Hobart Welding Products OM-947 212 149D manual

OM-947 212 149D 2006 − 08 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 8 − WIRE WELDING GUIDELINES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical FCA W Process Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical MIG Process Connections 28 [...]

OM-947 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 messag[...]

OM-947 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

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 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F4[...]

OM-947 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : s e protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les util isés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss ibl[...]

OM-947 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau. [...]

OM-947 Page 7 2-3 . Dange rs suppléme ntaire s en r elation a vec l’installa tion, le f onctionneme nt et la m aintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’[...]

OM-947 Page 8 2-5. Princi pales nor mes de sécuri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldin[...]

OM-947 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Specifications 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 @ 1 9 V olts DC, 20% Duty Cycle 63 A @ 2 1 V olts DC, 20% Duty Cycle * 30 − 125 29 20 15 * 2.90 2.20 *[...]

OM-947 Page 10 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 − 210 518 8.0 13.0 18.0 23.0 28.0 33.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 1 10.0 120.0 130.0 Amp[...]

OM-947 Page 1 1 4-2. Process/Polarity T able Process Polarity Cable Connections P rocess P o l ar i ty 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 − R[...]

OM-947 Page 12 4-4. Installing Gas Supply This Section only applies to MIG units or units equipped with MIG kit. NOTE 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[...]

OM-947 Page 13 4-5. 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 8 [...]

OM-947 Page 14 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 time-de- lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 AWG fo r up to 50 ft (15 m) or 12 A WG for 50 up to 200 ft (61 m)[...]

OM-947 Page 15 4-7. Installing Contact T ip And Nozzle T ools Needed: Ref. 804 241-A Y 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 4-8). 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 16 4-8. 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 hold[...]

OM-947 Page 17 SECTION 5 − OPERATION 5-1. 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 5-3 as applicable). Do not switch under load. . Switch must “click” into detent position f[...]

OM-947 Page 18 5-3. W eld Parameter Chart[...]

OM-947 Page 19 210 428[...]

OM-947 Page 20 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. Overload Protection 803 379-A 1 Su[...]

OM-947 Page 21 6-4. 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 22 6-5. Replacing Gun Contact Tip T ools Needed: Ref. 804 241-A Y T ur n off welding power source. 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 23 6-6. Cleaning Gun Liner 804 241-A / 803 838-A Y T ur n 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 4-8. Reassemble dr[...]

OM-947 Page 24 6-7. 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 25 6-7. 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 26 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). d oes no t run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1). Reset welding power source supplementary protector [...]

OM-947 Page 27 SECTION 7 − ELECTRICAL DIAGRAM 230 950-A Figure 6-1. Circuit Diagram[...]

OM-947 Page 28 SECTION 8 − WIRE WELDING GUIDELINES 8-1. T ypical FCA W Process Connections Y 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 29 8-3. T ypical Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, 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 A 40 − 145 A 50 − 180 A Convert Material Thickness to[...]

OM-947 Page 30 8-4. 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 Electrode [...]

OM-947 Page 31 8-5. 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. NOTE Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFIL[...]

OM-947 Page 32 8-6. 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 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 Along [...]

OM-947 Page 33 8-9. 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 34 8-12. 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 35 8-15. 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 36 SECTION 9 − 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 8-1. Main Assembly[...]

OM-947 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 210 432 CASE SECTION, front/bottom/rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 530 BLANK, snap-in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-947 Page 38 1 804 243-A 2 3 5 − See T able 8-1 4 6 7 7 Figure 8-2. H-9B Gun Description Part No. 225 397 Item No. Figure 8-2. 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 39 803 442-B 4 5 1 6 7 8 9 2 3 Figure 8-3. Wire Drive Assembly Quantity Description Part No. 209 532 Item No. Figure 8-3. Wire Drive Assembly 1 212 377 BEARING, idler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212 379 ROLL, drive .024-.030/.[...]

Notes[...]

Notes[...]

Notes[...]

Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2006 − 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[...]

PRINTED IN USA © 2005 Hobart Welding Products. 6/05 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 (Date which equipment was delivered t[...]