Hobart Welding Products OM-944 196 639G manual

Processes OM-944 196 639G October 2003 H a n d l e r 1 3 5 / 1 7 5 And H-10 Gun Arc W elding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding Visit our website at www.HobartWelders.com[...]

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[...]

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 8 − MIG WELDING (GMA W) GUIDELINES 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical MIG Process Connections 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical MIG Process Control Settin[...]

OM-944 Page 1 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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 symb[...]

OM-944 Page 2 Return T o T able Of Contents 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 wa[...]

OM-944 Page 3 Return T o T able Of Contents 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 prot[...]

OM-944 Page 4 Return T o T able Of Contents 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containe[...]

OM-944 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION 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. Y Identifie un message de sécurit?[...]

OM-944 Page 6 Revenez à la table des matières Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent c au- ser des brûlures oculaires et cuta- née[...]

OM-944 Page 7 Revenez à la table des matières 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produi[...]

OM-944 Page 8 Revenez à la table des matières 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N. W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and[...]

OM-944 Page 9 Return T o T able Of Contents SECTION 3 − SPECIFICA TIONS 3-1. Specifications A. 1 15 V AC Model Rated Welding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 1 15 V , 60 Hz, Single- Phase KV A KW W eight W/ Gun Overall Dimensions 90 A @ 19 V olts DC, 20% Duty Cycle 63 A @ 21 V olts DC, 20%[...]

OM-944 Page 10 Return T o T able Of Contents 3-2. 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. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding dut[...]

OM-944 Page 1 1 Return T o T able Of Contents 3-3. 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 − 196 608 / 196 609 A. 1 15 V AC Model B. 230 V AC Model 0.0 5.0 10.0 15.0 20.0 25.0 [...]

OM-944 Page 12 Return T o T able Of Contents SECTION 4 − INST ALLA TION 4-1. Installing Welding Gun Ref. 802 440-A 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 gun open[...]

OM-944 Page 13 Return T o T able Of Contents 4-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect to negative (−) output terminal FCAW − Self-shielding wire − no shieldin[...]

OM-944 Page 14 Return T o T able Of Contents 4-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary 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 Cylinde[...]

OM-944 Page 15 Return T o T able Of Contents 4-6. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by ti me- 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 [...]

OM-944 Page 16 Return T o T able Of Contents 4-7. Selecting A Location And Connecting Input Power For 230 V AC 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 See Section 4-8. Y Special installation may be required where gasoline or volatile liquids[...]

OM-944 Page 17 Return T o T able Of Contents 4-8. Electrical Service Guide For 230 V AC Model Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In A WG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size[...]

OM-944 Page 18 Return T o T able Of Contents 4-10. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 6 1 3 4 5 Pull and hold wire; cut off end. 4 in (102 mm) Remove gun nozzle and contact tip. Open pressure assembly . Push wire[...]

OM-944 Page 19 Return T o T able Of Contents SECTION 5 − O P E R A T I O N 5-1. 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 5-2 and 5-3, as applicable). Do not switch under load. . Switch must “click” into detent position 1,[...]

OM-944 Page 20 Return T o T able Of Contents 5-2. W eld Parameter Chart For 1 15 V AC Model W elding Guide Settings are appr oximate. Adjust as requir ed. Thicker materials can be welded using pr oper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set Tension Knob Setting to 3 at Start. Adju[...]

OM-944 Page 21 Return T o T able Of Contents for 1 15 V olt W ir e W elding Package DCEN DCEP Wi re Speed listed is a starting value only − Wire Speed setting can be fine−tuned while welding. Wire Speed also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc. keep torch as straight as possible. A ?[...]

OM-944 Page 22 Return T o T able Of Contents 5-3. W eld Parameter Chart For 230 V AC Model W elding Guide Settings are appr oximate. Adjust as requir ed. Thicker materials can be welded using pr oper technique, joint pr eparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set Tension Knob Setting to 3 at Start. Adju[...]

OM-944 Page 23 Return T o T able Of Contents for 230 V olt W ire W elding Package DCEN DCEP Wi re Speed listed is a starting value only − Wire Speed setting can be fine−tuned while welding. Wire Speed also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc. keep torch as straight as possible. A ”[...]

OM-944 Page 24 Return T o T able Of Contents SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. 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 6-2. Over[...]

OM-944 Page 25 Return T o T able Of Contents 6-4. 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. Tigh ten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stamped markings on the [...]

OM-944 Page 26 Return T o T able Of Contents 6-6. Cleaning Or Replacing Gun Liner Ref. 802 446 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tight- en two full turns more. Cut liner of f so that 3/[...]

OM-944 Page 27 Return T o T able Of Contents 6-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Ne e d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tube in vice and tighten until [...]

OM-944 Page 28 Return T o T able Of Contents 6-8. 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 4-6). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1). Reset welding power so[...]

OM-944 Page 29 Return T o T able Of Contents SECTION 7 − ELECTRICAL DIAGRAM 194 324-C Figure 7-1. Circuit Diagram For 1 15 V AC Model[...]

OM-944 Page 30 Return T o T able Of Contents 194 325-A Figure 7-2. Circuit Diagram For 230 V AC Model[...]

OM-944 Page 31 Return T o T able Of Contents SECTION 8 − MIG WELDING (GMA W) GUIDELINES 8-1. 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 t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Re[...]

OM-944 Page 32 Return T o T able Of Contents 8-2. 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 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 [...]

OM-944 Page 33 Return T o T able Of Contents 8-3. 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 orkpi[...]

OM-944 Page 34 Return T o T able Of Contents 8-4. 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 Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) [...]

OM-944 Page 35 Return T o T able Of Contents 8-5. 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 −[...]

OM-944 Page 36 Return T o T able Of Contents 8-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les 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 exte[...]

OM-944 Page 37 Return T o T able Of Contents 8-1 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 bott[...]

OM-944 Page 38 Return T o T able Of Contents 8-14. 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[...]

OM-944 Page 39 Return T o T able Of Contents 8-16. 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 [...]

OM-944 Page 40 Return T o T able Of Contents Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire fee[...]

OM-944 Page 41 Return T o T able Of Contents Notes[...]

OM-944 Page 42 Return T o T able Of Contents SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. 802 449-E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 35 33 32 50 44 49 48 47 46 45 52 51 36 37 43 42 41 39 40 38 28 31 34 Figure 9-1. Main Assembly[...]

OM-944 Page 43 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quanti ty 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 HINGE, door 2 . . . . . . . . . . . . . . . . . . . . .[...]

OM-944 Page 44 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly (Continued) Quanti ty 41 196 574 SWITCH, rocker DPST (230 V AC model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 207 078 KNOB, pointer (WFS) 1 . . . . . . . . . . . . . . . . . . . . .[...]

OM-944 Page 45 Return T o T able Of Contents Quanti ty Description Part No. 195 957 Item No. Figure 9-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP , contact scr .023 wire x 1.125 . . . . . . . . . . . . . . . . . .[...]

Notes[...]

Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 8/03 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[...]

PRINTED IN USA  2003 Hobart Welding Products. 1/03 Hoba rt We lding Product s An I l li noi s T ool Works Company 600 W es t Main Street Troy , OH 45373 U SA For T echn i cal A ssistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o[...]