HobartWelders HANDLER 120/150 Owner's manual

Processes

OM-210 088A

July 1998

Handler 120 / 150 And

Piecemaker 14A Gun

Arc Welding Power Source And Wire

Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

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.

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

which exact part you may need to fix the

problem. Warranty and service information for

your particular model are also provided.

Hobart is registered to the

ISO 9001 Quality System

Standard.

From Hobart to You

Hobart offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

The following terms are

used interchangeably

throughout this manual:

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. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1. CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . .

1.1 Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing Welding Gun 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Changing Polarity 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Process/Polarity Table 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Installing Gas Supply 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Selecting A Location And Connecting Input Power For 120 VAC Model 14. . . . . . . . . . . . . . . .

3-6. Selecting A Location And Connecting Input Power For 230 VAC Model 15. . . . . . . . . . . . . . . .

3-7. Electrical Service Guide For 230 VAC Model 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Wire Spool And Adjusting Hub Tension 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Threading Welding Wire 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld Parameters For 120 VAC Model 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Weld Parameters For 230 VAC Model 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE &TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Changing Drive Roll Or Wire Inlet Guide 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Replacing Gun Contact Tip 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Cleaning Or Replacing Piecemaker 14-A Gun Liner 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Cleaning Or Replacing GA16C2 Gun Liner 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Troubleshooting Table 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MIG WELDING (GMAW) GUIDELINES 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Typical MIG Process Connections 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Typical MIG Process Control Settings 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Holding And Positioning Welding Gun 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Conditions That Affect Weld Bead Shape 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Gun Movement During Welding 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Poor Weld Bead Characteristics 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Good Weld Bead Characteristics 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Troubleshooting – Excessive Spatter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Troubleshooting – Porosity 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Troubleshooting – Excessive Penetration 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Troubleshooting – Lack Of Penetration 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Troubleshooting – Incomplete Fusion 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13. Troubleshooting – Burn-Through 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14. Troubleshooting – Waviness Of Bead 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15. Troubleshooting – Distortion 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16. Common MIG Shielding Gases 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – PARTS LIST 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-210088A

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OM-210 088 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

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.

1-2. Arc Welding Hazards

Y 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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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 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 and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

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 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 – do not use work clamp or work cable.

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

or another electrode from a different machine.

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.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

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

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

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

D Read 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 watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing 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 if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-210 088 Page 2

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.

ARC RAYS can burn eyes and skin.

D 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).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

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.

WELDING can cause fire or explosion.

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

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

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 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 closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

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 and fire hazards.

D Do not use welder to thaw frozen pipes.

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.

FLYING METAL 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 shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

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.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, 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 shielding gas cylinders, regulators, hoses, and fit-

tings 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 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-210 088 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 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 UNIT can cause injury.

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.

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.

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.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

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.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

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 installa-

tion.

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.

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.

1-4. Principal Safety Standards

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 Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting 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 Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

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.

OM-210 088 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

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 your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-210 088 Page 8

1.4 Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1.5 Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

L’extrait suivant est tiré des conclusions générales du document intitulé

Biological Effects of Power Frequency Electric & Magnetic Fields –

Background Paper, OTA–BP–E–53 (Washington DC : U.S. Govern-

ment Printing Office, mai 1989), publié par le Office of Technology

Assessment du Congrès américain : «... il existe maintenant d’abon-

dantes données scientifiques compilées à la suite d’expériences sur la

cellule ou d’études sur des animaux et des humains, qui montrent clai-

rement que les champs électromagnétiques basse fréquence peuvent

avoir des effets sur l’organisme et même y produire des transforma-

tions. Même s’il s’agit de travaux de très grande qualité, les résultats

sont complexes. Cette démarche scientifique ne nous permet pas

d’établir un tableau d’ensemble cohérent. Pire encore, elle ne nous per-

met pas de tirer des conclusions finales concernant les risques

éventuels, ni d’offrir des conseils sur les mesures à prendre pour rédui-

re sinon éliminer les risques éventuels». (Traduction libre)

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

vous.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les consignes mentionnées précédemment font partie de celles desti-

nées aux personnes ayant recours à un stimulateur cardiaque. Veuillez

consulter votre médecin pour obtenir plus de détails.

