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Hobart Welding Products 1800 manual

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Table of contents for the manual

  • Page 1

    BET A-MIG 1800 And M-15 Gun Processes OM-929 196 903B February 2000 Specifications Covered by this Manual: 500 438 Gas Metal Arc (MIG) W elding Flux Cored Arc (FCAW) W elding Description Arc Welding Power Source and Wire Feeder Visit our website at www.HobartWelders.com[...]

  • 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

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

  • Page 4

    [...]

  • Page 5

    OM-929 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! Watch O[...]

  • Page 6

    OM-929 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 Z87[...]

  • Page 7

    OM-929 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[...]

  • Page 8

    OM-929 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects 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 years [...]

  • Page 9

    OM-929 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 particulier . [...]

  • Page 10

    OM-929 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 dans le[...]

  • Page 11

    OM-929 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 surcharger l[...]

  • Page 12

    OM-929 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 the[...]

  • Page 13

    OM-929 Page 9 SECTION 2 – INTRODUCTION 2-1. Specifications Max. Open Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Circuit V oltage 200 V 230 V KV A KW 150 A at 23 VDC, 60% Duty Cycle 33 30 1.6* 26 1.4* 6 0.27* 5 0.13* Wire T ype and Diameter Wire Feed Speed Dimensions W eight Solid Steel/ Stainless Steel Aluminum Flux Cored 90 –[...]

  • Page 14

    OM-929 Page 10 2-3. V olt-Ampere Curves V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 – 180 824 2-4. Installing Welding Gun Ref. 802 285-A 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end through openin[...]

  • Page 15

    OM-929 Page 1 1 2-5. Setting Gun Polarity For Wire T ype T ools Nee d e d : 3/4 in Shown As Shipped – Set For Electrode Positive (DCEP) For Solid Steel Or Aluminum Wires (GMA W Process). Reverse Lead Connections – For Electrode Negative (DCEN) For Flux Cored Wires (FCA W Process). Drive Assembly Becomes Negative S-185 249 Wire Drive Assembly Le[...]

  • Page 16

    OM-929 Page 12 2-6. Installing Gas Supply Ref. 801 789 / Ref. 149 827-B / Ref. 158 697-A 1 T ools Ne eded: 2 CO 2 Gas 4 5 1 Argon Gas OR 3 Chain gas cylinder to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection Fitting has 5/8-18 ri[...]

  • Page 17

    OM-929 Page 13 2-8. Changing Input V oltage From 230 V olts T o 200 V olts Ref. 801 878-B Cut cable ties as necessary . 1 230 V olt Lead 2 T ubing Locate lead marked 230 V A C. Slide tubing down and disconnect lead splice. Fold tubing over 230 volt lead stub and secure. 3 200 V olt Lead Locate lead marked 200 V A C. Slide tubing down, and connect 2[...]

  • Page 18

    OM-929 Page 14 2-10. Selecting A Location And Connecting Input Power 801 876-B 1 Rating Label Supply correct input power . 2 Plug 3 Receptacle Connect plug to receptacle. 4 Input And Grounding Conductors Connect directly to line disconnect device if hard wiring is required. 5 Line Disconnect Device See Section 2-9. Y Special installation may be req[...]

  • Page 19

    OM-929 Page 15 2-1 1. Threading Welding Wire Ref. 802 472 / 802 480 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: 6 in (150 mm) Pull and hold wire; cut off end. 4 in (102 mm) T ighten Remove gun nozzle and contact tip. T urn O[...]

  • Page 20

    OM-929 Page 16 SECTION 3 – OPERA TION 3-1. Controls 1 Wire Speed Control Th e scale around the control is per- cent, not wire feed speed. 2 V oltage Control The higher the selected number , the thicker the material that can be welded (see welding guide and Section 3-2). 3 Welding Guide 4 Power Switch 1 2 4 3 Ref. 196 876-A[...]

  • Page 21

    OM-929 Page 17 3-2. W eld Parameters Material Thickness Wire T ype, 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 (3.2 mm) 12 ga 14 ga 16 ga 18 ga 20 ga 22 ga V oltage T a p – – 654332211 .023 Wire Speed – – 100 80 65 55 45 35 25 15 5 E70S-6 V oltage T a p 6 54332[...]

  • Page 22

    OM-929 Page 18 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 o[...]

  • Page 23

    OM-929 Page 19 4-3. Cleaning Or Replacing Gun Liner Ref. ST-800 797-C 5/16 in, 10 mm T o Reassemble Gun: Insert new liner . Install and tighten wire outlet guide. 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. Lay gun cable out straight before installing new liner . Head Tube 5[...]

  • Page 24

    OM-929 Page 20 4-4. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 1 Remove handle locking nut. 2 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 [...]

  • Page 25

    OM-929 Page 21 4-5. Replacing Gun Contact Tip Ref. 800 797-C Y T urn Off unit. 1 Nozzle 2 Contact Tip Cut of f welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 1 2 T ools Needed: 4-6. Changing Drive Roll And Wire Inlet Guide Ref. ST-801 875 1 Inlet Wire G u i d e S e c u r i n g Screw 2 I[...]

  • Page 26

    OM-929 Page 22 4-8. Wire Drive/Gun T roubleshooting T able Wire Drive/Gun T rouble Remedy Electrode wire feeding stops during welding. Straighten gun cable and/or replace damaged parts (see Section 4-3). Adjust drive roll pressure (see Section 2-1 1) . Readjust hub tension (see Section 2-7). Check circuit breakers CB1 and/or CB2, and reset if neces[...]

  • Page 27

    OM-929 Page 23 SECTION 5 – ELECTRICAL DIAGRAM SC-186 683 Figure 5-1. Circuit Diagram For Welding Power Source[...]

  • Page 28

    OM-929 Page 24 SECTION 6 – P ARTS LIST 801 873-C . Hardware is common and not available unless listed. Figure 6-1. Main Assembly[...]

  • Page 29

    OM-929 Page 25 Description Part No. Dia. Mkgs. Item No. Quantity Figure 6-1. Main Assembly 1 196 902 LABEL, set, nameplate & side decals 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 670 HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 30

    OM-929 Page 26 ST-801 877-C . Hardware is common and not available unless listed. Figure 6-2. Center Baffle w/Components[...]

  • Page 31

    OM-929 Page 27 Description Part No. Dia. Mkgs. Item No. Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 10) 1 170 201H NUT , retaining w/warning label 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 738 SP ACER, spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-929 Page 28 . Hardware is common and not available unless listed. 800 792-B 8 9 10 14 17 11 12 11 12 13 9 15 16 1 2 3 5 Figure 6-3. M-15 Gun Description Quantity Part No. 169 589 Item No. Figure 6-3. M-15 Gun (Fig 6-1 Item 41) 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 33

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  • Page 35

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 4/00 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 distribut[...]

  • Page 36

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding Produc ts An I l li noi s T ool Works Company 600 West M ain St reet Troy , OH 45373 US A For Technical Assi stance: Call1-800-332-3281 For Lit erature O r Nearest D ealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to or[...]