Hobart Welding Products HWC-115A User Manual

OM-185 480B

March 1999

Processes

MIG (GMAW) Welding

Description

Weld Control For Spoolmatic Gun

HWC-115A

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

Hobart is registered to the
ISO 9001 Quality System
Standard.

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

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.

Hobart offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING

OM-185 480 – 2/97

1-1. Symbol Usage

safety_som1 4/95

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, MOVING
PARTS, 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. Arc Welding Hazards

WARNING

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 1-4. 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.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.

4. 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).

5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.

6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground

ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping,
grinding, and welds cooling throw off pieces of

NOISE

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

metal or slag.

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

7. When making input connections, attach proper grounding
conductor first – double-check connections.

8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.

9. Turn off all equipment when not in use.

10. Do not use worn, damaged, undersized, or poorly spliced
cables.

11. Do not drape cables over your body.

12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.

13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.

14. Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.

15. Wear a safety harness if working above floor level.

16. Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to
workpiece or worktable as near the weld as practical.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.

4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.

5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.

FUMES AND GASES can be
hazardous to your health.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.

5. 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.

6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.

7. 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 if necessary, while
wearing an air-supplied respirator . The coatings and any metals
containing these elements can give off toxic fumes if welded.

OM-185 480 Page 1

CYLINDERS can explode if damaged.

Shielding 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.

1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.

2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical
circuits.

4. Never drape a welding torch over a gas cylinder.

5. Never allow a welding electrode to touch any cylinder.

6. Never weld on a pressurized cylinder – explosion will result.

7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.

8. T urn face away from valve outlet when opening cylinder valve.

9. Keep protective cap in place over valve except when cylinder is
in use or connected for use.

10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

WELDING can cause fire or
explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before
doing any welding.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 3 5 f t (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS F4.1
(see Safety Standards).

8. 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 and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

1-3. Additional Installation, Operation, And Maintenance Hazards

FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.

1. Do not locate unit on, over, or near combustible
surfaces.

2. Do not install unit near flammables.

FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.

1. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.

2. Use equipment of adequate capacity to lift unit.

3. If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

HOT PARTS can cause severe burns.

1. Do not touch hot parts bare handed.

2. Allow cooling period before working on gun or
torch.

MOVING PARTS can cause injury.

1. Keep away from moving parts such as fans.

2. Keep all doors, panels, covers, and guards closed
and securely in place.

MAGNETIC FIELDS FROM HIGH
CURRENTS can affect pacemaker
operation.

1. Pacemaker wearers keep away.

2. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
operations.

MOVING PARTS can cause injury.

1. Keep away from moving parts.

2. Keep away from pinch points such as drive rolls.

FLYING PIECES OF MET AL or DIRT can
injure eyes.

1. Wear safety glasses with side shields or face
shield.

WELDING WIRE can cause puncture
wounds.

1. Do not press gun trigger until instructed to do so.

2. Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.

HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services, computers, and
communications equipment.

1. Have only qualified persons familiar with
electronic equipment perform this installation.

2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.

3. If notified by the FCC about interference, stop
using the equipment at once.

4. Have the installation regularly checked and
maintained.

5. 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.

OM-185 480 Page 2

OVERUSE can cause OVERHEATED
EQUIPMENT.

1. Allow cooling period.

2. Reduce current or reduce duty cycle before
starting to weld again.

3. Follow rated duty cycle.

STATIC ELECTRICITY can damage parts
on circuit boards.

1. Put on grounded wrist strap BEFORE handling
boards or parts.

2. Use proper static-proof bags and boxes to store,
move, or ship PC boards.

1-4. Principal Safety Standards

SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.

1. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.

BUILDUP OF SHIELDING GAS can harm
health or kill.

1. Shut of f shielding gas supply when not in use.

Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society , 550 N.W . LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

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

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 o ffer clear science-based advice on strategies to minimize
or avoid potential risks.”

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.

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 also recommended for pacemaker
wearers. Consult your doctor for complete information.

OM-185 480 Page 3

SECTION 2 – INSTALLATION

2-1. Typical Process Connections

NOTE

Constant current and/or
constant voltage transformer
and engine-driven DC power
sources. If the power source
does not have a weld output
contactor, the optional
contactor kit should be
ordered.

Weld Power Cable (Not Included)

10 ft (3 m) Contactor Cord

10 ft (3 m) 115 VAC Power Cord

Use gun Owner’s Manual when making connections.

115 Volt

Control

2-2. Gun/Feeder Connections

40 ft (12 m) Gas Hose

30 ft (9 m) Control Cord

30 ft (9 m) Weld Power Cable

Voltage Sensing Lead For CC Mode

Work

1 Gun Control Receptacle
2 Weld Power Grommet
3 Regulator/Flowmeter

2

4 Gas Fitting

Tools Needed:

3

5/8, 3/4 in

Left Side

Wrapper Off

4

1

2

Ref. ST-149 966-C / Ref. ST-149 549-B / Ref. S-0621-C

OM-185 480 Page 4