AUTO ARC 120 Specifications

OM-243 712D
2014−02
Processes
Flux Cored (FCAW) Welding
MIG (GMAW) Welding
Description
Arc Welding Power Source and Wire
Feeder
R
Auto Arc 130
And H-9B Welding Gun
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1.
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2.
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3.
Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . .
1-4.
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5.
Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6.
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1.
Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
2-4.
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5.
Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6.
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1.
Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.
Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1.
Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2.
Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3.
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4.
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1.
Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2.
Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3.
Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4.
Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5.
Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6.
Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7.
Connecting 115 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8.
Installing Contact Tip And Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9.
Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1.
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2.
Operating The Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3.
Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2.
Drive Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3.
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4.
Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5.
Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6.
Cleaning Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7.
Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8.
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − FCAW/GMAW WELDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ACCESSORIES/CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.HobartWelders.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
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Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
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 explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
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disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM- 243 712 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
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.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM- 243 712 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
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D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM- 243 712 Page 3
1-4. California Proposition 65 Warnings
Welding 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.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM- 243 712 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2013−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
D
D
D
D
D
D
D
D
D
D
D
D
D
D
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
OM-243 712 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
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 peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
OM-243 712 Page 6
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
LE BRUIT peut endommager l’ouïe.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
spécifique; les maintenir ainsi que les éléments associés en bon
état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
2-3. Dangers supplémentaires 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 proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
OM-243 712 Page 7
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
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
D
D
D
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
OM-243 712 Page 8
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les CEM peuvent créer des interférences
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux
doivent être prises: Limiter par exemple tout accès aux passants ou
procéder à une évaluation des risques individuels pour les soudeurs.
Tous les soudeurs doivent appliquer les procédures suivantes pour
minimiser l’exposition aux CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-243 712 Page 9
OM-243 712 Page 10
. A complete Parts List is available at www.HobartWelders.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
X
I1eff
U1
Amperes
V
Voltage
Positive
Direct Current
(DC)
Alternating
Current (AC)
Single Phase
Input
Voltage Input
Output
Single Phase
TransformerRectifier
Off
On
Gas Metal Arc
Welding (GMAW)
Flux Cored Arc
Welding (FCAW)
Do Not Switch
While Welding
Wire Feed
Circuit Protector
Increase
Duty Cycle
Percent
Protective Earth
(Ground)
Temperature
Line Connection
Suitable For Welding In An Environment With Increased Risk Of
Electric Shock
MIG Gun/Spool
Gun
I1
Rated Supply
Current
Rated Welding
Current
U0
Rated No-Load
Voltage (Average)
Maximum Effective
Supply Current
Primary Voltage
S
I1max
U2
Rated Maximum
Supply Current
I2
Negative
Hz
Hertz
Conventional Load
Voltage
OM-243 712 Page 11
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SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the 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.
4-2. Unit Specifications
Rated Welding
Output
Maximum OpenCircuit Voltage
DC
Amperage
Range
Amperes Input at
Rated Load Output
115 V, 60 Hz, SinglePhase
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 16-7/8 in.
(429 mm)
85 A @ 17.5 Volts DC,
20% Duty Cycle
30 − 130
20
2.78
2.62
15*
1.71*
1.59*
26
51 A @ 21 Volts DC,
20% Duty Cycle*
46 lb
(20.9 kg)
Width: 9-7/8 in.
(251 mm)
Height: 12-1/8 in.
(308 mm)
Wire Type
And Dia
Flux Cored
Solid/
Stainless
Wire Feed Speed Range
.030 − .035 in.
(0.8 − 0.9 mm)
.024 − .030 in.
(0.6 − 0.8 mm)
314 − 783 IPM (7.9 − 19.8 m/min) At No Load
170 − 360 IPM (4.3 − 9.1 m/min) Feeding Wire
* CSA Rating
4-3. Duty Cycle And Overheating
Output Amperes
20% duty cycle at 85 amps
135
100
80
60
40
2 Minutes Welding
8 Minutes Resting
20
10
1
2
4
Duty Cycle is percentage of 10 minutes that
unit can weld at rated load without
overheating.
