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OM-944 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.

ARC RAYS can burn eyes and skin.

D

Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).

D

Wear approved safety glasses with side shields under your
helmet.

D

Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.

D

Wear protective clothing made from durable, flame-resistant mate-
rial (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.

WELDING can cause fire or explosion.

D

Protect yourself and others from flying sparks and hot metal.

D

Do not weld where flying sparks can strike flammable material.

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

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, floor, bulkhead, or partition can
cause fire on the hidden side.

D

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).

D

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.

D

Do not use welder to thaw frozen pipes.

D

Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.

D

Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

D

Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D

Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.

D

Wear approved safety glasses with side
shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D

Shut off shielding gas supply when not in use.

D

Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on gun or
torch.

MAGNETIC FIELDS can affect pacemakers.

D

Pacemaker wearers keep away.

D

Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D

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.

CYLINDERS can explode if damaged.

D

Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.

D

Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.

D

Keep cylinders away from any welding or other electrical circuits.

D

Never drape a welding torch over a gas cylinder.

D

Never allow a welding electrode to touch any cylinder.

D

Never weld on a pressurized cylinder – explosion will result.

D

Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve.

D

Keep protective cap in place over valve except when cylinder is in
use or connected for use.

D

Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

Summary of Contents for H-10

Page 1: ...Processes OM 944 196 639C October 2001 Handler 135 175 And H 10 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding ...

Page 2: ...e 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 which exact part you may need to fix the problem Warranty and service information for your particul...

Page 3: ...ATION 19 4 1 Controls 19 4 2 Weld Parameters For 115 VAC Model 20 4 3 Weld Parameters For 230 VAC Model 21 SECTION 5 MAINTENANCE TROUBLESHOOTING 22 5 1 Routine Maintenance 22 5 2 Overload Protection 22 5 3 Drive Motor Protection 22 5 4 Changing Drive Roll Or Wire Inlet Guide 23 5 5 Replacing Gun Contact Tip 23 5 6 Cleaning Or Replacing Gun Liner 24 5 7 Replacing Switch And Or Head Tube 25 5 8 Trou...

Page 4: ......

Page 5: ... that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not...

Page 6: ...elding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag ...

Page 7: ...aintained D 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 D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area is ...

Page 8: ...s 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 sid...

Page 9: ...on est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement s ...

Page 10: ... D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à l...

Page 11: ...ispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l installa ...

Page 12: ...tiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de pre...

Page 13: ...030 045 in 0 8 1 1 mm 030 035 in 0 8 0 9 mm 370 840 IPM 9 2 21 8 m min At No Load 50 800 IPM 1 3 20 3 m min Feeding Wire CSA Rating B 230 VAC Model Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 230 V 50 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 130 A 20 Volts DC 30 Duty Cycle At 60 Hz Input 20 Duty Cycle At 50 Hz Input 30 175...

Page 14: ...Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 196 617 196 618 A 115 VAC Model B 230 VAC Model 3 Minutes Welding 7 Minutes Resting Duty Cycle Output Amperes 10 20 40 60 80 100 200 10 20 30 40 50 60 70 80 100 130 20 duty cycle at 90 amps 30 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz 2 Minutes Welding 8 ...

Page 15: ...between the curves shown ssb1 1 10 91 196 608 196 609 A 115 VAC Model B 230 VAC Model 0 0 5 0 10 0 15 0 20 0 25 0 30 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 LOAD AMPS OUTPUT VOLTS Range 4 Range 3 Range 2 Range 1 0 0 5 0 10 0 15 0 20 0 25 0 30 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 LOAD AMPS OUTPUT VOLTS Range 4 Range 3 Range 2 Range 1 ...

Page 16: ...ainst drive assembly Tighten thumbscrew 4 Gun Trigger Leads Insert leads one at a time through gun opening on front panel Connect female friction terminals to matching male terminals in unit Polarity is not important Close door 4 1 2 3 3 2 Installing Work Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable 802 456 1 2 3 4 5 Tools Needed 3 8 7 16 in...

Page 17: ...tive output terminal FCAW Self shielding wire no shielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal 3 4 Changing Polarity 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 3 3 Close door ...

Page 18: ...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 manufactur er s recommended flow rate 8 CO2 Adapter Customer Sup plied 9 O Ring Customer Supplied Install ...

Page 19: ...dual branch circuit protected by time de lay fuses or circuit breaker is re quired 3 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 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 2 1 3 18 in 460 mm 18 in 460 mm 802 442 ...

Page 20: ...eptacle 4 Line Disconnect Device See Section 3 8 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 ssb2 2 1 94 802 443 Ref 802 085 1 18 in 457 mm of space for airflow L1 L2 L1 L2 2 230 VAC 1 Y Always connect grounding conductor first GND PE 4 3 Y Do not move or operate unit where it could tip ...

Page 21: ...Max Recommended Input Conductor Length In Feet Meters 66 20 Min Grounding Conductor Size In AWG Kcmil 12 Reference 1996 National Electrical Code NEC S 0092 J 3 9 Installing Wire Spool And Adjusting Hub Tension S 0499 15 16 in Standard Wire Spool 8 in 1 Lb Wire Spool 4 in Turn wingnut When a slight force is needed to turn spool tension is set Tools Needed Adjusting Hub Tension Install spool so weld...

