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Hobart Welding Products Handler 120 Owner's Manual

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Handler 120 / 150 And
Piecemaker 14A Gun
OM-210 088D
November 1999
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Arc Welding Power Source And Wire


Table of Contents

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   Summary of Contents for Hobart Welding Products Handler 120

  • Page 1 OM-210 088D November 1999 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 120 / 150 And Piecemaker 14A Gun...
  • Page 2 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.
  • Page 3: Table Of Contents

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.
  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.
  • Page 9: Section 1. Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...
  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
  • Page 13: Section 2 - Specifications

    SECTION 2 – SPECIFICATIONS 2-1. Specifications A. 120 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage Output Range W/ Gun Dimensions 120 V, 60 Hz, Single-Phase Length: 19-1/8 in (489 mm) 90 A @ 19 Volts DC, 2.88 2.45...
  • Page 14: Duty Cycle And Overheating

    2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 120 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.
  • Page 15: Volt-ampere Curves

    2-3. Volt-Ampere Curves The volt-ampere curves show the A. 120 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. B. 230 VAC Model ssb1.1 10/91 – ST-802 082 / ST-802 089 OM-210 088 Page 11...
  • Page 16: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Installing Welding Gun Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. Gun Trigger Leads Insert leads, one at a time, through small grommet on front panel.
  • Page 17: Installing Gas Supply

    3-4. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.
  • Page 18: Selecting A Location And Connecting Input Power For 120 Vac Model

    3-5. Selecting A Location And Connecting Input Power For 120 VAC Model Rating Label Grounded Receptacle A 120 volt, 20 ampere individual 18 in branch circuit protected by time-de- (460 mm) lay fuses or circuit breaker is re- quired. 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).
  • Page 19: Selecting A Location And Connecting Input Power For 230 Vac Model

    3-6. Selecting A Location And Connecting Input Power For 230 VAC Model Rating Label Supply correct input power. Plug Receptacle Connect plug to receptacle. Line Disconnect Device 18 in (457 mm) of space for airflow See Section 3-7. Y Special installation may be required where gasoline or volatile liquids are present –...
  • Page 20: Electrical Service Guide For 230 Vac Model

    3-7. Electrical Service Guide For 230 VAC Model Input Voltage Input Amperes At Rated Output 19.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC)
  • Page 21: Threading Welding Wire

    3-9. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly.
  • Page 22: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Controls Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. Voltage Switch - Purge “0”...
  • Page 23: Weld Parameters For 120 Vac Model

    4-2. Weld Parameters For 120 VAC Model 205406A Welding Guide Settings are approximate. Adjust as required. WIRE THICKNESS WIRE GAS FLOW WELDING WIRE STICKOUT (Inches/ POLARITY VOLTAGE SPEED TO WELD: (Cubic Ft/Hr) TYPE\SIZE (Inches) Gauge) HB–28 .022” or C DCEP 3–4 Auto Body 24 GA.
  • Page 24: Weld Parameters For 230 Vac Model

    4-3. Weld Parameters For 230 VAC Model 205424A Welding Guide Settings are approximate. Adjust as required. WIRE THICKNESS WIRE GAS FLOW WELDING WIRE STICKOUT (Inches/ POLARITY VOLTAGE SPEED TO WELD: (Cubic Ft/Hr) TYPE\SIZE (Inches) Gauge) .022” HB–28 (.024) or C Auto Body DCEP 4.5–5.5...
  • Page 25: Section 5 - Maintenance &troubleshooting

    SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 5-2.
  • Page 26: Changing Drive Roll Or Wire Inlet Guide

    5-3. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves.
  • Page 27: Cleaning Or Replacing Piecemaker 14-a Gun Liner

    5-5. Cleaning Or Replacing Piecemaker 14-A Gun Liner Tools Needed: Y Disconnect gun from unit. 1/16 in Head Tube Remove nozzle, contact tip, adapter, and wire outlet guide. 1/2 in 1/16 in Loosen liner set screw. Quick-Connect Plug Remove liner. Lay gun cable out straight before installing new liner.
  • Page 28: Troubleshooting Table

    5-6. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not 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 (see Section 5-2).
  • Page 29 Notes OM-210 088 Page 25...
  • Page 30: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM ST-205 400 Figure 6-1. Circuit Diagram For 120 VAC Model OM-187 926 Page 26...
  • Page 31 Overload Feed Motor ST-210 011-C Figure 6-2. Circuit Diagram For 120 VAC CSA Model OM-210 088 Page 27...
  • Page 32 ST-205 423-B Figure 6-3. Circuit Diagram For 230 VAC Model OM-187 926 Page 28...
  • Page 33: Section 7 - Mig Welding (gmaw) Guidelines

    SECTION 7 – MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y 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/...
  • Page 34: Typical Mig Process Control Settings

    7-2. Typical MIG Process Control Settings NOTE 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 Convert Material .125 in Thickness to...
  • Page 35: Holding And Positioning Welding Gun

    7-3. Holding And Positioning Welding Gun NOTE 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. Hold Gun and Control Gun Trigger Workpiece...
  • Page 36: Conditions That Affect Weld Bead Shape

    7-4. Conditions That Affect Weld Bead Shape NOTE 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. Push Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...
  • Page 37: Gun Movement During Welding

    7-5. Gun Movement During Welding NOTE 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. Stringer Bead – Steady Movement Along Seam Weave Bead –...
  • Page 38: Troubleshooting - Excessive Spatter

    7-8. Troubleshooting – Excessive Spatter Excessive Spatter – 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.
  • Page 39: Troubleshooting - Excessive Penetration

    7-11. Troubleshooting – Lack Of Penetration Lack Of Penetration – 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.
  • Page 40: Troubleshooting - Waviness Of Bead

    7-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – 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.
  • Page 41: Common Mig Shielding Gases

    7-16. 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.
  • Page 42: Section 8 - Parts List

    SECTION 8 – PARTS LIST Hardware is common and not available unless listed. ST-802 066 Figure 8-1. Main Assembly OM-210 088 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....+203 563-1 . . . PANEL, top (gray) ..........
  • Page 44 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ..... 129 696 . . . CONTACTOR, input (120 VAC model) .
  • Page 45 Item Part Description Quantity Figure 8-2. Gun And Cable Assembly, Piecemaker 14-A ....379 718 NOZZLE, slip on assembly ......... .
  • Page 46 Table 8-2. Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PART NO. INCHES (mm) 407 230-1 .024 (.6) and .030/.035 (.8 and .9) 203 568 .035, 5356 Aluminum 407 230-4 .024 (.6) and .045 (1.2) Table 8-3. Kits To Convert Piecemaker 14-A Gun And Machine To Optional Wire Sizes WIRE SIZE PART NO.
  • Page 47 LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting Warranty Questions? below, Hobart Welding Products., Troy, Ohio, warrants to its Torches original retail purchaser that new Hobart equipment sold after Call...
  • Page 48 Welding Process Handbooks Call 1-877-Hobart1 Contact the Delivering Carrier for: 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. PRINTED IN USA 2000 Hobart Welding Products. 1/00...

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