Hobart HANDLER 210 MVP User guide

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OM-260 274A 2012−11

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source And Wire Feeder

Handler 210 MVP

www.HobartWelders.com

File: MIG (GMAW)

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.................................................................

1-2. Arc Welding Hazards 1............................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.......................

1-4. California Proposition 65 Warnings 4.................................................

1-5. Principal Safety Standards 4.......................................................

1-6. EMF Information 4................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5..........................

2-1. Symboles utilisés 5...............................................................

2-2. Dangers relatifs au soudage à l’arc 5................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7

2-4. Proposition californienne 65 Avertissements 8.........................................

2-5. Principales normes de sécurité 9....................................................

2-6. Informations relatives aux CEM 9...................................................

SECTION 3 − DEFINITIONS 11..................................................................

3-1. Manufacturer’s Warning Label Definitions 11...........................................

3-2. Miscellaneous Symbols And Definitions 11............................................

SECTION 4 − SPECIFICATIONS 13..............................................................

4-1. Specifications For 230 VAC 13.......................................................

4-2. Specifications For 115 VAC 13.......................................................

4-3. Duty Cycle And Overheating 14......................................................

4-4. Volt-Ampere Curves 15.............................................................

SECTION 5 − INSTALLATION 16................................................................

5-1. Installing Nozzle, Contact Tip, And Adapter 16.........................................

5-2. Installing Welding Gun 16...........................................................

5-3. Installing Work Clamp 17...........................................................

5-4. Process/Polarity Table 17...........................................................

5-5. Changing Polarity 17...............................................................

5-6. Installing Gas Supply 18............................................................

5-7. Electrical Service Guide 19..........................................................

5-8. Extension Cord Data (Use Shortest Cord Possible) 19...................................

5-9. Multi−Voltage Plug (MVP) Connection 20..............................................

5-10. Serial Number And Rating Label Location 21...........................................

5-11. Selecting A Location And Connecting Input Power 21....................................

5-12. Connecting 1−Phase Input Power 22.................................................

5-13. Connecting 1-Phase Input Power For 115 VAC Input 24..................................

5-14. Installing Wire Spool And Adjusting Hub Tension 24.....................................

5-15. Connecting Optional Spool Gun 25...................................................

5-16. Threading Welding Wire 26..........................................................

SECTION 6 − OPERATION 27..................................................................

6-1. Controls 27.......................................................................

6-2. Weld Parameter Chart 28...........................................................

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 29..........................................

7-1. Routine Maintenance 29............................................................

7-2. Overload Protection 29.............................................................

7-3. Drive Motor Protection 30...........................................................

7-4. Changing Drive Roll Or Wire Inlet Guide 30............................................

7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing 31.............

7-6. Replacing Switch And/Or Head Tube 32...............................................

7-7. Troubleshooting Table 33...........................................................

SECTION 8 − ELECTRICAL DIAGRAM 34........................................................

Hobart is registered to the ISO 9001 Quality System Standard.

TABLE OF CONTENTS

SECTION 9 − GMAW WELDING (MIG) GUIDELINES 36............................................

9-1. Typical GMAW (MIG) Process Connections 36.........................................

9-2. Typical GMAW (MIG) Process Control Settings 37......................................

9-3. Holding And Positioning Welding Gun 38..............................................

9-4. Conditions That Affect Weld Bead Shape 39...........................................

9-5. Gun Movement During Welding 40...................................................

9-6. Poor Weld Bead Characteristics 40..................................................

9-7. Good Weld Bead Characteristics 40..................................................

9-8. Troubleshooting − Excessive Spatter 41..............................................

9-9. Troubleshooting − Porosity 41.......................................................

9-10. Troubleshooting − Excessive Penetration 41...........................................

9-11. Troubleshooting − Lack Of Penetration 42.............................................

9-12. Troubleshooting − Incomplete Fusion 42..............................................

9-13. Troubleshooting − Burn-Through 42..................................................

9-14. Troubleshooting − Waviness Of Bead 43..............................................

9-15. Troubleshooting − Distortion 43......................................................