OM-210 088 Page 9

SECTION 2 – SPECIFICATIONS

2-1. Specifications

A. 120 VAC Model

Rated Welding

Output

Amperage

Range

Maximum Open-

Circuit Voltage

DC

Amperes Input at

Rated Load Output

120 V, 60 Hz,

Single-Phase

KVA KW

Weight

W/ Gun

Overall

Dimensions

90 A @ 19 Volts DC,

30% Duty Cycle

75 A @ 19 Volts DC,

20% Duty Cycle*

30 – 130

28

24

20*

2.88

2.40*

2.45

2.04*

67 lb

(30 kg)

Length: 19-1/8 in

(489 mm)

Width: 10-1/2 in

(267 mm)

Height: 14-1/2 in

(368 mm)

Wire Type

Solid/

Stainless

Flux Cored/

Aluminum

Wire Feed Speed Range At No Load

Wire Type

And Dia

.023 – .030 in

(0.6 – 0.8 mm)

.030 – .035 in

(0.8 – 0.9 mm)

160 – 870 IPM (4.1 – 22.5 m/min)

* CSA Rating

B. 230 VAC Model

Rated Welding

Output

Amperage

Range

Maximum Open-

Circuit Voltage

DC

Amperes Input at

Rated Load Output

230 V, 50/60 Hz,

Single-Phase

KVA KW

Weight

W/ Gun

Overall

Dimensions

130 A @ 20 Volts

DC, 30% Duty Cycle

At 60 Hz Input – 20%

Duty Cycle At 50 Hz

Input

30 – 175

30 19.5 4.49 3.83

70 lb

(31.8 kg)

Length: 19-1/8 in

(489 mm)

Width: 10-1/2 in

(267 mm)

Height: 14-1/2 in

(368 mm)

Wire Type

Solid/

Stainless

Flux Cored/

Aluminum

Wire Feed Speed Range At No Load

Wire Type

And Dia

.023 – .030 in

(0.6 – 0.8 mm)

.030 – .035 in

(0.8 – 0.9 mm)

160 – 954 IPM (4.1 – 24 m/min)

OM-210 088 Page 10

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes 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.

Y Exceeding duty cycle can

damage unit or gun and void

warranty.

Overheating

0

15

A or V

OR

Reduce Duty Cycle

Minutes

duty1 4/95 – SA-802 090 / SA-802 091

A. 120 VAC Model

B. 230 VAC Model

3 Minutes Welding 7 Minutes Resting

30%dutycycle at 90 amps

3 Minutes Welding 7 Minutes Resting

30%dutycycle at 130 amps, 60 Hz –

20% duty cycle at 130 amps, 50 Hz

OM-210 088 Page 11

2-3. 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.

ssb1.1 10/91 – ST-802 082 / ST-802 089

A. 120 VAC Model

B. 230 VAC Model

OM-210 088 Page 12

SECTION 3 – INSTALLATION

3-1. Installing Welding Gun

Ref. ST-802 024

1 Drive Assembly

2 Gun Securing Thumbscrew

3 Gun End

Loosen thumbscrew. Insert gun

end through opening until it bottoms

against drive assembly. Tighten

thumbscrew.

4 Gun Trigger Leads

Insert leads, one at a time, through

small grommet on front panel. Con-

nect female friction terminals to

matching male terminals in unit.

Polarity is not important.

Close door.

4

1

2

3

3-2. Changing Polarity

1 Lead Connections For Direct

Current Electrode Positive

(DCEP)

2 Lead Connections For Direct

Current Electrode Negative

(DCEN)

Always read and follow wire

manufacturer’s recommended po-

larity, and see Section 3-3.

Close door.

1

Ref. ST-802 024

2

3-3. Process/Polarity Table

Cable Connections

Process Polarity

Cable To Gun Cable To Work

GMAW – Soild wire with shield-

ing gas

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

put terminal

Connect to negative (–) output

terminal

FCAW – Self-shielding wire –

no shielding gas

DCEN – Straight Polarity Connect to negative (–)

output terminal

Connect to positive (+) output

terminal

OM-210 088 Page 13

3-4. Installing Gas Supply

Obtain gas cylinder and chain to

running gear, wall, or other station-

ary 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 customer supplied gas

hose between regulator/flowmeter

gas hose connection, and fitting on

rear of welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufactur-

er’s recommended flow rate.

8CO

2

Adapter (Customer Sup-

plied)

9 O-Ring (Customer Supplied)

Install adapter with O-ring between

regulator/flowmeter and CO

2

cylinder.

