Hobart Beta Mig 135 P User manual
MIG (GMAW) Welding
%HWD 0LJ 3
February 1999
Effective with serial number:
1 5P - 152 45
175P - 152 85
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OM-194 0 4 Page 1
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Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
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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.
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$ ', - .//!
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 thewelding wire areelectrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
-
Do not touch live electrical parts.
-
Wear dry, hole-free insulating gloves and body protection.
-
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
-
Do not use AC output in dampareas, if movement is confined, or if
there is a danger of falling.
-
Use AC output ONLY if required for the welding process.
-
If AC output is required, use remote output control if present on
unit.
-
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).
-
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
-
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.
-
When making input connections, attach proper grounding
conductor first -- double-check connections.
-
Frequently inspect input power cord for damage or bare wiring --
replace cord immediately if damaged -- bare wiring can kill.
-
Turn off all equipment when not in use.
-
Do not use worn, damaged, undersized, or poorly spliced cables.
-
Do not drape cables over your body.
-
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
-
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
-
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
-
Wear a safety harness if working above floor level.
-
Keep all panels and covers securely in place.
-
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
-
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
-
Do not connect more than one electrode or work cable to any
single weld output terminal.
0$ 1 -2 +*-/ 2
3 4 *!
-
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.
)80(6 $1' *$6(6 FDQ EH KD]DUGRXV
-
Keep your head out of the fumes. Do not breathe the fumes.
-
If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
-
If ventilation is poor, use an approved air-supplied respirator.
-
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
-
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
breathing air is safe.
-
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
-
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-194 0 4 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.
- 53 6 -7 .!
-
Wear a weldinghelmet fitted with a proper shade offilter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
-
Wear approved safety glasses with side shields under your
helmet.
-
Use protective screens or barriers toprotect others from flash and
glare; warn others not to watch the arc.
-
Wear protective clothing made from durable, flame-resistant
material (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.
)$ - -3 2 1/!
-
Protect yourself and others from flying sparks and hot metal.
-
Do not weld where flying sparks can strike flammable material.
-
Remove all flammables within 5 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
-
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
-
Watch for fire, and keep a fire extinguisher nearby.
-
Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
-
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).
-
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.
-
Do not use welder to thaw frozen pipes.
-
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
-
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
-
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
$ $ - 83 6!
-
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
-
Wear approved safety glasses with side
shields even under your welding helmet.
$ - 83 .//!
-
Shut off shielding gas supply when not in use.
-
Always ventilate confined spaces or use
approved air-supplied respirator.
' - -3 * 53!
-
Do not touch hot parts bare handed.
-
Allow cooling period before working on gun or
torch.
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-
Pacemaker wearers keep away.
-
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
- 7-+-9 :-9!
Noise from some processes or equipment can
damage hearing.
-
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.
$ - 1/7 2 7-+-97!
-
Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
-
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
-
Keep cylinders away from any welding or other electrical circuits.
-
Never drape a welding torch over a gas cylinder.
-
Never allow a welding electrode to touch any cylinder.
-
Never weld on a pressurized cylinder -- explosion will result.
-
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
-
Turn face away from valve outlet when opening cylinder valve.
-
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
-
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-194 0 4 Page
;$ :-<-7!
-
Do not install or place unit on, over, or near
combustible surfaces.
-
Do not install unit near flammables.
-
Do not overload building wiring -- be sure power supply system
is properly sized, rated, and protected to handle this unit.
$$ - -3 836!
-
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
-
Use equipment of adequate capacity to lift and
support unit.
-
If using lift forks to move unit,be sure forks are
longenough toextend beyondopposite sideof
unit.
0 - -3 0'
-
Allow cooling period; follow rated duty cycle.
-
Reduce current or reduce duty cycle before
starting to weld again.
-
Do not block or filter airflow to unit.
-
Put on grounded wrist strap BEFORE
handling boards or parts.
-
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
0 - -3 836!
-
Keep away from moving parts.
-
Keep away from pinch points such as drive
rolls.
)$ ) - -3 836!
-
Do not press gun trigger until instructed to do
so.
-
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
0 - -3 836!
-
Keep away from moving parts such as fans.
-
Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
-
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
-
Have only qualified persons familiar with
electronic equipment perform this installation.