9-16. Common GMAW (MIG) Shielding Gases 44...........................................

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment 44.........................

SECTION 10 − ACCESSORIES/CONSUMABLES 46...............................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2011−10

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.

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 follow-

ing 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.

. 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.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in use.

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 equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and clothing to prevent burns.

OM-260 274 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.

D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

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 op-

erations. 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.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments 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 by-

pass 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.

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.

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 protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

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

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-260 274 Page 2

workpiece, and hot equipment can cause fires and

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, mechani-

cal 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. 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 num-

ber 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

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.

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 Sparks can cause fires — keep flammables away.

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.

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.

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.

H.F. RADIATION can cause interference.

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.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D 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.

ARC WELDING can cause interference.

MOVING PARTS can injure.

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.

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.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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-260 274 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.)

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 Glob-

al 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

1-6. EMF Information

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.

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 Indus-

try, 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).

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. 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.

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.

OM-260 274 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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.

fre_som_2011−10

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.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

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 UNIQUE-

MENT 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 condi-

tions 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 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 !

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, 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).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

D 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.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chaudes.

D Vérifier fréquemment le cordon d’alimentation afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide doublée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

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.

OM-260 274 Page 5

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 partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou 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.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

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 soudag

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant l 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.

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 des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

OM-260 274 Page 6

génère des rayons visibles et invisibles intense

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 va-

peurs 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 ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos po-

ches 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.

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

a e

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 confi-

nés 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.

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.

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 station-

naire 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 Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

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 suffi-

samment 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.

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 pro-

duits 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’assu-

rer 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.

D Ne pas obstruer les passages d’air du poste.

D Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cett manœuvre est à exécuter dans un endroit sû lorsque l’on porte l’équipement homologué d protection du visage, des mains et du corps.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les cir-

cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antista-

tiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

OM-260 274 Page 7

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 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.

L’EXPLOSION DE LA BATTERI 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.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

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.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D 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.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

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.

D Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

D 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).

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, 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)

OM-260 274 Page 8

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

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al 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).

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel 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.

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 Indus-

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-260 274 Page 9

OM-260 274 Page 10

SECTION 3 − DEFINITIONS

3-1. Manufacturer’s Warning Label Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Drive rolls can injure fingers.

3-2. Miscellaneous Symbols And Definitions

Safe1 2012−05

Safe32 2012−05

1max

Amperage

Positive

Output Voltage Input Off On

Do Not Switch

While Welding

Rated No Load

Voltage (Average)

Rated Maximum

Supply Current

Temperature Increase Percent

Suitable For

Welding In An Environment With Increased Risk Of

Electric Shock

Voltage

Direct Current

(DC)

Gas Metal Arc

Welding (GMAW)

Primary Voltage

Rated Welding

Current

Rated Supply

Current

1eff

Single Phase Input

Wire Feed Circuit Protector

Conventional Load

Duty Cycle

Maximum Effective

Supply Current

Hertz Negative

Voltage

Line Connection

Single Phase Transformer-

Rectifier

Protective Earth

(Ground)

OM-260 274 Page 11

Notes

OM-260 274 Page 12

SECTION 4 − SPECIFICATIONS

4-1. Specifications For 230 VAC

Rated Welding

Output

150 A @ 23 Volts

DC, 30% Duty Cycle

Wire Type

And Diameter

Amperage

Range

25 − 210

Solid/

Stainless

.023 − .035 in.

(0.6 − 0.9 mm)

Maximum Open-

Circuit Voltage

Flux Cored

.030 − .045 in.

(0.8 − 1.2 mm)

4-2. Specifications For 115 VAC

Rated Welding

Output

90 A @ 19

Volts DC, 20%

Duty Cycle

Wire Type

And Diameter

Amperage Range

25 − 140

Solid/Stain-

less

.023 - .035 in.

(0.6 - 0.9

mm)

Flux Cored Aluminum

.030 - .035 in.

(0.8 - 0.9

mm)

Amperes Input at

Rated Load Output

34 24 5.54 4.72

Maximum

Open-Circuit

Voltage DC

28 20 2.84 2.41

.030 in.

