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OM-923 223 112C
2006 −08
Processes
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Handler 125 EZ
And H-9B Gun
File: Flux Cored (FCAW)
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From Hobart to You 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
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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,
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TABLE OF CONTENTS SECTION 8 − WIRE WELDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8-1. Typical FCAW Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8-2. Typical Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8-3. Holding And Positioning Weldi
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − SPECIFICATIONS 3-1. Specifications Amperes Input at Maximum Open- Rated Welding Maximum Rated Load Output Weight Overall Circuit Voltage KVA KW Output Amperage 115 V, 60 Hz, Single- W/ Gun Dimensions DC Phase Length: 16-7/8 in 90 A @ 19 Volts DC, (429 mm) 20 2.90 2.50 20% Duty Cycle 50 lb Width: 9-7/8 in 125 29 (22.7 kg) (251 mm) 63 A @ 21 Volts DC, 15* 2.20* 1.77* 20% Duty Cycle* Height: 12-1/8 in (308 mm) Flux Cored Wire Feed Speed Range Wire T Wire Type ype .030 − .035 in 183 − 2
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3-3. 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. 33.0 28.0 23.0 18.0 13.0 8.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 130.0 Amperage (18-16 ga) R ange 1 (16-12 ga) R ange 2 (12-10 ga) R ange 3 R ange 4 (10ga-3/16”) ssb1.1 10/91 − 210 519-A OM-923 Page 10 Voltage
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SECTION 4 − INSTALLATION 4-1. Installing Work Clamp Connection hardware must be tightened with proper tools. Do not just 1 Nut hand tighten hardware. A loose electrical connection will cause poor 2 Work Cable From Unit weld performance and excessive heating of the work clamp. 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable. 6 Insulator Grip 3 1 Slide one insulating grip over work cable before connecting to clamp. 6 Slide insulating grips over handles. 2 4 5 Tools Needed: 7/1
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4-4. Installing Wire Spool And Adjusting Hub Tension Installing 4 in (102 mm) Wire Spool Overtightening hub tension may cause wire feed problems. When a slight force is needed to turn spool, tension is set. Installing 8 in (203 mm) Wire Spool Adapter used with Only applies to units equipped with 8 in (203 mm) optional hub kit. spool only. When a slight force is needed to turn spool, tension is set. Retaining ring used with 8 in (203 mm) spool only. Tools Needed: 1/2 in Ref. 802 971-C / 803
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4-5. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 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). Special installation may be Do not move or operate unit required where gasoline or where it could tip. volatile liquids are present − see NEC Article 511 or CEC 18
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4-6. Installing Contact Tip And Nozzle Turn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 4-7). 3 Slide contact tip over wire and tighten 2 tip into tip adapter. Install nozzle. 1 Flux Nozzle MIG Nozzle Use with flux cored wire only. Use with solid or flux cored wire. Narrow design allows access in tight spaces and provides better visibility of puddle during welding. Push nozzle over contact tip and Push nozzle over c
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4-7. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Cable Lay gun cable out straight. 4 + − Tools Needed: 6 5 12 3 Hold wire tightly to keep it from unraveling. + − + − 6 in 4 in (150 mm) (102 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun liner; continue to hold wire. Loosen knob completely, then rotate Tighten pressure adjustment knob in a clockwise direction until drive roll i
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SECTION 5 − OPERATION 5-1. Controls 1 Material Thickness Selector Switch Use switch to select the material thickness range. Do not switch under load. Switch must “click” into detent position for weld output. 2 Power Switch 1 2 Ref. 230 001-A OM-923 Page 16
