Hobart Welding Products H-9A Gun User Manual

OM-952 220 361A

June 2004

Processes

Description

Semi-Automatic, Air-Cooled Flux Cored (FCAW) And MIG (GMAW) Welding Gun

H-9A Gun

Flux Cored (FCAW) Welding

MIG (GMAW) Welding (Optional)

Visit our website at

www.HobartWelders.com

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part

Hobart is registered to the ISO 9001:2000 Quality System Standard.

you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do − every power source from Hobart is backed by the best warranty in the business.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1.

Hob_Thank 7/03

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR FCAW AND

GMAW WELDING GUNS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1-2. FCAW And GMAW Gun Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SAFETY INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Gun Into Welding Power Source 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Threading Welding Wire 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Operating The Gun 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Replacing Gun Contact Tip 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Cleaning Gun Liner 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Replacing Gun Liner 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Replacing Liner O-Ring 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Replacing Switch And/Or Head Tube 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Removing Gun From Welding Power Source 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Routine Maintenance 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Troubleshooting 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − PARTS LIST 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 −SAFETY PRECAUTIONS FOR FCAW AND

GMAW WELDING GUNS − READ BEFORE USING

1-1. Symbol Usage

SR7_8/03

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. FCAW And GMAW Gun Hazards

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information found in the wire feeder and welding power source Owner’s Manuals. Read and follow all safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked gun or cable insulation.

5. Turn off welding power source before changing contact tip or gun parts.

6. Keep all covers and handle securely in place.

GMAW WELDING can be hazardous.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin with spatter-resistant clothing.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

FUMES AND GASES can be hazardous to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. Read Material Safety Data Sheets (MSDSs) and manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

BUILD UP OF GAS can injure or kill

1. Shut off shielding gas supply when not in use.

2. Always ventilate confined spaces or use approved air-supplied respirator.

NOISE can damage hearing; SOME APPLICATIONS, SUCH AS PULSING, are noisy.

1. Check for noise level limits exceeding those specified by OSHA.

2. Use approved ear plugs or ear muffs if noise level is high.

3. Warn others nearby about noise hazard.

WELDING WIRE can cause puncture wounds.

1. Keep hands and body away from gun tip when trigger is pressed.

OM-952 Page 1

EMF INFORMATION

NOTE

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields − Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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OM-952 Page 2

SECTION 2 − SAFETY INFORMATION

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 2

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

NOTE

Turn Off switch when using high frequency.

SECTION 3 − INSTALLATION

3-1. Specifications

Air-Cooled Welding Gun For FCAW And GMAW Welding

Note: Using gasless flux cored wire reduces gun duty cycle.

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

READ SAFETY BLOCKS at start of Section 3-1 before proceeding.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death or serious injury can happen.

CAUTION means possible minor injury or equipment damage can happen.

3 Statement Of Hazard And

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each symbol shown.

7 NOTE

Special instructions for best operation − not related to safety.

H-9 Feeds .030 − .035 in (0.8 − 0.9 mm) Flux Cored Wire Or .023 − .030 in (0.6 − 0.8 mm) Hard Wire Duty Cycle Rating:

100%: 40 A With Flux Cored Wire 100%: 100 A With CO 60%: 100 A With Mixed Gases Weight With 8 ft (2.4 m) Power Cable: 2.2 lb (1.0 kg)

803 836-A

3-2. Duty Cycle And Overheating

See Section 3-1. Specifications for amperage rating and duty cycle.

100%dutycycle

Continuous Welding

Overheating

6 Minutes Welding 4 Minutes Resting

Minutes

Shielding Gas

60%dutycycle

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

Y Exceeding duty cycle can

damage unit and void warranty.

A or V

Reduce Duty Cycle

sduty1 5/95

OM-952 Page 3

3-3. Installing Gun Into Welding Power Source

Open pressure assembly.

. If existing gun requires removal, see Section 5-6.

Remove screws (3) from cover, and remove cover from wire drive assembly.

Y Turn off welding power source.

Insert gun cable through opening in front panel. Route weld cable, trigger leads, and gas hose through opening in drive housing.

Remove wrapper from unit.

Reinstall cover and secure with screws (3).

. Route wires, cable, and hose to avoid contact

with sharp edges, hot surfaces, or moving parts.

Connect trigger leads to RC3 and RC4 on PC1.

Route weld cable through opening in baffle.

Connect gas hose to adapter (if unit is not equipped with gas solenoid valve, secure hose to wiring harness).

Secure leads and hose with cable tie(s).

Reinstall cable end into drive housing with retaining grooves inserted into the two retaining ribs. Be sure to position gas hose up. Position liner in groove so that end is flush with back of groove.

Connect weld cable to weld terminal.

Reinstall wrapper onto unit.

. Thread wire according to

Section 3-4.

803 497-A / Ref. 803 378-A

OM-952 Page 4

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