Hobart Welding Products Handler 190, Owner'S Manual

Page 1: ...Description OM 260273F 2020 03 Processes File MIG GMAW Handler 190 R Arc Welding Power Source And Wire Feeder MIG GMAW Welding Flux Cored FCAW Welding www HobartWelders com ...

Page 2: ...ld Parameters And Settings 10 4 4 Unit Specifications 10 4 5 Welding Power Source Duty Cycle And Overheating 10 4 6 Volt Ampere Curves 11 SECTION 5 INSTALLATION 11 5 1 Selecting A Location 11 5 2 Installing Nozzle Contact Tip And Adapter 11 5 3 Installing Work Clamp 12 5 4 Installing Welding Gun 12 5 5 Process Polarity Table 12 5 6 Changing Polarity 13 5 7 Installing Gas Supply 13 5 8 Installing W...

Page 3: ...llow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomati...

Page 4: ...not possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling fl...

Page 5: ...to move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING D Allow cooling period follow r...

Page 6: ...cuments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Website www csagrou...

Page 7: ... de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliques telles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitab...

Page 8: ...udure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflamma...

Page 9: ...vant de mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire D Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil D En utilisant des fourches de levage pour déplacer l u...

Page 10: ...ards Institute Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents Website www global ...

Page 11: ... are found only on CE products A Amperage V Voltage Hz Hertz Negative Positive Direct Current DC Single Phase Input Output Voltage Input Off On Do Not Switch While Welding Gas Metal Arc Welding GMAW Wire Feed Flux Cored Arc Welding FCAW Line Connection U1 Primary Voltage U2 Conventional Load Voltage Percent Single Phase Transformer Rectifier U0 Rated No Load Voltage OCV I1 Rated Supply Current I2 ...

Page 12: ... adjustment of default weld parameters and settings and ultimate quality and durability of all resultant welds Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose 4 4 Unit Specifications Do not use information in unit specifications table to determine electrical service requirements See Sections 5 9 and 5 10 for info...

Page 13: ...cial installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Lifting Handle Use handle to lift unit 2 Line Disconnect Device Locate unit near correct input power supply 5 1 Selecting A Location 2 18 in 460 mm 18 in 460 mm Location And Airflow Loc_handler 2015 11 Do not move or operate unit where it could tip 1 5 2 Installing Nozzle Contac...

Page 14: ...opening until it bottoms against drive assembly Tighten thumbscrew Welding gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in MIG Gun position Close door Be sure that gun end is tight against drive assembly 4 Correct Gun Fully Seated 4 Incorrect Gun Not Seated Expo...

Page 15: ...w blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and ...

Page 16: ...ool And Adjusting Hub Tension When a slight force is needed to turn spool tension is set 1 2 in Tools Needed 803 012 803 013 B Ref 802 971 C Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool Retaining ring used with 8 in 203 mm spool only Adapter used with 8 in 203 mm spool only Notes ...

Page 17: ...mmended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 25 Normal Operating Fuses 3 30 Min Input Conductor Size In AWG 4 14 Max Recommended Input Conductor Length In Feet Meters 67 20 Min Grounding Conductor Size In AWG 4 14 Reference 2014 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comp...

Page 18: ... terminal See rating label on unit and check input volt age available at site 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal 4 Disconnect Device Line Terminals 5 Black And White Input Conductor L1 And L2 6 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to disconnect device grounding termina...

Page 19: ...k To make proper polarity connection see welding power source Owner s Manual Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriate setting 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual or door cha...

Page 20: ...it from unraveling 260 587 A 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 Be sure that Voltage range switch is set to range 1 2 3 4 5 6 or 7 to feed wire Rotate knob until it clicks into detent Wire will not feed if range switch is set between ranges 6 in 150 mm Tighten Use pr...

Page 21: ...setting label in welding power source or Section 6 2 as applicable 2 Power Switch 3 Voltage Switch The higher the selected number the thicker the material that can be welded see weld setting label in welding power source or Section 6 2 as applicable Do not switch under load Switch must click into detent position 4 Gun Trigger Receptacle 5 Trigger Switch When pressed energized wire feeds and shield...

Page 22: ... A complete Parts List is available at www HobartWelders com OM 260273 Page 20 6 2 Weld Parameter Chart For 230 VAC Model 248 827 B ...

Page 23: ... l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels Weld Terminals l Damaged Gas Hose nl Weld Cables nl Cords nl Gun Cables Every 6 Months OR Drive Rolls Inside Unit 7 2 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trigger and wait until protection circuit r...

Page 24: ...e VK Knurled groove is used for flux cored wire and V groove is used for solid wire 4 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot 5 Drive Roll Tension Knob Using flux core wire with VK groove tension should be set between 1 1 2 to 2 Higher setting may cause welding wire to deform and not allow ...

Page 25: ...r plug connection at welding power source wire feeder Check and if necessary replace gun trigger switch see MIG gun owner s manual Check contact tip Check for kinks in gun cable Blow out liner and gun casing see Section 5 2 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during ...

Page 26: ...OM 260273 Page 24 SECTION 8 ELECTRICAL DIAGRAMS 248830 B Figure 8 1 Circuit Diagram ...

Page 27: ...ess to amperage A 0 001 in 0 025 mm 1 ampere 0 0625 in 1 59 mm 0 001 62 5 A 2 Select Wire Size See table below 3 Select Wire Feed Speed Amperage Wire feed speed amperage controls weld pene tration See table below 4 Select Voltage Voltage controls height and width of weld bead Low Voltage wire stubs into work High Voltage arc is unstable spatter Set voltage midway between high and low voltage 1 16 ...

Page 28: ...90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle Groove Welds End View of Work Angle Side View of Gun Angle Fillet Welds 9 3 Holding And Positioning Welding Gun Slow Fillet Weld Electode Extensions Stickout Electrode Extensions Stickout Gun Angles And Weld Bead Profiles 10 10 S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Weld bead shape d...

Page 29: ...se weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 5 Gun Movement During Welding 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer...

Page 30: ... in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding...

Page 31: ...welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions 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 Im...

Page 32: ...port hand on solid surface or use two hands 9 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower v...

Page 33: ...GMAW P Stainless Steel Spray Arc Aluminum Short Circuiting Aluminum GMAW P Aluminum Argon All Positions All Positions All Positions All Positions Argon 1 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 2 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 5 CO2 Flat Horizontal Fillet All Positions Argon 10 CO2 Flat Horizontal Fillet All Positions All Positions...

Page 34: ...ch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle 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 Lo...

Page 35: ...9 10 per package 030 in 0 8 mm 770177 5 per package 000067 10 per package 035 in 0 9 mm 770180 5 per package 000068 10 per package 045 in 1 2 mm 770183 5 per package 000069 10 per package MIG Nozzle Standard 770 404 169715 Gasless Flux Cored Nozzle 770 487 226190 Tip Adapter 770 402 169716 Replacement Liners 023 025 in 0 6 mm 196139 194010 030 035 in 0 8 0 9 mm 196139 194011 035 045 in 0 9 1 2 mm ...

Page 36: ...OM 260273 Page 34 Notes ...

Page 37: ...OM 260273 Page 35 Notes ...

Page 38: ...Notes ...

Page 39: ...mum of one year whichever is greater HF Units MIG Flowgauge Regulators No Labor MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Spoolguns 4 6 Months Parts Batteries 5 Engines and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components s...

Page 40: ...LC 2020 01 Miller Electric Mfg LLC An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA For Assistance Call 1 800 332 3281 Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Please complete and retain with your personal records Owner s Record Thank you for purchasing Hobart Our trained tec...