Professional Documents
Culture Documents
Handler 187 and H100S2-10 Gun Owner's Manual
Handler 187 and H100S2-10 Gun Owner's Manual
Handler 187 and H100S2-10 Gun Owner's Manual
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Handler 187
And H100S2−10 Gun
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 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 Working as hard as you
do − every power source
Hobart is registered to the you may need to fix the problem. Warranty and from Hobart is backed by
ISO 9001 Quality System the best warranty in the
Standard.
service information for your particular model
business.
are also provided.
Hob_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read and follow these precautions.
WELDING can cause fire or explosion. D Wear approved ear protection if noise level is
high.
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 CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause Shielding gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is pressure. If damaged, a cylinder can explode. Since
safe before doing any welding. gas cylinders are normally part of the welding
process, be sure to treat them carefully.
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 Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Never weld on a pressurized cylinder − explosion will result.
cause fire on the hidden side. D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Do not weld on closed containers such as tanks, drums, or pipes, tings designed for the specific application; maintain them and
unless they are properly prepared according to AWS F4.1 (see associated parts in good condition.
Safety Standards). D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-228 187 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
LES RAYONS DE L’ARC peuvent D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des brûlures dans les
yeux et sur la peau. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
génère des rayons visibles et invisibles intense
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité). DES PIECES DE METAL ou DES
D Porter des lunettes de sécurité avec écrans latéraux même sous
SALETES peuvent provoquer des
votre casque. blessures dans les yeux.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
protéger les autres contre les rayonnements les éblouissements
fil de fer, et le meulage génèrent des étincelles et des particules
et les étincelles ; prévenir toute personne sur les lieux de ne pas métalliques volantes. Pendant la période de refroidissement des
regarder l’arc.
soudures, elles risquent de projeter du laitier.
D Porter des vêtements confectionnés avec des matières résistan- D Porter des lunettes de sécurité avec écrans latéraux ou un écran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
OM-228 187 Page 6
LES ACCUMULATIONS DE GAZ LES BOUTEILLES peuvent exploser
risquent de provoquer des blessures si elles sont endommagées.
ou même la mort.
Des bouteilles de gaz protecteur contiennent du gaz
D Fermer l’alimentation du gaz protecteur en cas sous haute pression. Si une bouteille est endom-
de non-utilisation. magée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
D Veiller toujours à bien aérer les espaces confi- soudage, les manipuler avec précaution.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) de se renverser.
peuvent affecter les implants médicaux.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester D Ne jamais placer une torche de soudage sur une bouteille à gaz.
à distance. D Une électrode de soudage ne doit jamais entrer en contact avec
D Les porteurs d’implants médicaux doivent consulter une bouteille.
leur médecin et le fabricant du dispositif avant de s’approcher D Ne jamais souder une bouteille pressurisée − risque d’explosion.
de la zone où se déroule du soudage à l’arc, du soudage
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
par points, du gougeage, de la découpe plasma
tuyaux et raccords convenables pour cette application spécifique ;
ou une opération de chauffage par induction.
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
LE BRUIT peut endommager l’ouïe. la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffi-
Le bruit des processus et des équipements peut samment de personnes pour soulever et déplacer les bouteilles.
affecter l’ouïe.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
D Porter des protections approuvées pour les l’équipement connexe et le dépliant P-1 de la CGA (Compressed
oreilles si le niveau sonore est trop élevé. Gas Association) mentionné dans les principales normes de sécu-
rité.
A Amperage V Voltage
Hz Hertz Negative
Direct Current
Positive Single Phase Input
(DC)
SECTION 4 − SPECIFICATIONS
4-1. Specifications
Amperes Input at
Maximum Open-
Rated Welding Amperage Rated Load Output Weight Overall
Circuit Voltage KVA KW
Output Range 230 V, 50/60 Hz, W/ Gun Dimensions
DC
Single-Phase
Length: 19-1/2 in.
130 A @ 21.5 Volts (495 mm)
DC, 30% Duty Cycle
68 lb Width: 10-5/8 in.
At 60 Hz Input − 20% 25 − 185 31 20.5 4.7 3.88 (31 kg) (270 mm)
Duty Cycle At 50 Hz
Input Height: 12-3/8 in.
(314 mm)
Solid/ Flux Cored Aluminum
Wire Feed Speed Range
Wire Type Stainless
And Diameter .023 − .035 in. .030 − .045 in. .030 − .035 in. 50 − 740 IPM (1.3 − 18.8 m/min) At No Load
(0.6 − 0.9 mm) (0.8 − 1.2 mm) (0.8 − 0.9 mm) 40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire
20
10
10 20 30 40 50 60 70 80 100
Duty Cycle %
30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 217 757-A
15 2
1
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Amperage
8 mm
Tools Needed:
8 mm
246 669-A
3 3
Exposed O-rings
will cause shielding
Incorrect gas leakage. Correct
Gun Not Seated Gun Fully Seated
804 621-A
3
1
6
2
5 4
Tools Needed:
7/16 in.
7/16 in.
802 456-A
DCEP
Electrode positive for
solid wire
Tools Needed:
5/8, 1-1/8 in.
230 VAC, 1
Tools Needed:
1 2 3 5
4 in.
(120 mm)
6 in.