6
8 10
20
Duty Cycle %
40
60 80 100
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 duty cycle can
damage unit or gun and void warranty.
Overheating
0
A or V
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − 243 724-A
4-4. Volt-Ampere Curves
28
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
26
24
Voltage
22
20
Range 1
Range 2
Range 3
Range 4
18
16
14
12
10
8
0
OM-243 712 Page 12
10
20
30
40
50
60 70 80
Amperage
90 100 110 120 130
ssb1.1 10/91 − 243 725-A
. A complete Parts List is available at www.HobartWelders.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
18 in.
(460 mm)
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
!
Do not move or operate unit
where it could tip.
1
Grounded Receptacle
1
2
Locate unit near correct input
power supply.
18 in.
(460 mm)
803 443-C
5-2. Installing Work Clamp
. Connection hardware must be tightened with proper tools. Do not just
hand tighten hardware. A loose electrical connection will cause poor
weld performance and excessive heating of the work clamp.
Tools Needed:
7/16 in.
3
Nut
Work Cable From Unit
Work Clamp
Screw
Work Clamp Tabs
Bend tabs around work cable.
1
6
6
Insulator Grip
Slide one insulating grip over work
cable before connecting to clamp.
2
7/16 in.
1
2
3
4
5
Slide insulating grips over handles.
5
4
Ref. 802 456
5-3. Process/Polarity Table
Cable Connections
Process
Polarity
Cable To Gun
Cable To Work Clamp
FCAW − Self-shielding wire − no
shielding gas
DCEN − Straight Polarity
Connect to negative (−) output
terminal
Connect to positive (+) output terminal
GMAW − Solid wire with shielding gas
DCEP − Reverse Polarity
Connect to positive (+) output
terminal
Connect to negative (−) output terminal
5-4. Changing Polarity
1
2
1
2
Lead Connections For Direct
Current Electrode Negative
(DCEN)
Lead Connections For Direct
Current Electrode Positive
(DCEP)
Always read and follow wire
manufacturer’s recommended polarity, and see Section 5-3.
Close door.
Ref. 210 428
OM-243 712 Page 13
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5-5. Installing Gas Supply
. This Section only applies to MIG units or units equipped with MIG kit.
2
5
7
4
Tools Needed:
3
8
11/16, 1-1/8 in.
1
6
9
Shielding
Gas
247 832-A
1
Cylinder
5
Obtain gas cylinder and chain to running
gear, wall, or other stationary support so
cylinder cannot fall and break off valve.
2
Cap
3
Cylinder Valve
Fixed Flow Regulator
Install either the adjustable regulator or
fixed flow regulator to cylinder valve. Be
sure that the adjustable regulator gauge
face is vertical for viewing and adjusting.
6
Adjustable Regulator/Flowmeter Gas
Hose Connection
Remove cap, stand to side of valve, and
open valve slightly. Gas flow blows dust
and dirt from valve. Close valve.
Install hose onto barbed fitting on regulator.
4
Install hose onto barbed fitting on regulator.
Adjustable Regulator/Flowmeter
7
Fixed Flow Regulator Gas Hose
Connection
8
Welding Power Source Gas Hose
Connection
Install hose onto threaded gas connector,
and tighten fitting.
9 Flow Adjust
Flow rate should be set when gas is flowing
through welding power source and welding
gun. Release pressure adjust arm on feed
head to prevent feeding wire. Pull trigger on
welding gun and turn flow adjust screw to
increase or decrease gas flow. Typical flow
rate is 25 cfh (cubic feet per hour). Check
wire manufacturer’s recommended flow
rate.
5-6. Installing Wire Spool And Adjusting Hub Tension
Installing 4 in. (102 mm) Wire Spool
Installing 8 in. (203 mm) Wire Spool
. Only applies to units equipped with optional hub kit.
Adapter used with 8 in.
(203 mm) spool only.
Tools Needed:
1/2 in.
OM-243 712 Page 14
When a slight force is needed
to turn spool, tension is set.
Retaining ring used with 8 in.
(203 mm) spool only.