Tools Needed:

CO

2

Gas

8 9

3

1

2

4

5

7

1

2

3

Argon Gas

OR

ST-802 028 / ST-802 086

5/8, 1-1/8 in

6

OM-210 088 Page 14

3-5. Selecting A Location And Connecting Input Power For 120 VAC Model

1 Rating Label

2 Grounded Receptacle

A 120 volt, 20 ampere individual

branch circuit protected by time-de-

lay fuses or circuit breaker is re-

quired.

3 Plug From Unit

Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for

50 up to 200 ft (61 m).

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

2

1

3

18 in

(460 mm)

18 in

(460 mm)

ST-802 084

OM-210 088 Page 15

3-6. Selecting A Location And Connecting Input Power For 230 VAC Model

1 Rating Label

Supply correct input power.

2 Plug

3 Receptacle

Connect plug to receptacle.

4 Line Disconnect Device

See Section 3-7.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

ssb2.2* 1/94 – Ref. ST-802 085

1

18 in (457 mm) of

space for airflow

L1

L2

L1

L2

2

230 VAC, 1

Y Always connect

grounding

conductor first.

= GND/PE

4

3

Y Do not move or operate unit

where it could tip.

OM-210 088 Page 16

3-7. Electrical Service Guide For 230 VAC Model

Input Voltage

230

Input Amperes At Rated Output

19.5

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

30

Min Input Conductor Size In AWG/Kcmil

14

Max Recommended Input Conductor Length In Feet (Meters)

66 (20)

Min Grounding Conductor Size In AWG/Kcmil

14

Reference: 1996 National Electrical Code (NEC) S-0092-J

3-8. Installing Wire Spool And Adjusting Hub Tension

S-0499

15/16 in

Standard Wire Spool (8 in)

1 Lb Wire Spool (4 in)

Turn wingnut. When a slight force is

needed to turn spool, tension is set.

Tools Needed:

Adjusting Hub Tension

Install spool so welding wire feeds from bottom.

OM-210 088 Page 17

3-9. Threading Welding Wire

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Outlet Wire Guide

7 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

7

61

3

4

5

6 in

(150 mm)

Pull and hold wire; cut off end.

4 in

(102 mm)

Tighten

Remove gun nozzle and contact tip.

Open pressure assembly.

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

. Hold wire tightly to keep it

from unraveling.

Ref. ST-802 081 / Ref. ST-205 837

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close and latch door.

Press gun trigger until wire comes

out of gun.

Reinstall contact tip and nozzle.

2

Turn power on.

INPUT

POWER

OM-210 088 Page 18

SECTION 4 – OPERATION

4-1. Controls

1 Voltage Switch

The higher the selected number,

the thicker the material that can be

welded (see weld setting label in

welding power source or Sections

4-2 and 4-3, as applicable). Do not

switch under load.

2 Voltage Switch - Purge “0”

Position

In purge position, fan runs but there

is no weld output.

3 Wire Speed Control

Use control to select a wire feed

speed. As Voltage switch setting in-

creases, wire speed range also in-

creases (see weld setting label in

welding power source or Sections

4-2 or 4-3, as applicable).

4 Power Switch

Ref. ST-205 387

2

1

3

MAX.

(STEEL)

THICKNESS

MATERIAL

18–24 GA.

.022–.047

.062

16 GA.

.125

11 GA.

1

0

WIRE

FEED

SPEED

2

3

4

WELD

VOLTS

10

9

8

7

6

5

OOFF

INPUT

POWER

ON

Do not switch

while welding

Ne pas commuter

durant LeSoudure

1

2

34

PURGE

4

OM-210 088 Page 19

4-2. Weld Parameters For 120 VAC Model

205 406-A

BracketsandRimsBasketball

Farm Equipment Frames,

Frames,

”A”

Axles,Brackets,

5356 (.035)

1/4

1/2

5/16

3/4

1/2

3/4

1/4

1/2

5/16

1/2

1/4

5/16

1/4

1/43–4

3–4

2–3

3–4

2–3

3–4

2–3

2

4–5

3–4

3

6–7

4–5

4

4–5

6

81

2

4

3

4

2

3

1

2

1

2

1

DCEP

DCEN

DCEP

20

ARGON

C

HB–28 (.035)

Fabshield 21B (.035)

HB–28 (.030)

(.024)

HB–28 (.024)

18 GA.

16 GA.

11 GA.

7 GA.

16 GA.

11 GA.

16 GA.

1/16”