(0.8 mm)

230 V, 60 Hz,

Single-Phase

Aluminum Wire Feed Speed Range

.030 − .035 in.

(0.8 − 0.9 mm)

Amperes Input at

Rated Load Output 120 V, 60 Hz,

Single-Phase

KVA KW

70 − 750 IPM (1.8 − 19.0 m/min) At No Load

40 − 680 IPM (1.0 − 17.3 m/min) Feeding Wire

KVA KW

Wire Feed Speed Range

60 − 740 IPM (1.5 − 18.8 m/min) At No Load

40 − 600 IPM (1.0 − 15.2 m/min) Feeding Wire

Weight

W/ Gun

79 lb

(36 kg)

Weight

W/ Gun

79 lb

(36 kg)

Overall

Dimensions

Length: 19-1/2 in.

(495 mm)

Width: 10-5/8 in.

(273 mm)

Height: 12-3/8 in.

(314 mm)

Overall

Dimensions

Length: 19-1/2 in.

(495 mm)

Width: 10-5/8 in.

(273 mm)

Height: 12-3/8 in.

(314 mm)

OM-260 274 Page 13

4-3. Duty Cycle And Overheating

230 VAC

30% duty cycle at 150 amps

3 Minutes Welding 7 Minutes Resting

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

NOTICE − Exceeding duty cycle can damage unit or gun and void warranty.

115 VAC

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting

Overheating

OM-260 274 Page 14

Minutes

A or V

Reduce Duty Cycle

duty1 4/95 − 249 620-A

4-4. Volt-Ampere Curves

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.

230 VAC

Voltage

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

7 6 5 4 3

2 1

Amperage

115 VAC

Voltage

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

Amperage

ssb1.1 10/91 − 249 621-A

OM-260 274 Page 15

SECTION 5 − INSTALLATION

5-1. Installing Nozzle, Contact Tip, And Adapter

Head Tube

8 mm

Tools Needed:

8 mm

! Turn off welding power

source.

1 Nozzle 2 Contact Tip 3 Tip Adapter

. Wire size stamped on tip − check

and match wire size.

5-2. Installing Welding Gun

Spool Gun

MIG Gun

. Be sure that gun end is tight against drive assembly.

Ref. 243 839-A

1 Drive Assembly 2 MIG Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew. Insert end

through opening until it bottoms against drive assembly. Tighten thumbscrew.

Welding gun must be inserted completely to prevent leakage of shielding gas.

5 Gun Trigger Leads Insert plug into receptacle, and

tighten threaded collar. 6 Spool Gun/MIG Gun Switch Place switch in MIG Gun position. Close door.

Incorrect

Gun Not Seated

OM-260 274 Page 16

Exposed O-rings

will cause shielding

gas leakage.

Correct

Gun Fully Seated

260 458-A

5-3. Installing Work Clamp

Tools Needed:

10 mm

5-4. Process/Polarity Table

Process Polarity

GMAW − Solid wire with shielding gas

FCAW − Self-shielding wire − no shielding gas

DCEP − Reverse polarity Connect to positive (+) out-

DCEN − Straight Polarity Connect to negative (−)

1 Work Clamp 2 Work Cable From Unit 3 Screw 4 Flat Washer 5 Lock Washer 6 Nut Route work cable through hole in

clamp handle. Secure cable with hardware as shown.

. 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.

Cable Connections

Cable To Gun Cable To Work

Connect to negative (−) output

put terminal

terminal Connect to positive (+) output

output terminal

terminal

258 550-A

5-5. Changing Polarity

Electrode negative

for flux cored wire

Electrode positive

CHANGING

POLARITY

DCEN

DCEP

for solid wire

! Turn off welding power

source.

1 Lead Connections For Direct

Current Electrode Negative (DCEN)

2 Lead Connections For Direct

Current Electrode Positive (DCEP)

Always read and follow wire manufacturer’s recommended polarity, and see Section 5-4.

Close door.

260 459-A

OM-260 274 Page 17

5-6. Installing Gas Supply

. DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter.

