Hobart Welding Products 1800 User manual

Brand: Hobart Welding Products

Model: 1800

Category: Welding System

Type: User manual

This manual is also suitable for

BETA-MIG 1800

BETA-MIG 1800

And M-15 Gun

Processes

OM-929 196 903B

February 2000

Specifications Covered by this Manual:

500 438

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)

Welding

Description

Arc Welding Power Source and Wire

Feeder

Visit our website at

www.HobartWelders.com

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.

Working as hard as you

do – every power source

from Hobart is backed by

the best warranty in the

business.

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.

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 – INTRODUCTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-2. Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Installing Welding Gun 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Setting Gun Polarity For Wire Type 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Installing Gas Supply 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Installing Wire Spool And Adjusting Hub Tension 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Changing Input Voltage From 230 Volts To 200 Volts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Electrical Service Guide 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Selecting A Location And Connecting Input Power 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11. Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Weld Parameters 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Circuit Breakers 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Cleaning Or Replacing Gun Liner 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Replacing Switch And/Or Head Tube 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Replacing Gun Contact Tip 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Changing Drive Roll And Wire Inlet Guide 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Welding Troubleshooting Table 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Wire Drive/Gun Troubleshooting Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAM 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-929B

The following terms are

used interchangeably

throughout this manual:

Stick = SMAW

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

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OM-929 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_4/98

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.

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-929 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-929 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-929 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-929 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

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

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

votre corps.

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 personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci–dessus.

OM-929 Page 9

SECTION 2 – INTRODUCTION

2-1. Specifications

Max. Open

Amps Input at Rated Output, 60 Hz, Single-Phase

Rated Output

Circuit

Voltage

200 V 230 V KVA KW

150 A at 23 VDC,

60% Duty Cycle

1.6*

1.4*

0.27*

0.13*

Wire Type and Diameter Wire Feed Speed Dimensions Weight

Solid Steel/

Stainless Steel

Aluminum Flux Cored

90–650 IPM

(2.3–16.5 m/min)

H: 29-7/8 in (759 mm)

W: 15-1/8 in (384 mm)

195 lb

(88 kg)

.023 – .035 in

(0.6 – 0.9 mm)

.030 – .035 in

(0.8 – 0.9 mm)

.030 – .045 in

(0.8 – 1.2 mm)

D: 33-3/8 in (848 mm)

* While idling

6 Minutes Welding 4 Minutes Resting

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

voltage, or duty cycle before

welding.

Y Exceeding duty cycle can

damage unit and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 – 181 009

60% Duty Cycle At 150 Amperes

OM-929 Page 10

2-3. Volt-Ampere Curves

Volt-ampere curves show minimum

and maximum voltage and amper-

age output capabilities of unit.

Curves of other settings fall be-

tween curves shown.

va_curve1 4/95 – 180 824

2-4. Installing Welding Gun

Ref. 802 285-A

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen knob. Insert gun end

through opening until it bottoms

against drive assembly. Tighten

knob.

4 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

Close door.

OM-929 Page 11

2-5. Setting Gun Polarity For Wire Type

Tools Needed:

3/4 in

Shown As Shipped – Set For Electrode Positive

(DCEP) For Solid Steel Or Aluminum Wires

(GMAW Process).

Reverse Lead Connections – For Electrode Negative

(DCEN) For Flux Cored Wires (FCAW Process). Drive

Assembly Becomes Negative

S-185 249

Wire Drive Assembly

Lead To Positive (+)

Output Terminal

Work Clamp Lead To

Negative (–) Output

Terminal

GUN POLARITY

CHANGEOVER CONNECTIONS

1 Polarity Changeover Label

2 Wire Drive Assembly

3 Positive (+) Output Terminal

4 Negative (–) Output Terminal

Always read and follow wire

manufacturer’s recommended

polarity.

Close door.

Ref. 802 472

OM-929 Page 12

2-6. Installing Gas Supply

Ref. 801 789 / Ref. 149 827-B / Ref. 158 697-A

Tools Needed:

Gas

4 5

Argon Gas

Chain gas cylinder to running gear,

wall, or other stationary support so

cylinder cannot fall and break off

valve.

