OM-248 841A 2011ï06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder R Handler 190 And H100S4-10 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.
TABLE OF CONTENTS SECTION 1 ï SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 9 ï MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . .
SECTION 1 ï SAFETY PRECAUTIONS - READ BEFORE USING som 2011ï01 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! ï Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
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 ï be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 ï CONSIGNES DE SÉCURITÉ ï LIRE AVANT UTILISATION fre_som_2011ï01 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! ï Indique une situation dangereuse qui si on 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.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
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. A complete Parts List is available at www.HobartWelders.com SECTION 3 ï DEFINITIONS 3-1.
. A complete Parts List is available at www.HobartWelders.com 4-2. Duty Cycle And Overheating Output Amperes 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. 200 175 130 100 80 NOTICE ï Exceeding duty cycle can damage unit or gun and void warranty.
. A complete Parts List is available at www.HobartWelders.com SECTION 5 ï INSTALLATION 5-1. Installing Nozzle, Contact Tip, And Adapter 2 3 Head Tube ! Turn off source. welding 1 Nozzle 2 Contact Tip 3 Tip Adapter power . Wire size stamped on tip ï check and match wire size. 1 8 mm Tools Needed: 8 mm Ref. 243 839-A 5-2. Installing Welding Gun 1 2 3 4 Spool Gun 6 Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew.
. A complete Parts List is available at www.HobartWelders.com 5-3. Installing Work Clamp . Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. 1 2 3 4 5 Nut Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable. 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp. Slide insulating handles.
. A complete Parts List is available at www.HobartWelders.com 5-4. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW ï Solid wire with shielding gas DCEP ï Reverse polarity Connect to positive (+) output terminal Connect to negative (ï) output terminal FCAW ï Self-shielding wire ï no shielding gas DCEN ï Straight Polarity Connect to negative (ï) output terminal Connect to positive (+) output terminal 5-5.
. A complete Parts List is available at www.HobartWelders.com 5-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. . DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 1 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.
. A complete Parts List is available at www.HobartWelders.com 5-7. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-8.
. A complete Parts List is available at www.HobartWelders.com 5-9. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase Input Voltage (V) 230 Input Amperes (A) At Rated Output 20.
. A complete Parts List is available at www.HobartWelders.com 5-11. Connecting Optional Spool Gun 1 2 3 4 7 Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew. Spool Gun ÇÇ ÇÇ Spool gun must be inserted completely to prevent leakage of shielding gas. 5 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar.
. A complete Parts List is available at www.HobartWelders.com 5-12. Threading Welding Wire 1 2 3 4 5 6 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. 6 Tools Needed: 1 2 3 5 . Hold wire tightly to keep it from unraveling. 4 in (120 mm) 6 in (150 mm) Open pressure assembly. Make sure feed roll is set to correct groove to match wire size (see Section 7-4). Tighten Pull and hold wire; cut off end.
. A complete Parts List is available at www.HobartWelders.com SECTION 6 ï OPERATION 6-1. Controls 2 1 4 3 5 Ref. 248 840-A / Ref. 246 668-A 1 Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2, as applicable).
. A complete Parts List is available at www.HobartWelders.com 6-2.
. A complete Parts List is available at www.HobartWelders.com SECTION 7 ï MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months l Unreadable Labels ~ Weld Terminals nl Cords nl Gun Cables Every 6 Months l = Replace l Damaged Gas Hose Reference nl Weld Cables OR ~ Drive Rolls ~ Inside Unit 7-2.
. A complete Parts List is available at www.HobartWelders.com 7-4. Changing Drive Roll Or Wire Inlet Guide ! Turn off source. 1 Inlet Wire Guide Securing Screw Inlet Wire Guide 2 welding power Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 1 3 4 2 Retaining Pin To remove drive roll, push drive roll in and rotate it (1/4 turn) to the open slot and slide it out over the retaining pin.
. A complete Parts List is available at www.HobartWelders.com 7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing 2 3 Head Tube ! Turn off source. welding 1 Nozzle 2 Contact Tip 3 Tip Adapter power . Wire size stamped on tip ï check and match wire size. 1 Cut off wire and disconnect gun from feeder. 8 mm Remove nozzle, contact tip, and adapter. Unscrew and remove liner. Blow out gun casing. Lay gun cable out straight before installing new liner.
. A complete Parts List is available at www.HobartWelders.com 7-6. Replacing Switch And/Or Head Tube ! Turn Off welding power source /wire feeder and disconnect gun. 1 Remove screws (5) and nuts (4). 2 Remove handle halves. 3 Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. Remove screw on opposite side. 4 Secure head tube in vice. 5 6 8 Loosen jam nut.
. A complete Parts List is available at www.HobartWelders.com 7-7. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-8). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protector (see Section 7-2). No weld output; wire does not feed; fan Thermostat TP1 open (overheating).
SECTION 8 ï ELECTRICAL DIAGRAM Figure 8-1.
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SECTION 9 ï MIG WELDING (GMAW) GUIDELINES mig1 2009ï12 9-1. Typical MIG Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/ Power Source Gun Shielding Gas Gas Workpiece Work Clamp Ref.
9-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) (0.001 in. = 1 ampere) 0.125 in. = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in. 30 ï 90 A 0.030 in. 40 ï 145 A 0.035 in.
9-3. Holding And Positioning Welding Gun . Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. 1 1 3 2 2 3 4 5 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) 1/4 to 1/2 in.
9-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
9-5. Gun Movement During Welding . Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 1 2 2 3 Stringer Bead ï Steady Movement Along Seam Weave Bead ï Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 3 S-0054-A 9-6.
9-8. Troubleshooting ï Excessive Spatter Excessive Spatter ï scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. 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.
9-11. Troubleshooting ï Lack Of Penetration Lack Of Penetration ï shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions 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.
9-14. Troubleshooting ï Waviness Of Bead Waviness Of Bead ï weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. Support hand on solid surface or use two hands. 9-15. Troubleshooting ï Distortion Distortion ï contraction of weld metal during welding that forces base metal to move.
9-16. Common MIG Shielding Gases 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.
Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. 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.
SECTION 10 ï ACCESSORIES/CONSUMABLES 10-1. Accessories 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. 195 186 Protective Cover Weatherproof nylon 245 926 H100S4-10 Replacement Gun 10 ft length/.030-.035 wire size 300 796 SpoolRunner 100 Spool Gun For push/pull wire feeding HOBART PACKAGE NO.* MILLER PACKAGE NO.** .023/.025 in (0.
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Notes
Effective January 1, 2011 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MB or newer. Warranty Questions? Call 1-800-332-3281 7 AM ï 5 PM EST Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281.
Owner’s Record Please complete and retain with your personal records. Model Name Protect Your Investment! Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number.