-
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
-
If notified by the FCC about interference, stop using the
equipment at once.
-
Have the installation regularly checked and maintained.
-
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.
-
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
-
Be sure all equipment in the welding area is
electromagnetically compatible.
-
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
-
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
-
Be sure this welding machine is installed and grounded
according to this manual.
-
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.
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6DIHW\ LQ :HOGLQJ DQG &XWWLQJ
, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 126
6DIHW\ DQG +HDOWK 6WDQGDUGV
, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
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&XWWLQJ RI &RQWDLQHUV 7KDW +D H +HOG +D]DUGRXV 6XEVWDQFHV
,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 126
1DWLRQDO (OHFWULFDO &RGH
, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
6DIH +DQGOLQJ RI &RPSUHVVHG *DVHV LQ &\OLQGHUV
, CGA Pamphlet
P-1, from Compressed Gas Association, 12 5 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
&RGH IRU 6DIHW\ LQ :HOGLQJ DQG &XWWLQJ
, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R .
S
DIH 3UDFWLFHV )RU 2FFXSDWLRQ $QG (GXFDWLRQDO (\H $QG )DFH
3URWHFWLRQ
, ANSI Standard Z87.1, from American National Standards
Institute, 14 0 Broadway, New York, NY 10018.
&XWWLQJ $QG :HOGLQJ 3URFHVVHV
, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-194 0 4 Page 4
$ % #
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.
. 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
possible.
% &'
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-194 0 4 Page 5
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1
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1 5P
1 0 A @ 20.5 Volts DC,
20% Duty Cycle
75 A @17.5 Volts DC,
60% Duty Cycle
55A @ 18.5 Volts DC
100% Duty Cycle
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60% Duty Cycle
65A @ 17.5 Volts DC
100% Duty Cycle
50 -- 140 21 24.5 5.6
255x410x 15 15.8
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Duty Cycle is percentage of 10
minutes 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.
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20% duty cycle at 140 amps, 50 Hz
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2 Minutes Welding 8 Minutes Resting
OM-194 0 4 Page 6
+'
1 Drive Assembly
2 Gun Securing Thumbscrew
Gun End
Loosen thumbscrew. Insert gun
end through opening until it bot-
toms against drive assembly.
Tighten thumbscrew.
4 Gun Trigger Leads
Insert leads, one at a time, through
small grommet on front panel.
Connect female friction terminals
to matching male terminals in unit.
Polarity is not important.
Close door.
4
1
2
(* "
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 - .
Close door.
1
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OM-194 0 4 Page 7
! + '
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.
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 man-
ufacturer’s recommended flow
rate.
8CO
Adapter (Customer Sup-
plied)
9 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO
cylinder.
Tools Needed:
CO
Gas
8 9
1
2
4
57
1
2
Argon Gas
OR
5/8, 1-1/8 in
6
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OM-194 0 4 Page 8
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1 Rating Label
Supply correct input power.
2 Plug
Obtain and install correct plug ac-
cording to its instructions.
Receptacle
Connect plug to matching recep-
tacle.
4 Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5 Line Disconnect Device
See Section -6.
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L2
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space for airflow
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OM-194 0 4 Page 9
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Reference: 1996 National Electrical Code (NEC)
3 4' ' -
15/16 in
1; 2 , 1 2
Turn wingnut. When a slight force is
needed to turn spool, tension is set.
Tools Needed:
%< 0
Install spool so welding wire feeds from bottom.
OM-194 0 4 Page 10
5 -*
1 Wire Spool
2 Welding Wire
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
4
5
6in
(150 mm)
Pull and hold wire; cut off end.
4in
(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.
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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.
,1387
32:(5
OM-194 0 4 Page 11
! (
1 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded. Do not switch under load.
2 Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting
increases, wire speed range also
increases.
Voltage Range (Min/Max)
Switch
Place switch in desired position.
4 Power Switch
2
1
4
OM-194 0 4 Page 12
! " 1 2(
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.
