Hobart Welding Products H-9A Gun Manual de usuario

Processes

OM-952 220 361A

June 2004

H-9A Gun

Description

MIG (GMAW) Welding (Optional)

Flux Cored (FCAW) Welding

Semi-Automatic, Air-Cooled

Flux Cored (FCAW) And MIG

(GMAW) Welding Gun

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 the 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 9001:2000 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

Hob_Thank 7/03

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR FCAW AND

GMAW WELDING GUNS −READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. FCAW And GMAW Gun Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 −SAFETY INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 −INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Gun Into Welding Power Source 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Threading Welding Wire 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 −OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Operating The Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 −MAINTENANCE & TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Replacing Gun Contact Tip 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Cleaning Gun Liner 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Replacing Gun Liner 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Replacing Liner O-Ring 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Replacing Switch And/Or Head Tube 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Removing Gun From Welding Power Source 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 −PARTS LIST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-952 Page 1

SECTION 1 −SAFETY PRECAUTIONS FOR FCAW AND

GMAW WELDING GUNS −READ BEFORE USING

SR7_8/03

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 ELECTRIC SHOCK and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

YMarks a special safety message.

.Means NOTE; not safety related.

1-2. FCAW And GMAW Gun Hazards

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The

safety information given below is only a summary of the more complete safety information found in the wire feeder

and welding power source Owner’s Manuals. Read and follow all safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY

QUALIFIED PEOPLE.

GMAW WELDING can be hazardous.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin with spatter-resistant

clothing.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked

gun or cable insulation.

5. Turn off welding power source before changing

contact tip or gun parts.

6. Keep all covers and handle securely in place.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

NOISE can damage hearing; SOME

APPLICATIONS, SUCH AS PULSING,

are noisy.

1. Check for noise level limits exceeding those

specified by OSHA.

2. Use approved ear plugs or ear muffs if noise level

is high.

3. Warn others nearby about noise hazard.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

FUMES AND GASES can be hazardous

to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING WIRE can cause puncture

wounds.

1. Keep hands and body away from gun tip when

trigger is pressed.

BUILD UP OF GAS can injure or

kill

1. Shut off shielding gas supply when not in

use.

2. Always ventilate confined spaces or use

approved air-supplied respirator.

OM-952 Page 2

EMF INFORMATION

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields −

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

Government Printing Office, May 1989): “. . . there is now a very large

volume of scientific findings based on experiments at the cellular

level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

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 the body.

4. Keep welding power source and cables as far away as practical.

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

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

OM-952 Page 3

SECTION 2 −SAFETY INFORMATION

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each

symbol shown.

7 NOTE

Special instructions for best

operation −not related to safety.

NOTE

ELECTRIC SHOCK can kill.

•Do not touch live electrical parts.

•Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

1 2

CAUTION

MOVING PARTS can injure.

•Keep away from moving parts.

•Keep all panels and covers closed

when operating.

Turn Off switch when using high frequency.

SECTION 3 −INSTALLATION

3-1. Specifications

Air-Cooled Welding Gun For FCAW And GMAW Welding

Note: Using gasless flux cored wire reduces gun duty cycle.

803 836-A

H-9 Feeds .030 −.035 in (0.8 −0.9 mm) Flux Cored Wire Or .023 −.030 in (0.6 −0.8 mm) Hard Wire

Duty Cycle Rating:

100%: 40 A With Flux Cored Wire

100%: 100 A With CO2Shielding Gas

60%: 100 A With Mixed Gases

Weight With 8 ft (2.4 m) Power Cable: 2.2 lb (1.0 kg)

Duty Cycle is percentage of 10

minutes that unit can weld at rated

load without overheating.

YExceeding duty cycle can

damage unit and void

warranty.

See Section 3-1. Specifications for amperage

rating and duty cycle.

Overheating

A or V

Reduce Duty Cycle

Minutes

sduty1 5/95

Continuous Welding

100%dutycycle

3-2. Duty Cycle And Overheating

6 Minutes Welding 4 Minutes Resting

60%dutycycle

OM-952 Page 4

3-3. Installing Gun Into Welding Power Source

803 497-A / Ref. 803 378-A

Open pressure assembly. Remove screws (3) from

cover, and remove cover

from wire drive assembly.

Insert gun cable through opening in front

panel. Route weld cable, trigger leads, and

gas hose through opening in drive housing.

Reinstall cover and

secure with screws (3).

Remove wrapper from

unit.

Connect gas hose to adapter

(if unit is not equipped with

gas solenoid valve, secure

hose to wiring harness).

Connect trigger leads to

RC3 and RC4 on PC1.

Route weld cable through

opening in baffle.

Connect weld cable

to weld terminal.

Reinstall wrapper onto unit.

Secure leads and hose

with cable tie(s). .Thread wire according to

Section 3-4.

YTurn off welding power source.

.If existing gun requires removal, see Section 5-6.

.Route wires, cable, and hose to avoid contact

with sharp edges, hot surfaces, or moving parts.

Reinstall cable end into drive

housing with retaining grooves

inserted into the two retaining ribs.

Be sure to position gas hose up.

Position liner in groove so that end is

flush with back of groove.

OM-952 Page 5

3-4. 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.

Tools Needed:

Pull and hold wire; cut off end.

4 in

(102 mm)

Remove gun nozzle and contact tip.

Open pressure assembly. Push wire thru guides into gun liner;

continue to hold wire.

.Hold wire tightly to keep it

from unraveling.

Ref. 803 444-A / Ref. 205 837

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Press gun trigger until wire comes

out of gun.

Turn power on.

INPUT

POWER

6 in

(150 mm)

Tighten

.Rotate pressure adjustment

knob in a clockwise direction

until drive roll is tight against

the welding wire. Adjust

drive roll pressure just tightly

enough to prevent wire from

slipping on or against drive

roll during operation.

Tighten

Be sure that wire is positioned

in proper feed roll groove.

Close and tighten pressure

assembly, and let go of wire.

Be sure that contact tip matches wire diameter.

Reinstall tip adapter, if applicable, contact tip

and nozzle.

.Tip adapter may also require removal

to allow wire to feed out end of gun.

OM-952 Page 6

SECTION 4 −OPERATION

4-1. Operating The Gun

Ref. 803 495-A

1 Trigger Switch

When pressed, energized wire

feeds and shielding gas flows.

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