Argon Gas Or

Mixed Gas

Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.

1 Cap

2 Cylinder Valve Remove cap, stand to side of valve,

and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source.

7 Flow Adjust Flow rate should be set when gas is

flowing through welding power source and welding gun. Open pressure assembly so that wire will not feed. Press gun trigger to start gas flow.

Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate.

After flow is set, close pressure assembly.

Pressure Assembly

Open

Tools Needed:

5/8, 1-1/8 in.

OM-260 274 Page 18

Pressure Assembly

Closed

260 460-A

5-7. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

60 Hz Single Phase Input Voltage (V) 230 Volts AC 115 Volts AC Input Amperes (A) At Rated Output 24 Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2011 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

(16)

Elec Serv 2011−08

A 20 ampere

individual branch

circuit

protected by

time-delay fuses

or circuit breaker

is required.

See Section 4-2

5-8. Extension Cord Data (Use Shortest Cord Possible)

. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Input Power

Input Voltage

115 V 1 60 14 AWG 25 ft (8 m)

115 V 1 60 12 AWG 55 ft (17 m)

115 V 1 60 10 AWG 100 ft (30 m)

230 V 1 60 14 AWG 53 ft (16 m)

Phase

Hertz Conductor Size Max. Cord Length

OM-260 274 Page 19

5-9. Multi−Voltage Plug (MVP) Connection

Selecting Plug

! Do not cut off power cord con-

nector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty.

Selecting Plug

1 Power Cord Connector From

Welding Power Source

Select plug for power supply receptacle available at site. Not all plugs shown are provided as standard with unit.

2 Plug − NEMA Type 5−15P 3 Receptacle − NEMA Type 5−15R

(Customer Supplied)

Connecting Plug To Power Cord

4 Plug − NEMA Type 5−20P (Optional) 5 Receptacle − NEMA Type 5−20R

(Customer Supplied) 6 Plug − NEMA Type 6−50P 7 Receptacle − NEMA Type 6−50R

(Customer Supplied)

! Follow electrical service guide for

230 VAC in Section 5-7. Do not use

plug rating to size branch circuit

protection.

MVP Plug1 2012−03 / Ref. 803 812-C

Connecting Plug To Power Cord

Align arrow on plug with arrow on power cord connector. Push together.

Tighten threaded collar. As threaded collar is tightened, push plug onto adapter until collar is completely tight.

Connect plug to receptacle.

OM-260 274 Page 20

5-10. Serial Number And Rating Label Location

The serial number and rating information for this product is located on 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.

5-11. Selecting A Location And Connecting Input Power

18 in. (457 mm) of space for airflow

! Do not move or operate

unit where it could tip.

Align arrows before threading together

250 332-B

! Do Not modify or rewire receptacle

connection.

! Do Not cut off power cord

connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty.

! Special installation may be required

where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

For 115 VAC input power, a 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required, see Section 5-13. For 230 VAC input power, see Section 5-12.

1 Rating Label Supply correct input power (see

Section 5-10). 2 Power Cord Connector 3 Plug − NEMA Type 5-15P 4 Receptacle − NEMA Type 5-15R

(Customer Supplied)

5 Plug − NEMA Type 5-20P (Optional) 6 Receptacle NEMA Type 5-20R

(Customer Supplied) 7 Plug − NEMA Type 6-50P 8 Receptacle − NEMA Type 6-50R

(Customer Supplied) Select plug for power supply receptacle

available at site. Install plug onto power cord adapter. As threaded collar is tightened, push plug onto adapter until collar is completely tight.

Connect plug to receptacle.

OM-260 274 Page 21

5-12. Connecting 1−Phase Input Power

L1 L2

=GND/PE Earth Ground

Tools Needed:

OM-260 274 Page 22

230 VAC, 1

input4 2012−05 − Ref. 803 766-C / 250 332-B

5-12. Connecting 1-Phase Input Power (Continued)

! Installation must meet all National and

Local Codes − have only qualified persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Always connect green or green/yellow

conductor to supply grounding terminal first, and never to a line terminal.

See rating label on unit and check input voltage available at site.

