Processes
OM-210 088D
November 1999
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. Troubleshooting Table 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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-210088D
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OM-210 088 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-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
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-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
1/2
1/2
1/2
3/4
1/4
1/2
1/2
5/16
1/2
1/4
5/16
5/16
5/16
5/16
1/4
1/4
1/43–4
3–4
2–3
2–3
3–4
2–3
3–4
2–3
2
4–5
3–4
3–4
3–4
3
6–7
4–5
4–5
4–5
4
4–5
6
81
2
4
4
3
4
4
4
2
2
3
3
3
1
1
2
2
2
1
2
2
1
DCEP
DCEN
DCEN
DCEN
DCEN
DCEN
DCEN
DCEN
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
20
20
20
20
20
20
20
20
20
20
20
20
20
20
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 (.024)
HB–28 (.030)
HB–28 (.035)
HB–28 (.035)
HB–28 (.030)
HB–28 (.024)
205406A
Fabshield 21B (.045)
Fabshield 21B (.035)
Fabshield 21B (.035)
Fabshield 21B (.035)
Fabshield 21B (.045)
Fabshield 21B (.045)
25
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
TRI–MIX
ARGON
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEP
DCEN
DCEN
DCEN
DCEN
DCEN
DCEN
DCEN
DCEP
1
2
2
1
2
2
2
1
1
3
3
3
2
2
4
4
4
3or4
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
1/4
1/4
5/16
5/16
5/16
5/16
1/2
1/2
5/16
3/8
3/8
1/2
1/2
1/2
1/2
1/2
1/2
3/4
3/8
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
ARGON
ARGON
20
20
20
DCEP
DCEP
DCEP
10
9–10
9
1/2
1/2
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)
5356 (.035)
5356 (.035)
Solid
Stainless
(.030)
HB–28 (.024)
HB–28 (.024)
HB–28 (.024)
HB–28 (.024)
HB–28 (.030)
HB–28 (.030)
HB–28 (.035)
HB–28 (.035)
HB–28 (.030)
HB–28 (.030)
HB–28 (.035)
Fabshield 21B (.035)
205424A
Fabshield 21B (.045)
Fabshield 21B (.045)
Fabshield 21B (.035)
Fabshield 21B (.045)
Fabshield 21B (.035)
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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