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; WARNING
The following terms areused interchangeablythroughout this manual:MIG = GMAW TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-198 683 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-198 683 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-198 683 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-198 683 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 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-198 683 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 – INSTALLATION; Specifications; A or V
OM-198 683 Page 9 SECTION 2 – INSTALLATION 2-1. Specifications Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Circuit Voltage 200 (208) V 230 V 400 V 460 V 575 V KVA KW 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle 38 48 2.3* 42 2* 24 1.2* 21 1* 17 0....
Page 14 - Welding Gun Duty Cycle And Overheating; CAUTION
OM-198 683 Page 10 2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Duty Cycle is percentage of 10minute...
Page 16 - Setting Gun Polarity For Wire Type; Changing Polarity; Installing Gas Supply
OM-198 683 Page 12 2-8. Setting Gun Polarity For Wire Type 1 Polarity Changeover LabelInformation Always read and follow manufac-ture’s recommended polarity. 1 3/4, 11/16 in Ref. 190 821-A Changing Polarity D D Wire DriveAssembly Lead Work Clamp Lead + Positive Terminal Shown as shipped – Electrode ...
Page 17 - -10. Installing Wire Spool and Adjusting Hub Tension
OM-198 683 Page 13 2-10. Installing Wire Spool and Adjusting Hub Tension ST-072573-B When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with8 in (200 mm) spools. Tools Needed: 2-11. Positioning Jumper Links 802 476-A Check input voltage available atsite. 1 J...
Page 18 - -13. Selecting A Location And Connecting Input Power
OM-198 683 Page 14 2-12. Electrical Service Guide Input Voltage 200 230 400 460 575 Input Amperes At Rated Output 48 42 24 21 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 60 50 30 25 20 Normal Operating 3 70 60 35 30 25 Min Input Conductor Si...
Page 22 - SECTION 3 – OPERATION; Controls
OM-198 683 Page 18 SECTION 3 – OPERATION 3-1. Controls 1 Voltage Control Turn control clockwise to increasevoltage. 2 Wire Speed Control Turn control clockwise to increasewire feed speed. 3 Power Switch 4 Voltmeter 5 Wire Feed Speed Meter 1 2 3 4 5 198 653
Page 23 - Voltmeter And Wire Feed Speed Meter Operation
OM-198 683 Page 19 3-2. Voltmeter And Wire Feed Speed Meter Operation 1 Voltmeter 2 Wire Feed Speed Meter Power Up Status Both meters display zeros at unitpower up. After one second, presetvalues appear on both meters. TheMIG gun settings (not spool gun)are always the default at initialpower up of t...
Page 24 - SECTION 4 – MAINTENANCE &TROUBLESHOOTING; Routine Maintenance; Months; Circuit Breaker CB1
OM-198 683 Page 20 SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. 3 Months Replace unreadable labels Repair or replacecracked weld cable Clean and tighten weld terminals 6 Months Blow out or ...
Page 26 - Aligning Drive Rolls and Wire Guide
OM-198 683 Page 22 4-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look-ing down with pressure assemblyopen. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver, and turn screwin or out until drive roll groove ...
Page 27 - Cleaning Or Replacing Gun Liner
OM-198 683 Page 23 4-7. Cleaning Or Replacing Gun Liner Ref. ST-800 797-C 5/16 in, 10 mm To Reassemble Gun: Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in[9.5 mm] for aluminum) from headtube. Install adapter, contact tip, andnozzle. Y Disconnect gun from unit first. Tools Needed...
Page 28 - Replacing Switch And/Or Head Tube
OM-198 683 Page 24 4-8. Replacing Switch And/Or Head Tube Ref. ST-800 795-C 1 Remove handlelocking nut. 2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, and secure with handle l...
Page 29 - Troubleshooting
OM-198 683 Page 25 4-9. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-13). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connecti...
Page 30 - Notes
Page 31 - SECTION 5 – ELECTRICAL DIAGRAM
OM-198 683 Page 27 SECTION 5 – ELECTRICAL DIAGRAM 197 699-D Figure 5-1. Circuit Diagram
Page 32 - SECTION 6 – PARTS LIST
OM–198 683 Page 28 SECTION 6 – PARTS LIST 802 059-B . Hardware is common andnot available unless listed. Figure 6-1. Main Assembly
Page 40 - Table 6-1. Drive Roll And Wire Guide Kits; Note
OM–198 683 Page 36 Table 6-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing t...
Page 44 - Hobart Welding Products; Please complete and retain with your personal records.; Contact your Distributor for:; Resources Available; For technical assistance:
PRINTED IN USA 2000 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...