1 Input Power Cord 2 Disconnect Device (switch shown in the

OFF position) 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals 5 Black And White Input Conductor (L1

And L2) 6 Green Or Green/Yellow Grounding

Conductor Connect green or green/yellow grounding

conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

7 Over-Current Protection Select type and size of over-current protec-

tion using Section 5-7 (fused disconnect switch shown).

8 Receptacle (NEMA 6-50R) Connect receptacle as shown. Close and secure door on disconnect device.

Follow established lockout/tagout procedures to put unit in service.

9 Plug (NEMA 6-50P) Connect plug to receptacle.

input4 2012−05 − 803 766-C / 260 711-A

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

OM-260 274 Page 23

5-13. Connecting 1-Phase Input Power For 115 VAC Input

! Installation must meet all National

and Local Codes − have only qualified persons make this installation.

! Always connect green or green/

yellow conductor to supply grounding terminal first, and never to a line terminal.

For 115 volts AC input power, a 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.

1 Multi-Voltage Plug And Power Cord

Connector (NEMA Type 5−15P Plug Shown)

For multi−voltage plug connections, see Section 5-11.

2 Receptacle − NEMA Type 5−15R

(Customer Supplied)

5-14. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in. (102 mm) Wire Spool

Installing 8 in. (203 mm) Wire Spool

Adapter used with 8 in.

(203 mm) spool only.

Ref. 250 332-B

When a slight force is needed to turn spool, tension is set.

Tools Needed:

OM-260 274 Page 24

Retaining ring used

with 8 in. (203 mm)

spool only.

1/2 in.

803 012 / 803 013 -B / Ref. 802 971-C

5-15. Connecting Optional Spool Gun

Spool Gun

MIG Gun

. Be sure that gun end is tight against drive assembly.

Exposed O-rings will

cause shielding gas

leakage.

Gun Not Seated

1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew. Insert end

through opening until it bottoms against drive assembly. Tighten thumbscrew.

CorrectIncorrect

Gun Fully Seated

Spool gun must be inserted completely to prevent leakage of shielding gas.

5 Gun Trigger Plug Insert plug into receptacle, and

tighten threaded collar. 6 Spool Gun/MIG Gun Switch Place switch in Spool Gun position. 7 Polarity Changeover Terminal

Block

To make proper polarity connection, see welding power source Owner’s Manual.

Close door. 8 Wire Feed Speed Control Wire feed speed is controlled by

welding power source Wire Speed control (see welding power source Owner’s Manual or door chart for appropriate setting).

9 Voltage Control Arc voltage is controlled by welding

power source Voltage control (see welding power source Owner’s Manual or door chart for appropriate setting).

10 Trigger Press trigger to energize welding

power source contactor, start shielding gas flow, and begin wire feed.

260 458-A / Ref. 260 573-A

OM-260 274 Page 25

5-16. Threading Welding Wire

Tools Needed:

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll

6 Gun Conduit Cable Lay gun cable out straight.

Open pressure assembly. Make sure

feed roll is set to correct groove to match wire size (see Section 7-4).

Tighten

. Hold wire tightly to keep it

from unraveling.

6 in

(150 mm)

Pull and hold wire; cut off end.

. Use pressure indicator

scale to set a desired drive roll pressure.

Pressure

Indicator

Scale

4 in

(120 mm)

Push wire thru guides into gun;

continue to hold wire.

Be sure that wire is positioned

in proper feed roll groove.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes out of gun.

OM-260 274 Page 26

Remove gun nozzle and contact tip.

Be sure that tip matches wire diameter. Reinstall contact tip and nozzle.

Turn power on. Be sure that Voltage range switch is set to range 1, 2, 3, 4, 5, 6, or 7 to feed wire. Rotate knob until it “clicks” into detent. Wire will not feed if range switch is set between ranges.

Tighten

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

260 587-A

6-1. Controls

SECTION 6 − OPERATION

1 Wire Speed Control Control varies the rate of wire being fed

through the welding gun. 2 Power Switch/Supplementary

Protector

Turns power on and off. Also, this switch functions as supplementary protector CB1.