Ref. 802 971-C / 803 012 / 803 013 -B
. A complete Parts List is available at www.HobartWelders.com
5-7. Connecting 115 Volt Input Power
!
Installation must meet all
National and Local Codes −
have only qualified persons
make this installation.
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
2
1
For 115 volts AC input power, a 20
ampere individual circuit protected
by time-delay fuses or circuit
breaker is required.
1
2
Plug From Unit
Receptacle − NEMA Type
5−15R (Customer Supplied)
Select extension cord of 12 AWG
for up to 50 ft (15 m) or 10 AWG for
50 up to 100 ft (30 m).
Input6 2011−03 / 803 443-C
5-8. Installing Contact Tip And Nozzle
2
3
!
Turn off welding power source.
1
Nozzle
Remove nozzle.
1
2
Contact Tip
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.
Tools Needed:
Flux Nozzle
Use with flux cored wire only. Narrow
design allows access in tight spaces
and provides better visibility of
puddle during welding.
Push nozzle over contact tip and
adapter until it is seated onto adapter.
Contact tip will be exposed
approximately 7/16 in. (11.3 mm)
when installed properly.
MIG Nozzle
Use with solid or flux cored wire.
Push nozzle over contact tip and
adapter until it is seated onto
adapter. End of contact tip will be
flush with end of nozzle when
installed properly.
Ref. 804 241-A
OM-243 712 Page 15
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5-9. Threading Welding Wire
1
2
3
4
5
6
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Gun Cable
Lay gun cable out straight.
4
Tools Needed:
6
1
2
3
5
. Hold wire tightly to keep it
from unraveling.
6 in.
(150 mm)
Open pressure assembly.
Tighten
Pull and hold wire; cut off end.
4 in.
(102 mm)
Push wire thru guides into gun liner;
continue to hold wire.
. Loosen knob completely, then rotate
pressure adjustment knob in a
clockwise direction until drive roll is
tight against the welding wire.
Adjust drive roll pressure just
tightly enough to prevent wire
from slipping against drive roll
during operation.
INPUT
POWER
Be sure that wire is positioned
in proper feed roll groove.
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn power on.
. Tip adapter may also require removal
to allow wire to feed out end of gun.
Tighten
WOOD
Press gun trigger until wire comes
out of gun.
Be sure that contact tip matches wire diameter. Feed wire to check drive roll pressure.
Reinstall tip adapter, if applicable, contact tip
Tighten knob enough to prevent slipping.
and nozzle.
Cut off wire. Close door.
Ref. 803 444-A / Ref. 205 837
OM-243 712 Page 16
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SECTION 6 − OPERATION
6-1. Controls
1
Voltage 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.
2
. Switch must “click” into detent
position for weld output.
2
Wire Feed Control
Use control to select a wire feed
speed. As Voltage switch setting increases, wire speed range also increases (see weld setting label in
welding power source or Section
6-3 as applicable).
3
1
Power Switch
3
Ref. 229 999-A
6-2. Operating The Gun
1
Trigger Switch
When pressed, energized wire
feeds and shielding gas flows.
1
Ref. 804 240-A
OM-243 712 Page 17
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6-3. Weld Parameter Chart
247 895-A
OM-243 712 Page 18
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SECTION 7 − MAINTENANCE &TROUBLESHOOTING
7-1. Routine Maintenance
!
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Reference
l = Replace
3 Months
l Damaged Or Unreadable Labels
l Repair Or Replace
Cracked Weld Cable
~ Clean And Tighten Weld
Terminals
6 Months
OR
~ Drive Rolls
~ Inside Unit
7-2. Drive Motor Protection
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit
resets allowing drive motor to feed wire again.
7-3. Overload Protection
1
Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
1
Reset supplementary protector.
803 379-A
7-4. Replacing Gun Contact Tip
2
1
Tools Needed:
3
!
Turn Off power before replacing
contact tip.
1
Nozzle
Remove nozzle.
2
Contact Tip
3
Tip Adapter
Cut off welding wire at contact tip.
Remove contact tip from tip adapter,
and install new contact tip. Reinstall
nozzle.