/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
2
2
4
4
4
or4
or4
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
--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
/8
/8
1/2
1/2
1/2
1/2
1/2
1/2
/4
/8
/8
1/2
Brackets, Axles, ”A” Frames,
Farm Equipment Frames,
Basketball Rimsand Brackets
/16”to1/4” 4
TRI--MIX 20 DCEP 6--7 /8
14 GA.
1/4”
/ 2”
4
2
5 56 (.0 5) ARGON
ARGON
ARGON
20
20
20
DCEP
DCEP
DCEP
10
9--10
9
1/2
1/2
1/2
11 GA.
1/8”
TO
/16
1/4
.187to.250
TRI--MIX= 90% HELIUM + 7--1/2% ARGON + 2--1/2% CARBON DIOXIDE
HB--28 (.024)
5 56 (.0 5)
5 56 (.0 5)
5 56 (.0 5)
Solid
Stainless
(.0 0)
HB--28 (.024)
HB--28 (.024)
HB--28 (.024)
HB--28 (.024)
HB--28 (.0 0)
HB--28 (.0 0)
HB--28 (.0 5)
HB--28 (.0 5)
HB--28 (.0 0)
HB--28 (.0 0)
HB--28 (.0 5)
Fabshield 21B (.0 5)
205424A
Fabshield 21B (.045)
Fabshield 21B (.045)
Fabshield 21B (.0 5)
Fabshield 21B (.045)
Fabshield 21B (.0 5)
Fabshield 21B (.0 5)
CO
or C
CO
= Carbon Dioxide
C
= Argon + 25% Carbon Dioxide
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
CO
or C
GAS
OM-194 0 4 Page 1
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labels.
Repair or
replace
cracked
weld cable.
Clean and
tighten weld
terminals.
% :
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
Or
$ (* &) 6 +'
1 Bearing
2 Feed Roll Plate
Drive Roll
The drive roll consists of two differ-
ent sized grooves. The stamped
markings on the end surface of the
drive roll refers to the groove on the
opposite side of the drive roll. The
groove closest to the motor shaft is
the proper groove to thread (see
Section -8). NOTE: when chang-
ing drive rolls, make sure the
woodruff key is on the motor shaft,
and not in the old drive roll.
4 Pressure Arm
Tools Needed:
1
2
4
.0 0 Groove .024 Groove
Stamped .024 Stamped .0 0
OM-194 0 4 Page 14
$ 6 +' ( -
?
"
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
1
2
Tools Needed:
$! -'* -
!
No weld output; wire does not feed; fan
d
o
e
s
n
o
t
r
u
n
Secure power cord plug in receptacle.
d
oes no
t
run. Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 4-1).
Check circuit breaker CB (CSA model), and reset if necessary).
No weld output; wire does not feed; fan
motor continues to run. Thermostat S open (overheating). Allow fan to run; thermostat closes when unit has cooled (see
Section 2-2).
Secure gun trigger leads (see Section -1).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 5- ).
Check for proper polarity connections (see Section -2).
Low weld output. Connect unit to proper input voltage or check for low line voltage.
Place voltage switch in desired position (see Section 4-1).
Electrode wire feeding stops during
w
e
l
d
i
n
g
Straighten gun cable and/or replace damaged parts.
welding. Adjust drive roll pressure (see Section -8).
Change to proper drive roll groove (see Section 5-2).
Readjust hub tension (see Section -7).
Replace contact tip if blocked (see Section 5- ).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-2).
Replace drive roll or pressure bearing if worn or slipping (see Section 5-2).
Secure gun trigger leads or repair leads (see Section -1).
Check circuit breaker CB or CB2 (depending on Model), and reset if necessary.
Check and clear any restrictions at drive assembly and liner (see Section -8).
Have nearest Factory Authorized Service Agent check drive motor.
OM-194 0 4 Page 15
GND
34
50/60Hz S1
PL
GS
P.C.B.
--
+
Z
SWS4
TP1 TP2
VR
SR
S
S2 MAX
MIN
T1
93 %! 3 -9-+
OM-194 0 4 Page 16
+DUGZDUH LV FRPPRQ DQG
QRW D DLODEOH XQOHVV OLVWHG
1
2
4
7
6
5
8
10
9
11
14
12
15
2
18
19
24
25
26 27
28
4
1 2
16 17
21
20
0
29 5
6
9
41
8
19
40
44
4
7
45
1
22
42
93 (! +/ +5/6
This manual suits for next models
1
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