1/8”

1/16”

3/16”

1/8”

1/16”

3/64”

24 GA.

.022”

Aluminum

Equipment

Counter Tops, Kitchen

Stainless Steel Fryers,

Trailer Hitches, Door Hinge

Bailers, Combines, Bumpers

Brackets, Grain Wagons,

Wheelbarrows, Garage Door

Trailers, Trailer Frames,

Fencing, Lawnmower Decks,

Work, Auto Door Brackets,

Galvanized Roofing, Trailer

Sides, Garage Door Tracks,

Tailpipes, Motorcycles

Decks, Basketball Posts,

Wheelbarrows, Lawnmower

Tailpipes, Bicycles

Wagons, Tricycles, Duct

Lawnmower Handles,

Auto Body

THICKNESS

(Cubic Ft/Hr)

(Inches)

STICKOUT

WIRE

SPEED

WIRE

VOLTAGE

WELDING

POLARITY

GAS FLOW

GAS

Gauge)

(Inches/

TO WELD:

TYPE\SIZE

WIRE

Settings are approximate. Adjust as required.Welding Guide

C

HB–28

Stainless

(.030)

Solid

HB–28 (.030)

HB–28 (.024)

HB–28 (.030)

HB–28 (.035)

HB–28 (.030)

HB–28 (.024)

205406A

Fabshield 21B (.045)

Fabshield 21B (.035)

Fabshield 21B (.045)

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

= Carbon Dioxide

C

25

= Argon + 25% Carbon Dioxide

OM-210 088 Page 20

4-3. Weld Parameters For 230 VAC Model

205 424-A

Welding Guide Settings are approximate. Adjust as required.

WIRE

TYPE\SIZE

TO WELD:

(Inches/

Gauge)

GAS FLOW

POLARITY

WELDING

VOLTAGE

WIRE

SPEED

WIRE

STICKOUT

(Inches)

(Cubic Ft/Hr)

THICKNESS

Auto Body

Lawnmower Handles,

Wagons, Tricycles, Duct

Tailpipes, Bicycles

Wheelbarrows, Lawnmower

Decks, Basketball Posts,

Tailpipes, Motorcycles

Sides, Garage Door Tracks,

Galvanized Roofing, Trailer

Work, Auto Door Brackets,

Fencing, Lawnmower Decks,

Trailers, Trailer Frames,

Wheelbarrows, Garage Door

Brackets, Grain Wagons,

Bailers, Combines, Bumpers

Trailer Hitches, Door Hinge

Stainless Steel Fryers,

Counter Tops, Kitchen

Equipment

Aluminum

.022”

24 GA.

3/64”

1/16”

1/8”

.187”

1/16”

1/8”

1/16”

16 GA.

11 GA.

16 GA.

.250”

11 GA.

16 GA.

18 GA.

TRI–MIX

ARGON

20

DCEP

DCEN

DCEP

1

2

1

2

1

3

2

4

3or4

3

2

19

6–7

4.5–5.5

4–5

5

4–5

6–7

7–8

4–5

5–6

4–5

4.5–5.5

6–7

5–5.5

4–5

3–4

4.5–5.5

4–5.5

4–5

4.5–5.5

4–5.5

4.5–5.5

1/4

5/16

1/2

5/16

3/8

1/2

3/4

3/8

1/2

Brackets, Axles,

”A”

Frames,

Farm Equipment Frames,

Basketball Rimsand Brackets

3/16”to1/4”

4TRI–MIX 20

DCEP

6–7

3/8

14 GA.

1/4”

3/32”

4

3

2

5356 (.035)

ARGON

20

DCEP

10

9–10

9

1/2

11 GA.

1/8”

TO

3/16

1/4

.187to.250

TRI–MIX= 90% HELIUM + 7–1/2% ARGON + 2–1/2% CARBON DIOXIDE

HB–28 (.024)

5356 (.035)

Solid

Stainless

(.030)

HB–28 (.024)

HB–28 (.030)

HB–28 (.035)

HB–28 (.030)

HB–28 (.035)

Fabshield 21B (.035)

205424A

Fabshield 21B (.045)

Fabshield 21B (.035)

Fabshield 21B (.045)

Fabshield 21B (.035)

CO

2

or C

25

CO

2

= Carbon Dioxide

C

25

= Argon + 25% Carbon Dioxide

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

CO

2

or C

25

GAS

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