Ref. 804 241-A
OM-243 712 Page 19
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7-5. Changing Drive Roll Or Wire Inlet Guide
1
2
Pressure Adjustment Knob
Pressure Assembly
Pivot pressure adjustment knob
down, and lift pressure assembly
up.
3
4
5
6
Pivot Tube Plate
Securing Screws
Pressure Arm Pivot Tube
Inlet Wire Guide
Remove screws and pivot tube
plate. Lift out pressure arm pivot
tube, and slide inlet wire guide out of
tube.
2
Slide replacement wire guide into
tube, and place tube back into drive
assembly. Be sure tip of wire guide
is as close to drive roll as possible
without touching.
Reinstall plate and tighten screws.
7
1
Retaining Knob
Rotate counterclockwise
remove knob.
7
8
and
Drive Roll
The drive roll consists of two
different sized grooves. Each side
is stamped with the proper size.
Select the groove that matches the
wire size on the wire spool. Install
drive roll onto motor shaft so that
correct groove size stamp faces out
away from drive housing.
5
6
3
4
9
Retaining Knob Opening
Install retaining knob by placing
opening over drive roll (opening
faces rear of unit). Rotate retaining
knob clockwise to secure drive roll.
Position wire into outer groove of
drive roll (see Section 5-9).
.030/.035
VK Groove
.024 Groove
Stamped .030/.035
Stamped .024
Tools Needed:
8
9
5/16 in.
Ref. 802 444-B / 803 442-A
OM-243 712 Page 20
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7-6. Cleaning Gun Liner
!
Turn Off welding power source.
1
Nozzle
2
Contact Tip
3
Adapter
Head
Tube
1
2
3
8 mm
Remove nozzle. Cut off 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.
Remove screws (3) from
cover, and remove cover
from wire drive assembly.
Tools Needed:
Lay gun cable out straight,
and blow out liner.
8 mm
Reassemble drive cover
and gun in reverse order
from taking it apart.
. Thread wire
according to
Section 5-9.
804 241-A / 803 838-A
OM-243 712 Page 21
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7-7. Replacing Gun Liner
!
Turn Off welding power source.
Tools Needed:
Head
Tube
1
8 mm / 10 mm
2
3
8 mm
Remove nozzle. Cut off wire
at contact tip, and remove
contact tip and tip adapter.
Remove screws (3) from
cover, and remove cover
from wire drive assembly.
Open pressure assembly. Retract
wire from liner onto spool.
Loosen liner setscrew.
. Hold wire tightly to keep it
from unraveling. Secure
end of wire at spool.
Twist top and bottom handle locking rings
counterclockwise 1/4 turn. Slide bottom ring
down cable and top ring forward over head
tube. Separate gun handle halves.
Remove black sleeving from
end of replacement liner.
8 mm
Loosen and remove
retaining nut from liner.
Pull liner out of gun
cable. If necessary, twist
cable to ease removal.
Install retaining nut on one end of liner. Lay
gun cable straight on a flat surface. Insert
bare end of liner (end without retaining nut)
into wire drive end of cable. Push liner
toward gun. If necessary, twist cable to
ease installation.
Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A
OM-243 712 Page 22
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7-7. Replacing Gun Liner (Continued)
13/16 in.
(21 mm)
8 mm
When liner exits cable at gun
handle, guide liner into head
tube. Continue to push liner until
it exits end of head tube.
Insert retaining nut into adapter, and adjust liner stickout as
shown. Tighten retaining nut. Reinstall cable end into drive
housing with retaining grooves inserted into the two retaining
ribs. Be sure to position gas hose up. Position liner in groove
so that end is flush with back of groove, adjust if necessary
3/8 in (10 mm)
Be sure that cable is straight.
Tighten liner setscrew. Cut
liner so that 3/8 in. (10 mm)
sticks out of head tube. File
down any sharp points on
liner after cutting to length.
Reinstall cover onto wire
drive assembly, and secure
with screws (3).
Reassemble gun by placing head tube
and cable into one half of handle. Be
sure trigger is properly installed into
trigger slot.