1 Regulator/Flow Gauge

Install so face is vertical.

2 Gas Hose Connection

Fitting has 5/8-18 right-hand

threads.

3 Flow Adjust

Typical flow rate is 20 cfh (cubic

feet per hour). Check wire man-

ufacturer’s recommended flow

rate (see Section 3-2). This flow

gauge can be adjusted between 5

and 25 cfh.

4CO

Adapter

Customer Supplied

5 O-Ring

Install adapter with O-ring between

regulator/flow gauge and CO

cylinder.

1-1/8, 5/8 in

2-7. Installing Wire Spool And Adjusting Hub Tension

801 790

When a slight force is needed

to turn spool, tension is set.

9/16 in

Tools Needed:

Small Spool Adapter

OM-929 Page 13

2-8. Changing Input Voltage From 230 Volts To 200 Volts

Ref. 801 878-B

Cut cable ties as necessary.

1 230 Volt Lead

2 Tubing

Locate lead marked 230 VAC.

Slide tubing down and disconnect

lead splice.

Fold tubing over 230 volt lead stub

and secure.

3 200 Volt Lead

Locate lead marked 200 VAC.

Slide tubing down, and connect 200

volt lead stub to top half of the for-

mer 230 volt lead, and secure with

existing hardware.

Slide tubing over connection and

secure.

Tools Needed:

5/16, 3/8 in

2-9. Electrical Service Guide

Input Voltage 200 230

Input Amperes At Rated Output 30 26

Max Recommended Standard Fuse Rating In Amperes

Time-Delay

35 30

Normal Operating 3 45 40

Min Input Conductor Size In AWG/Kcmil 10 10

Max Recommended Input Conductor Length In Feet (Meters)

(29)

128

(39)

Min Grounding Conductor Size In AWG/Kcmil 10 10

Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

OM-929 Page 14

2-10. Selecting A Location And Connecting Input Power

801 876-B

1 Rating Label

Supply correct input power.

2 Plug

3 Receptacle

Connect plug to receptacle.

4 Input And Grounding

Conductors

Connect directly to line disconnect

device if hard wiring is required.

5 Line Disconnect Device

See Section 2-9.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

230 VAC, 1

Y Always connect grounding

conductor first.

= GND/PE

Y Do not move

or operate unit

where it could tip.

18 in (457 mm) of

space for airflow

OM-929 Page 15

2-11. Threading Welding Wire

Ref. 802 472 / 802 480

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:

6 in

(150 mm)

Pull and hold wire; cut off end.

4 in

(102 mm)

Tighten

Remove gun nozzle and contact tip. Turn On.

WOOD

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire.

Close door.

Open pressure assembly.

Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

6123

. Hold wire tightly to keep it

from unraveling.

OM-929 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 be

welded (see welding guide and

Section 3-2).

3 Welding Guide

4 Power Switch

Ref. 196 876-A

OM-929 Page 17

3-2. Weld Parameters

Material Thickness

Wire Type,

Shielding Gas,

And Flow Rate

Wire

Diameter

(inch)

Operator

Controls

3/8 in

(9.5

mm)

1/4 in

(6.4

mm)

3/16 in

(4.8

mm)

1/8 in

(3.2

mm)