(150 mm)
Open pressure assembly. Make sure Pull and hold wire; cut off end. Push wire thru guides into gun;
feed roll is set to correct groove to continue to hold wire.
match wire size (see Section 7-4).
1 Pressure
2 Indicator
3 Scale
4
Be sure that wire is positioned in proper drive Remove gun nozzle Turn power on. Be sure that Voltage range
roll groove and wire is laying in the groove. and contact tip. switch is set to range 1, 2, 3, 4, 5, 6, or 7 to
Close and tighten pressure assembly, feed wire. Rotate knob until it “clicks” into det-
and let go of wire. ent. Wire will not feed if range switch is set
between ranges.
Tighten
1
2
3
4
Press gun trigger until wire comes Be sure that tip matches wire diameter. Feed wire to check drive roll pressure.
out of gun. Reinstall contact tip and nozzle. Tighten knob enough to prevent slipping.
Cut off wire. Close door.
1 2
1 Wire Speed Control 3 Voltage Switch . Switch must “click” into detent
Use control to select a wire feed speed. As position.
Voltage switch setting increases, wire The higher the selected number, the
speed range also increases (see weld thicker the material that can be welded 4 Trigger Switch
setting label in welding power source or (see weld setting label in welding power
Section 6-2, as applicable). source or Section 6-2, as applicable). Do When pressed, energized wire feeds and
2 Power Switch not switch under load. shielding gas flows.
CFH
~ 1/35
Flux Cored
E71T−11
Good for windy or ~ 1/30
“Set Polarity
outdoor applications
for (DCEN)”
~ ~
Solid Wire ~ ~
ER70S−6
“Set Polarity ~ ~
for (DCEP)”
~ ~
~ 3/40
Stainless
Steel
“Set Polarity ~ 3/30
for (DCEP)”
~ 3/15
Aluminum** ~ ~
“Set Polarity
for (DCEP)”
~ ~
227010
227 010-A
3 Months
6 Months
Blow out or
vacuum inside.
During heavy Or
service, clean
monthly.
802 441
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun
trigger and wait until protection circuit resets allowing drive motor to feed wire again.
OM-228 187 Page 24
7-4. Changing Drive Roll Or Wire Inlet Guide
Unscrew and
remove liner.
10 mm
Reassemble gun in
reverse order from
taking it apart.
Install
5/8 in. Liner
(16 mm)
Liner
Stickout
Tools Needed:
4 Secure head
tube in vice.
9 Reinstall screws
8 Remove from vice. Reposition handle halves, and and nuts.
install switch housing.
Reinstall screw on
opposite side.
Tools Needed:
15 mm
phillips 243 840-A
Trouble Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-7).
does not run.
Replace building line fuse or reset circuit breaker if open.
No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
motor continues to run. unit has cooled (see Section 4-2).
Check Voltage range switch position. Rotate knob until it “clicks” into detent at desired range setting.
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.
Wire does not feed; wire is not ener- Check contact tip. Check for kinks in gun cable and liner.
gized; wire feeds unevenly.
Check gun trigger plug connection at welding power source/wire feeder.
Check, and if necessary, replace gun trigger switch (see Section 7-6).
Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 7-5).
Low weld output. Connect unit to proper input voltage or check for low line voltage.
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding.
Adjust drive roll pressure (see Section 5-10).
Change to proper drive roll groove (see Section 7-4).
Readjust hub tension (see Section 5-9).
Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.
Replace contact tip if blocked (see Section 7-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 or Section 7-5).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).
Secure gun trigger leads or repair leads (see Section 5-2).
Check and clear any restrictions at drive assembly and liner (see Section 5-10 or Section 7-5).
Release gun trigger and allow gun and motor protection circuitry to reset (see Section 7-3).
Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tighten
if necessary.
mig1 2009−12
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gun
Shielding Gas
Gas
Workpiece
Work Clamp
0°-15°
90° 90°
GROOVE WELDS
45° 0°-15°
45°
10°
Push
10°
Perpendicular Drag
S-0054-A
2 3 4
5
S-0053-A
5
S-0052-B
S-0636
Wire feed speed too high. Select lower wire feed speed.
Electrode extension (stickout) too long. Use shorter electrode extension (stickout).
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0635
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0637
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
S-0640
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Argon X
Argon + 25% CO2 X
80% or greater Argon +
X X1
balance CO2 or Oxygen
100% CO2 X
Tri-Mix2 X
1 Limited short circuiting use
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.
22
not available unless listed.
53
21
15
20
14
18
16
19
23
17
24
25
26
13
12
27
11
10
52
28
8
7
6
5
29
4
3
35
34
37
36
31
30
32
49
2
39
33
38
48
43
1
47
44
40
50
46
45
54
51
42
41
804 624-A
7 7
11
10
246 670-A
+OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model is required when ordering parts from your local distributor.
10-4. Options
PART NO. DESCRIPTION REMARKS
770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max.
194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max.
246 800 H100S2-10 Replacement Gun 10 ft length/.030-.035 wire size
195 186 Protective Cover Weatherproof nylon
212 492 Regulator/Flowmeter For use with CO2 shielding gas, 10−50 CFH
144 108 Gas Hose 5 ft For use with regulator/flowmeter 212 492
NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.
Distributor
Address
Resources Available
Always provide Model Name and Serial/Style Number.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.