8 mm
Place other half of handle over
head tube and cable.
Slide locking rings over top and
bottom of handle, and secure by
twisting rings clockwise 1/4 turn.
Thread welding wire through
gun (see Section 5-9). Reinstall
adapter, contact tip, and nozzle.
OM-243 712 Page 23
. A complete Parts List is available at www.HobartWelders.com
7-8. Troubleshooting Table
Trouble
Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-7).
does not run.
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 weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
unit has cooled (see Section 4-3).
motor continues to run.
Be sure that Voltage switch is not set between ranges (see Section 6-1).
Disassemble torch handle and check trigger switch lead connections, tighten or reconnect any loose
connections.
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Check cable connection at work clamp and tighten hardware, if necessary (see Section 5-2).
Replace contact tip (see Section 7-4).
Check for proper polarity connections (see Section 5-4).
Low weld output.
Connect unit to proper input voltage or check for low line voltage.
Place voltage switch in desired position (see Section 6-1).
If using an extension cord, check that wire size and length is the proper size for power rating of welding
power source (see Section 4-2).
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding.
Adjust drive roll pressure (see Section 5-9).
Change to proper drive roll groove (see Section 7-5).
Readjust hub tension (see Section 5-6).
Replace contact tip if blocked (see Section 7-4).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-5).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-5).
Check and clear any restrictions at drive assembly and liner (see Section 7-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Have nearest Factory Authorized Service Agent check drive motor.
OM-243 712 Page 24
SECTION 8 − ELECTRICAL DIAGRAM
247 077-A
Figure 8-1. Circuit Diagram
OM-243 712 Page 25
SECTION 9 − FCAW/GMAW WELDING GUIDELINES
9-1. Typical FCAW Process Connections
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Wire Feeder/
Power Source
Gun
Work Clamp
Workpiece
Self-Shielding Flux
Core Wire
FCAW/GMAW1 2011−03 − Ref. 803 444-A
9-2. Typical GMAW (MIG) Process Connections
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Power Source
Shielding
Gas
Gas Hose
Gun
Work Clamp
Workpiece
Solid Wire
803 444-A
OM-243 712 Page 26
9-3. Typical Control Settings
. These settings are guidelines only. Material and wire type, joint design, fitup, position, etc. affect settings. Test welds to be sure they comply to
specifications.
Material thickness determines weld
parameters.
1/8 or 0.125 in.
Convert Material
Thickness to
Amperage (A)
(0.001 in. = 1 ampere)
0.125 in. = 125 A
.035 in
Wire
Size
Wire Size
Amperage Range
0.023 in.
30 − 90 A
0.030 in.
40 − 145 A
0.035 in.
50 − 180 A
Recommendation
Wire Speed
(Approx.)
0.023 in.
3.5 in per ampere
3.5 x 125 A = 437 ipm
0.030 in.
2 in per ampere
2 x 125 A = 250 ipm
0.035 in.
1.6 in per ampere
1.6 x 125 A = 200 ipm
Select Wire Size
Select Wire Speed
(Amperage)
125 A based on 1/8 in.
material thickness
ipm = inches per minute
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Select Voltage
Set voltage midway between high/low voltage
Voltage controls height and
width of weld bead.
Wire speed (amperage) controls weld
penetration (wire speed = burn-off rate).
OM-243 712 Page 27
9-4. 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.
1
2
3
4
1
5
3
2
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
Solid Wire − 3/8 to 1/2 in.
(9 to 13 mm)
Flux Cored Wire − 1/2 to 5/8 in.
(13 to 16 mm)
Cradle Gun and Rest Hand on
Workpiece
5
4
0°-15°
90°
90°
End View of Work Angle
Side View of Gun Angle
GROOVE WELDS
0°-15°
45°
45°
End View of Work Angle
Side View of Gun Angle
FILLET WELDS
S-0421-A
OM-243 712 Page 28
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.
. The Drag or Pull technique is generally recommended when welding with flux-cored tubular wire.