CB1 protects unit from overload. If CB1 opens, unit shuts down.

Reset power switch/supplementary protector.

3 Voltage Control

Control varies the voltage level of the welding arc. The voltage range is 4 (minimum) to 7 (maximum) on 115 VAC and 1 (minimum) to 7 (maximum) on 230 VAC.

250 650-A

. Switch must “click” into detent

position. DO NOT switch under load.

4 Over Temperature Light Light illuminates if main transformer

overheats. 5 Gun Trigger Receptacle 6 Trigger Switch When pressed, energizes wire feed motor

and gas valve for shielding gas flow.

OM-260 274 Page 27

6-2. Weld Parameter Chart

OM-260 274 Page 28

250 015-B

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power

. Maintain more often

during severe conditions.

n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent

before maintaining.

Reference

Every

Months

Every

Months

l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose nl Weld Cables

nl Cords nl Gun Cables

~ Drive Rolls ~ Inside Unit

7-2. Overload Protection

1 Supplementary Protector

CB1/Power Switch

CB1 protects unit from overload. If CB1 opens, unit shuts down.

Reset supplementary protector/ power switch.

CB1 also turns unit on and off.

250 653-A

OM-260 274 Page 29

7-3. 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.

7-4. Changing Drive Roll Or Wire Inlet Guide

1 Inlet Wire Guide Securing

Screw 2 Inlet Wire Guide Loosen thumbscrew. Slide tip as

close to drive rolls as possible without touching. Tighten thumbscrew.

3 Drive Roll The drive roll consists of two

Example

.030/.035 V Groove

.030/.035 VK Groove

different grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 5-16).

4 Retaining Pin To secure drive roll, locate open slot

and push drive roll completely over retaining pin, then rotate drive roll (1/4 turn) to closed slot.

Actual drive roll may differ from that shown. See Section 5-16 for additional drive roll configurations.

Notes

Stamped .030/.035 VK

Stamped .030/.035 V

258 380-A

OM-260 274 Page 30

7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing

! Turn off welding power

source.

1 Nozzle 2 Contact Tip

Head Tube

3 Tip Adapter

. Wire size stamped on tip − check

and match wire size.

8 mm

Remove nozzle, contact tip, and adapter.

Blow out gun casing.

Cut off wire and disconnect gun from feeder.

Unscrew and remove liner.

Lay gun cable out straight before installing new liner.

10 mm

Reassemble gun in reverse order from taking it apart.

Tools Needed:

8 mm, 10 mm

Liner

Stickout

5/8 in.

(16 mm)

Install

Liner

. Thread wire according to

welding power source/wire feeder manual.

243 839-A

OM-260 274 Page 31

7-6. Replacing Switch And/Or Head Tube

! Turn Off welding power source

/wire feeder and disconnect gun.

Remove screws (5) and nuts (4).

Remove screw on opposite side.

Secure head tube in vice.

Remove handle halves.

Remove switch housing. Install new switch and connect leads (polarity is

not important). Reassemble in reverse order. If replacing head tube, continue to end of figure.

Hand-tighten head tube into cable connector.

Remove from vice. Reposition handle halves, and install switch housing.

Loosen jam nut. Remove from vice and turn head tube out by hand.

Place head tube in vice and tighten until nuts are tight.

Reinstall screws and nuts.

Tools Needed:

OM-260 274 Page 32

phillips

Reinstall screw on opposite side.

15 mm

243 840-A

7-7. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fan does not run.

No weld output; wire does not feed; fan motor continues to run.

No weld output; wire feeds.

Wire does not feed; wire is not energized; wire feeds unevenly.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Secure power cord plug in receptacle (see Section 5-11).

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 (see Section 7-2).

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when unit has cooled (see Section 4-3).

Check Voltage range switch position. Rotate knob until it “clicks” into detent at desired range setting.

Secure gun trigger leads (see Section 5-2).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 7-5).

Check for proper polarity connections (see Section 5-5).

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Check contact tip. Check for kinks in gun cable and liner.

Check gun trigger plug connection at welding power source/wire feeder.