Page 22: ...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 Hold wire tightly to keep it from unraveling Ref 802 444 Ref 205 837 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 Rein...

Page 23: ... switch under load Switch must click into detent position 1 2 3 4 or purge for proper contact 2 Voltage Switch Purge 0 Position In purge position fan runs but there is no weld output 3 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting in creases wire speed range also in creases see weld setting label in welding power source or Sections 4 2 or 4 3 as applicable 4 ...

Page 24: ...OM 944 Page 20 4 2 Weld Parameters For 115 VAC Model 196 052 ...

Page 25: ...OM 944 Page 21 4 3 Weld Parameters For 230 VAC Model 196 081 A ...

Page 26: ...ths Blow out or vacuum inside During heavy service clean monthly Or 5 2 Overload Protection 802 441 1 Circuit Breaker CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset breaker 1 5 3 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 resets allowing dri...

Page 27: ...ide of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 3 10 NOTE when changing drive rolls make sure the woodruff key is on the motor shaft and not in the old drive roll 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 Ref 802 444 802 139 5 5 Replacing Gun Contact Tip Ref 802 399 A Y Turn Off power before replaci...

Page 28: ...1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tight en two full turns more Cut liner off so that 3 4 in 19 mm sticks out of head tube Install gas diffuser adapter contact tip and nozzle Lay gun cable out straight before installing new liner Head Tube 8 mm Remove liner Remove nozzle contact tip adapter gas diffuser and wire outlet guide Blow out gun casing 10 mm ...

Page 29: ...ten head tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle locking nut Y Turn Off welding power source wire feeder and disconnect gun Remove switch housing Install new switch and connect leads polarity is not important Reas semble in reverse order If replacing head tube continue to end...

Page 30: ...screw securing gun end to feed head adapter and tighten if necessary 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 Straightengun cable and or replace damaged parts welding Adjust drive roll pressure see Section 3 10 Change to proper drive roll groove see Section 5 4 Rea...

Page 31: ...OM 944 Page 27 SECTION 6 ELECTRICAL DIAGRAM 194 324 NEUTRAL Figure 6 1 Circuit Diagram For 115 VAC Model ...

Page 32: ...OM 944 Page 28 194 325 Figure 6 2 Circuit Diagram For 230 VAC Model ...

Page 33: ...tions 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 Wire Feeder Power Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp light mig 5 967 Ref 802 445 ...

Page 34: ...35 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ipm 1 6 x 125 A 200 ipm 3 5 x 125 A 437 ipm Set voltage midway between high low voltage Low voltage wire stubs into work High voltage arc is unstable spatter 125 A based on 1 8 in Thickness to Amperage m...

Page 35: ...3 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 GROOVE WELDS FILLET WELDS End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View Of Gun Angle 1 0 15 S 0421 A ...

Page 36: ...trode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS STICKOUT FILLET WELD ELECTRODE EXTENSIONS STICKOUT Push Perpendicular Drag GUN TRAVEL SPEED Slow Normal Fast S 0634 ...

Page 37: ...ent Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 7 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 7 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or laye...

Page 38: ...nsufficient 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 gas change to different gas Dirty welding wire Use clean ...

Page 39: ...n 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 Improper welding technique Place stringer bead in proper loc...

Page 40: ...pport hand on solid surface or use two hands 7 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 ...

Page 41: ... most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Positions Argon 25 CO2 Flat Horizontal1 Fillet All Positions All Positions2 CO2 Flat Horizontal1 Fillet All Positions Tri Mix3 All Positions 1 Globular Transfer 2 Single Pass Welding Only 3 90 HE 7 1 2 AR 2...

Page 42: ...IST Hardware is common and not available unless listed 802 449 B 3 4 9 8 32 35 13 5 34 33 11 12 24 26 2 17 6 18 10 38 37 42 1 31 14 16 36 29 30 15 27 28 41 25 23 22 19 21 20 7 39 40 47 46 45 44 43 48 49 50 51 Figure 8 1 Main Assembly ...

Page 43: ...RD ASSY control 115 VAC model 1 13 195 887 CIRCUIT CARD ASSY control 230 VAC model 1 14 409 477 SWITCH rotary 25A 5 position 1 15 196 575 SWITCH rocker SPST 115 VAC model 1 15 196 574 SWITCH rocker DPST 230 VAC model 1 16 194 513 POTENTIOMETER 1 17 193 144 INSULATOR output stud 1 18 134 201 STAND OFF 1 19 203 556 SHAFT spool hub 1 20 409 615 002 WASHER spring finger 2 21 203 555 WASHER brake 1 22 ...

Page 44: ...3 081 SCREW feed roll 1 47 196 052 LABEL weld chart 115 VAC model 1 47 196 081 LABEL weld chart 230 VAC model 1 48 010368 CLAMP work 1 49 089 899 LATCH 1 50 198 585 PLATE support 230 VAC model only 1 51 203 390 KEY woodruff 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only...

Page 45: ...of 1 9 194 014 LINER monocoil 4 64 AL wire x 10ft nyl consisting of 1 10 197 123 O RING 312 ID x 062 70 Dura BUNA N 2 11 196 255 SWITCH trigger 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Table 8 1 Optional Drive Rolls For All Feed Head ...

Page 46: ...Notes ...

Page 47: ...obart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warra...

Page 48: ...r To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact th...

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