Push
Perpendicular
Drag or Pull
10°
10°
Electrode directed
ahead of bead
Electrode pointed
back into bead
Direction Of Welding
GUN ANGLES AND WELD BEAD PROFILES
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTODE EXTENSIONS (STICKOUT)
Slow
Normal
Fast
GUN TRAVEL SPEED
S-0634
OM-243 712 Page 29
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 across gaps,
a weave bead or multiple stringer beads works better.
1
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
1
2
3
S-0054-A
9-7.
Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
3
4
5
9-8.
S-0053-A
Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
1
2
3
No Overlap
Good Penetration into Base
Metal
4
5
OM-243 712 Page 30
4
5
S-0052-B
9-9.
Troubleshooting − 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.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Incorrect polarity.
Check polarity required by welding wire, and change to correct polarity at welding power source.
9-10. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc
(GMAW).
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas (GMAW).
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
OM-243 712 Page 31
9-11. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
9-12. Troubleshooting − 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 proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Incorrect polarity.
Check polarity required by welding wire, and change to correct polarity at welding power source.
9-13. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
OM-243 712 Page 32
9-14. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Corrective Actions
Excessive heat input.
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
9-15. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding 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 on solid surface or use two hands.
9-16. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-243 712 Page 33
9-17. Common GMAW (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
Spray Arc
Stainless Steel
Short Circuiting
Stainless Steel
Argon
Argon + 1% O2
Flat & Horizontal5
Fillet
Flat & Horizontal5
Fillet
Argon + 2% O2
Flat & Horizontal5
Fillet
Flat & Horizontal5
Fillet
Argon + 5% O2
Flat & Horizontal5
Fillet
Argon + 8% CO2
Flat & Horizontal5
Fillet
All Positions
Argon + 25%
CO2
Flat & Horizontal1
Fillet
All Positions
Argon + 50%
CO2
CO2
Short Circuiting
Aluminum
All Positions5
All Positions
All Positions3
All Positions
Flat & Horizontal1
Fillet
All Positions
Helium
All Positions2
Argon + Helium
All Positions2
Tri-Mix4
1
2
3
4
5
Spray Arc
Aluminum
All Positions
Globular Transfer
Heavy Thicknesses
Single Pass Welding Only
90% HE + 7-1/2% AR + 2-1/2% CO2
Also for GMAW-P, All Positions
9-18. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Probable Cause
Wire feed motor operates, but Too little pressure on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls.
Wire curling up in front of the
wire feed rolls (bird nesting).
OM-243 712 Page 34
Remedy
Increase pressure setting on wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high.
Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly.
Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Too much pressure on wire feed rolls.
Decrease pressure setting on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner.
Replace liner.
Problem
Probable Cause
Remedy
Wire feeds, but no gas flows
(GMAW).
Gas cylinder empty.
Replace empty gas cylinder.
Gas nozzle plugged.
Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted.
Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid.
Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source.
for correct voltage.
Welding arc not stable.
Wire slipping in drive rolls.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-243 712 Page 35
SECTION 10 − ACCESSORIES/CONSUMABLES
10-1. Accessories
Part No.
Description
Remarks
194 776
Small Running Gear/Cylinder Rack
For One Small Gas Cylinder, 75 lb (34 kg)
195 216
Hub Kit
For 8 in Wire Spool
195 157R
H-9B Replacement Gun
8 ft (2.4 m) length/.030-.035 (0.8-0.9 mm) Wire Size
770717
Preset Mixed Gas Regulator/Hose Kit
For Argon and Argon mixed shielding gas.
Use with replacement hose 183 581
10-2. Consumables
Item
Hobart Package Part No.
.023/.025 in. (0.6 mm)
770 174 (5 per package)
.030 in. (0.8 mm)
770 177 (5 per package)
.035 in. (0.9 mm)
770 180 (5 per package)
Contact Tips
MIG Nozzle (Standard)
770 404
Gasless Flux Cored Nozzle
770 487
Tip Adapter
770 402
.030/.035 in. (0.8/0.9 mm)
210 970R
Replacement Liner
Replacement Drive Roll
.023/.025 in. (0.6 mm) and
.030/.035 in (0.8/0.9 mm)
V and VK Groove
212 379R
. A complete Parts List is available on-line at www.HobartWelders.com
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-243 712 Page 36
Effective January 1, 2013
3/1 WARRANTY applies to all Auto Arc welding equipment and plasma cutters with a serial number preface of MD or newer.