Check, and if necessary, replace gun trigger switch (see Section 7-6).

Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 7-5).

Electrode wire feeding stops during welding.

Weld porosity.

Place voltage switch in desired position (see Section 6-1).

Straighten gun cable and/or replace damaged parts.

Adjust drive roll pressure (see Section 5-16).

Change to proper drive roll groove (see Section 7-4).

Readjust hub tension (see Section 5-14).

Replace contact tip if blocked (see Section 7-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 or Section 7-5).

Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).

Secure gun trigger leads or repair leads (see Section 5-2).

Check and clear any restrictions at drive assembly and liner (see Section 7-4 or Section 7-5).

Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Have nearest Factory Authorized Service Agent check drive motor.

Remove weld spatter buildup in nozzle.

Check O-rings on gun connector and replace if damaged.

Make sure inner head tube is tight in cable connector.

Check gun connector to be sure it is fully inserted into drive assembly.

Check shielding gas flow/supply.

Check for proper output polarity (see Section 5-5)

OM-260 274 Page 33

SECTION 8 − ELECTRICAL DIAGRAM

OM-260 274 Page 34

Figure 8-1. Circuit Diagram

249 315-A

OM-260 274 Page 35

SECTION 9 − GMAW WELDING (MIG) GUIDELINES

9-1. Typical GMAW (MIG) Process Connections

Regulator/

Flowmeter

Wire Feeder/

Power Source

! 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.

Shielding Gas

Notes

Gun

Gas

Workpiece

Work Clamp

GMAW1 2011−03 (GMAW Only) − Ref. 801 909-A

OM-260 274 Page 36

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

9-2. Typical GMAW (MIG) Process Control Settings

. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, 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

0.023 in.

0.030 in.

0.035 in.

Recommendation

3.5 in. per ampere 2 in. per ampere

1.6 in. per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

30 − 90 A 40 − 145 A 50 − 180 A

Wire Speed

(Approx.)

3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm

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

Select Voltage

Voltage controls height and width of weld bead.

Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)

OM-260 274 Page 37

9-3. Holding And Positioning Welding Gun

. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)

past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control Gun

Trigger

2 Workpiece 3 Work Clamp 4 Electrode Extension (Stickout)

Solid Wire − 3/8 to 1/2 in.

(9 to 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

0°-15°

90° 90°

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

45°

End View of Work Angle Side View of Gun Angle

FILLET WELDS

0°-15°

OM-260 274 Page 38

S-0421-A

9-4. Conditions That Affect Weld Bead Shape

. Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed

(weld current), and voltage.

10°

Push

Perpendicular

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT)

10°

Drag

Short Normal Long

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow

Normal Fast

GUN TRAVEL SPEED

S-0634

OM-260 274 Page 39

9-5. Gun Movement During Welding

. Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,

a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam

1 2

3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

9-6. Poor Weld Bead Characteristics

9-7. Good Weld Bead Characteristics

1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap

5 Poor Penetration

S-0053-A

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded.

4 No Overlap 5 Good Penetration into Base

Metal

OM-260 274 Page 40

S-0052-B

9-8. 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.

9-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. 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. 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.

9-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Good Penetration

Increase travel speed.

S-0639

OM-260 274 Page 41

9-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

S-0638

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

maintaining proper welding wire extension and arc characteristics.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Reduce travel speed.

9-12. 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.

9-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

S-0640

OM-260 274 Page 42

Increase and/or maintain steady travel speed.

9-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

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.

9-15. 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.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

S-0641

S-0642

Notes

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-260 274 Page 43

9-16. 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

Spray Arc

Aluminum

Argon All Positions

Argon + 1% O

Argon + 2% O

Argon + 5% O

Argon + 8% CO

Argon + 25%

Argon + 50%

Flat & Horizontal

Fillet

Flat & Horizontal

Fillet

Flat & Horizontal

Fillet

All Positions

All Positions All Positions

All Positions

Helium All Positions

Argon + Helium All Positions

Short Circuiting

Aluminum

All Positions

Tri-Mix

All Positions

1 Globular Transfer 2 Heavy Thicknesses 3 Single Pass Welding Only 4 90% HE + 7-1/2% AR + 2-1/2% CO

5 Also for GMAW-P, All Positions

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but wire does not feed.

