477 SWITCH, rotary range 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 45

    OM-210 088 Page 41 Description Part No. Item No. Figure 8-2. Gun And Cable Assembly , Piecemaker 14-A Quantity 1 379 718 NOZZLE, slip on assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 379 708 ADAPTER, nozzle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 46

    OM-210 088 Page 42 T able 8-2. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 407 230-1 .024 (.6) and .030/.035 (.8 and .9) 203 568 .035, 5356 Aluminum 407 230-4 .024 (.6) and .045 (1.2) T able 8-3. Kits T o Convert Piecemaker 14-A Gun And Machine T o Optional Wire Sizes P ART NO. WIRE SIZE INCHES (mm) ITEMS I[...]

  • Page 47

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 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 distrib[...]

  • Page 48

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding Product s An I l li noi s T ool Works Com pany 600 West Main St reet Troy , OH 45373 U SA For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o[...]