This limited warranty supersedes all previous Auto Arc warranties and is exclusive with
no other guarantees or warranties expressed or implied.
Auto Arc products are serviced by Hobart or Miller Authorized Service Agencies.
LIMITED WARRANTY − Subject to the terms and conditions below, Hobart
Brothers Co., Troy, Ohio and Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Auto Arc equipment sold after the
effective date of this limited warranty is free of defects in material and workmanship
at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Hobart/Miller will repair or replace any
warranted parts or components that fail due to such defects in material or
workmanship. Hobart/Miller must be notified in writing within thirty (30) days of such
defect or failure, at which time Hobart/Miller will provide instructions on the warranty
claim procedures to be followed.
Hobart/Miller shall honor warranty claims on warranted equipment listed below in
the event of such a failure within the warranty time periods. All warranty time periods
start on the delivery date of the equipment to the original retail purchaser, and not to
exceed one year after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International distributor.
1.
2.
3 Years — Parts and Labor
* Original Main Power Rectifiers only to include SCRs, diodes, and
discrete rectifier modules
*
Reactors
*
Stabilizers
*
Transformers
*
Drive Systems
*
PC Boards
*
Solenoid Valves
*
Switches and Controls
1 Year — Parts and Labor Unless Specified
(90 days for industrial use)
* Accessories
*
Contactors
*
Field Options
(NOTE: Field options are covered for the remaining warranty period of
the product they are installed in, or for a minimum of one year —
whichever is greater.)
*
*
Flowgauge and Flowmeter Regulators (No Labor)
MIG Guns/TIG Torches
*
Motor-Driven Guns
*
Plasma Cutting Torches
*
Regulators
*
Relays
*
Replacement Parts (No labor) − 90 days
*
Running Gear/Trailers
The Auto Arc 3/1 Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips, cutting nozzles,
contactors, brushes, relays, work station table tops and welding
curtains, or parts that fail due to normal wear. (Exception: brushes
and relays are covered on all engine-driven products.)
Items furnished by Hobart/Miller, but manufactured by others, such as
engines or trade accessories. These items are covered by the
manufacturer’s warranty, if any.
Equipment that has been modified by any party other than Hobart/Miller,
or equipment that has been improperly installed, improperly operated or
misused based upon industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment which has been
used for operation outside of the specifications for the equipment.
HOBART/AUTO ARC PRODUCTS ARE INTENDED FOR PURCHASE AND USE
BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at Hobart’s/Miller’s option: (1) repair; or (2) replacement; or, where
authorized in writing by Hobart/Miller in appropriate cases, (3) the reasonable cost
of repair or replacement at an authorized Hobart/Miller service station; or (4)
payment of or credit for the purchase price (less reasonable depreciation based
upon actual use) upon return of the goods at customer’s risk and expense.
Hobart’s/Miller’s option of repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Hobart/Miller authorized service facility as determined by
Hobart/Miller. Therefore no compensation or reimbursement for transportation
costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL
HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER
BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE,
AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER
LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY
IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY HOBART/MILLER IS EXCLUDED AND
DISCLAIMED BY Hobart/Miller.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides
specific legal rights, and other rights may be available, but may vary from state to
state.
In Canada, legislation in some provinces provides for certain additional warranties
or remedies other than as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
vary from province to province.
Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST
auto arc warr 2013−08
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Protect Your Investment!
Support
Need fast answers to the
tough welding questions?
Call 1-800-332-3281. The
expertise of Hobart is
there to help you, every
step of the way.
Assistance
Visit the Hobart website:
www.HobartWelders.com
Hobart Brothers Co.
Register your product at:
HobartWelders.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA
An Illinois Tool Works Company
2200 Corporate Drive
Troy, OH 45373 USA
© 2013 Hobart Brothers Co. 2013−08