Page 2 - From Hobart to You
Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Hobart distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-877-Ho...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-192 440 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T...
Page 6 - WELDING can cause fire or explosion.
OM-192 440 Page 2 Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld. ARC RAYS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-192 440 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly siz...
Page 8 - EMF Information
OM-192 440 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-192 440 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un mes...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-192 440 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer ...
Page 13 - SECTION 2 – INTRODUCTION; Specifications; Duty Cycle And Overheating; A or V
OM-192 440 Page 9 SECTION 2 – INTRODUCTION 2-1. Specifications Max. Open Circuit Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Max. Open Circuit Voltage 200 V 230 V KVA KW 200 A at 24 VDC, 60% Duty Cycle 35 40 1.1* 35 1.3* 8 0.31* 6.8 0.18* Wire Type and Diameter No Load Wire Fe...
Page 14 - Installing Welding Gun
OM-192 440 Page 10 2-3. Volt-Ampere Curves Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of unit.Curves of other settings fall be-tween curves shown. va_curve1 4/95 – SB-192 436 2-4. Installing Welding Gun Ref. ST-801 875 1 Drive Assembly 2 Gun Securing Thumbsc...
Page 15 - Installing Work Clamp; Setting Gun Polarity For Wire Type
OM-192 440 Page 11 2-5. Installing Work Clamp 1 Work Cable Route cable out front panel openingfrom inside. 2 Negative (–/Black) OutputTerminal Connect cable to terminal. 3 Hardware 4 Work Clamp Route cable through clamp handleand secure as shown. Close door. Ref. ST-802 285 / Ref. ST-801 566 Tools N...
Page 17 - Changing Input Voltage From 230 Volts To 200 Volts
OM-192 440 Page 13 2-9. Changing Input Voltage From 230 Volts To 200 Volts Ref. ST-802 287 Cut cable ties as necessary. 1 230 Volt TransformerLead/Fan Lead 2 Black Switch Lead 3 Tubing Locate lead marked 230 VAC.Slide tubing down and disconnectblack switch lead from splice. Besure 230 volt transform...
Page 18 - -11. Selecting A Location And Connecting Input Power
OM-192 440 Page 14 2-11. Selecting A Location And Connecting Input Power ST-802 286 1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle. 4 Input And GroundingConductors Connect directly to line disconnectdevice if hard wiring is required. 5 Line Disconnect Devic...
Page 20 - SECTION 3 – OPERATION; Controls
OM-192 440 Page 16 SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Control The scale around the control is per-cent, not wire feed speed. 2 Voltage Control The higher the selected number,the thicker the material that can bewelded (see welding guide andSection 3-2). 3 Power Switch 1 Ref. ST-192 372 ...
Page 21 - Weld Parameters
OM-192 440 Page 17 3-2. Weld Parameters WIRE TYPE WIRE MACHINE MATERIAL THICKNESS GAS SIZE SETTINGS* 3/8 5/16 1/4 3/16 12GA 14GA 16GA 18GA 20GA 22GA FLOW RATE .023” VOLTAGE – – 6 5 4 3 3 2 2 1 0.6MM WIRESPEED – – 100 85 75 60 50 36 30 15 E70S–6 .030” VOLTAGE 5 5 4 4 3 3 2 2 2 1 CO2 0.8MM WIRESPEED 6...
Page 22 - SECTION 4 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; Months; Circuit Breakers
OM-192 440 Page 18 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replacecracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. Duringheavy service, clean mon...
Page 23 - Replacing Drive Roll And Wire Inlet Guide; Replacing Gun Contact Tip
OM-192 440 Page 19 4-3. Replacing Drive Roll And Wire Inlet Guide Ref. ST-801 875 1 Inlet Wire Guide SecuringScrew 2 Inlet Wire Guide Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw. 3 Drive Roll Install correct drive roll for wire sizeand type. 4 Drive Roll...
Page 24 - Cleaning Or Replacing Piecemaker 20-A Gun Liner
OM-192 440 Page 20 4-5. Cleaning Or Replacing Piecemaker 20-A Gun Liner Ref. ST-802 290 7/16 in To Reassemble Gun: Inspect o-rings for chips or cuts be-fore inserting new liner. A light lu-brication on the o-rings will makeliner installation easier. Insert new liner. Push liner against quick-connect...
Page 25 - Welding Troubleshooting Table; Troubleshooting Table
OM-192 440 Page 21 4-6. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-11). Check and replace power switch if necessary. Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2). Repl...
Page 26 - SECTION 5 – ELECTRICAL DIAGRAM; Figure 5-1. Circuit Diagram For Welding Power Source
OM-192 440 Page 22 SECTION 5 – ELECTRICAL DIAGRAM SC-192 433 Figure 5-1. Circuit Diagram For Welding Power Source
Page 27 - Notes
Page 28 - SECTION 6 – PARTS LIST
OM-192 440 Page 24 SECTION 6 – PARTS LIST ST-802 281 . Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 9–(Fig. 6-2) 10–(Fig.6-3) 11 12 13 14 15 16 17 (Fig. 6-4) 18 19 20–(Fig. 6-5) Figure 6-1. Main Assembly
Page 34 - Description
OM-192 440 Page 30 . Hardware is common andnot available unless listed. Scan 28 29 30 31 Figure 6-5. Gun And Cable Assembly, Piecemaker 20-A Description Part No. Item No. Figure 6-5. Gun And Cable Assembly, Piecemaker 20-A Quantity 1 379 300 NOZZLE, slip on assembly 1 . . . . . . . . . . . . . . . ....
Page 39 - Hobart Warranty
Effective January 1, 1997 This limited warranty supersedes all previous manufacturerswarranties and is exclusive with no other guarantees orwarranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditionsbelow, warrants to its original retail purchaser that newequipment sold a...
Page 40 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA 1998 Hobart Welding Products. 1/00 Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equ...