Wire curling up in front of the wire feed rolls (bird nesting).

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect 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.

OM-260 274 Page 44

Dirty or damaged (kinked) liner. Replace liner.

Problem RemedyProbable Cause

Wire feeds, but no gas flows.

Welding arc not stable.

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

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

Incorrect primary voltage connected to welding power source.

Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn

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 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.

gas hose in gun and cable assembly.

solenoid valve.

Check primary voltage and relink welding power source for correct voltage.

drive rolls if necessary.

Readjust welding parameters.

OM-260 274 Page 45

SECTION 10 − ACCESSORIES/CONSUMABLES

10-1. Accessories

PART NO. DESCRIPTION REMARKS

770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max. 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max. 195 186 Protective Cover Weatherproof nylon 245 926 H100S4-10 Replacement Gun 10 ft length/.030-.035 wire size 300 796 SpoolRunner 100 Spool Gun For push/pull wire feeding

10-2. Consumables

ITEM HOBART PACKAGE NO.* MILLER PACKAGE NO.**

Contact Tips

.023/.025 in (0.6 mm) 770 174 (5 per package) 087 299 (10 per package) .030 in (0.8 mm) 770 177 (5 per package) 000 067 (10 per package) .035 in (0.9 mm) 770 180 (5 per package) 000 068 (10 per package) .045 in (1.2 mm) 770 183 (5 per package) 000 069 (10 per package)

MIG Nozzle (Standard) 770 404 169 715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716

Replacement Liners

.023/.025 in (0.6 mm) 196 139 194 010 .030/.035 in (0.8/0.9 mm) 196 139 194 011 .035/.045 in (0.9/1.2 mm) 196 140 194 012

*Available at farm and tool supply retailers. **Available at Hobart/Miller welding distributors.

10-3. Replacement Drive Rolls

For All Feed Head Assemblies

PART NO.

237 338 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 246 565 .030/.035 (.8 and .9) V/VK Grooves

WIRE DIAMETER

INCHES (mm)

10-4. Regulator/Flowmeter

PART NO. DESCRIPTION REMARKS

212 492* Regulator/Flowmeter

*Available at Hobart/Miller welding distributors.

For use with CO2 shielding gas, 10−50 CFH. Use

with gas hose 144 108.

. 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-260 274 Page 46

Warranty Questions?

Call 1-800-332-3281 7 AM − 5 PM EST

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Assistance

Visit the Hobart website: www.HobartWelders.com

Effective January 1, 2012

5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a

serial number preface of MC or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive with

Hobart 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 Hobart 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. 5 Years — Parts and Labor * Original Main Power Rectifiers only to include SCRs,

diodes, and discrete rectifier modules * Reactors * Stabilizers * Transformers

2. 3 Years — Parts and Labor * Drive Systems * Idle Module * PC Boards * Rotors, Stators and Brushes * Solenoid Valves * Spot Welder Transformer * Switches and Controls

3. 1 Year — Parts and Labor Unless Specified (90 days for industrial use)

* Accessories * Batteries (Trek 180 Only) * 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) * HF Units * MIG Guns/TIG Torches * Motor-Driven Guns * Plasma Cutting Torches * Regulators * Relays * Remote Controls * Replacement Parts (No labor) − 90 days * Running Gear/Trailers * Water Coolant Systems

4. Engines, batteries (except Trek 180) and tires are warranted separately by the manufacturer.

no other guarantees or warranties expressed or implied.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. 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.)

2. 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.

3. 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 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.

hobart_warr 2012-03

Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, operation, or service, contact us!

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Service Center:

Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:

Call 1-800-332-3281 7 AM to 5 PM EST − Monday through Friday

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

Hobart Brothers Co.

An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA

For Assistance:

Call1-800-332-3281

Hobart HANDLER 210 MVP User guide

Specifications and Main Features

Frequently Asked Questions

User Manual