12 ga 14 ga 16 ga 18 ga 20 ga 22 ga

Voltage Tap – – 6 5 4 3 3 2 2 1 1

.023

Wire Speed – – 100 80 65 55 45 35 25 15 5

E70S-6

Voltage Tap 6 5 4 3 3 2 2 1 1 – –

20 cfh+

.030

Wire Speed 80 70 60 55 45 35 25 15 5 – –

Voltage Tap 6 5 4 3 3 2 2 2 – – – –

.035

Wire Speed 70 60 50 45 40 30 20 10 – – – –

Voltage Tap – – 5 4 3 3 2 2 1 1 1

.023

Wire Speed – – 90 80 70 60 50 40 35 25 12

E70S-6

75% Argon

Voltage Tap 6 5 4 3 3 2 2 1 1 1

75% Argon

25% CO

20 cfh+

.030

Wire Speed 85 75 65 55 50 45 35 20 5 0

20 cfh+

Voltage Tap 6 5 4 3 3 2 2 1 1 – –

.035

Wire Speed 80 70 60 45 40 30 20 10 0 – –

Voltage Tap 6 5 5 4 4 3 2 1 – – – –

E71T-GS

.030

Wire Speed 80 70 65 55 50 30 20 10 – – – –

E71T-GS

Flux Core

Voltage Tap 6 5 4 3 3 2 1 – – – – – –

.035

Wire Speed 60 50 40 30 25 20 10 – – – – – –

Voltage Tap 5 4 4 4 3 3 3 2 2 2

.023

Wire Speed 95 85 80 60 50 50 50 30 20 20

ER 308

Stainless Steel

90% HE /

Voltage Tap 5 5 4 3 3 2 2 2 1 – –

90% HE /

7.5% Argon /

2.5% CO

.030

Wire Speed 70 70 70 50 45 50 45 40 0 – –

20 cfh+

Voltage Tap 6 5 5 4 3 2 2 2 – – – –

.035

Wire Speed 65 40 40 30 30 25 20 10 – – – –

*Do not change Voltage switch position while welding. Wire Speed is a starting value only, and can be adjusted while welding. Weld conditions also

depend on other variables such as stickout, travel speed, weld angle, cleanliness of metal, etc.

OM-929 Page 18

SECTION 4 – MAINTENANCE AND TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace unreadable labels.

Repair or replace

cracked weld cable.

Clean and tighten weld terminals.

6 Months

Blow out or vacuum inside. During

heavy service, clean monthly.

Remove drive roll

and apply light coat

of oil or grease to

drive motor shaft.

4-2. Circuit Breakers

Ref. 802 472

Y Turn Off unit.

1 Circuit Breaker CB1

CB1 protects main circuit board PC1

if drive motor shorts or fails. If CB1

opens, wire feeding stops. Check for

gun liner blockage or kinks, and check

for jammed wire, or binding drive rolls.

2 Circuit Breaker CB2

CB2 protects the trigger circuit from

overload. If CB2 opens, weld output

stops. Check gun switch, and trigger

leads.

Correct problem. Press button to reset

circuit breaker. Close door.

OM-929 Page 19

4-3. Cleaning Or Replacing Gun Liner

Ref. ST-800 797-C

5/16 in, 10 mm

To Reassemble Gun:

Insert new liner.

Install and tighten wire outlet guide.

Cut liner off 3/4 in (20 mm) (3/8 in

[9.5 mm] for aluminum) from head

tube.

Install adapter, contact tip, and

nozzle.

Lay gun cable out straight

before installing new liner.

Head Tube

5/16 in

Remove liner.

Remove nozzle, contact tip, and

adapter.

Blow out gun casing.

Y Disconnect gun first.

Tools Needed:

10 mm

OM-929 Page 20

4-4. Replacing Switch And/Or Head Tube

Ref. ST-800 795-C

1 Remove handle

locking nut.

2 Remove switch housing. Note: If installing new

switch, push switch lead connectors onto terminal of

new switch (polarity is not important). Install switch

back into handle, and secure with handle locking nut.

If replacing head tube, continue to end of figure.

3 Slide handle.

4 Secure head

tube in vice.

5 Loosen jam nut. Remove

from vice and turn head

tube out by hand.

6 Install existing shock washer onto

new head tube. Hand-tighten head

tube into connector cable.

7 Place head tube in vice and tighten

until nuts are tight.

8 Remove from vice. Reposition

handle and install switch housing.

Secure with handle locking nut.

Y Disconnect gun first.

3/4 in

Tools Needed:

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Hobart Welding Products 1800 User manual

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Model: 1800

Category: Welding System

Type: User manual

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