Hobart H100S4-10, Technical Manual

Page 1: ...rtWelders com TM 260 273B 2013 02 Eff w Serial No MC420249Y Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding File MIG GMAW Handler 190 And H100S4 10 Gun R ...

Page 2: ...Guide 11 3 11 Connecting Input Power 12 3 12 Connecting Optional Spool Gun 14 3 13 Threading Welding Wire 15 SECTION 4 OPERATION 16 4 1 Controls 16 4 2 Weld Parameter Chart For 230 VAC Model 17 SECTION 5 THEORY OF OPERATION 18 SECTION 6 TROUBLESHOOTING 20 6 1 Troubleshooting Table 20 6 2 Troubleshooting Circuit Diagram For Welding Power Source 22 6 3 Control Board PC1 Testing Information 24 6 4 Co...

Page 3: ...ng a live unit use the one hand method Do not put both hands inside unit Keep one hand free D Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power D Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Troublesh...

Page 4: ... all labels and the Technical Manual carefully be fore installing operating or servicing unit Read the safety in formationat the beginning of the manual and in each section 1 3 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 ...

Page 5: ... 10 5 8 in 270 mm Height 12 3 8 in 314 mm Wire Type And Diameter Solid Stainless Flux Cored Aluminum Wire Feed Speed Range 023 035 in 0 6 0 9 mm 030 045 in 0 8 1 2 mm 030 035 in 0 8 0 9 mm 50 740 IPM 1 3 18 8 m min At No Load 40 700 IPM 1 0 17 8 m min Feeding Wire 2 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit over...

Page 6: ...tween the curves shown ssb1 1 10 91 248 833 A 0 5 10 15 20 25 30 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Voltage Amperage 1 2 3 4 5 6 7 SECTION 3 INSTALLATION 3 1 Installing Nozzle Contact Tip And Adapter Ref 243 839 A Turn off welding power source 1 Nozzle 2 Contact Tip 3 Tip Adapter Wire size stamped on tip check and match wire size Tools Needed 8 mm Head Tube 8 ...

Page 7: ...mbscrew 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 Correct Incorrect Be sure that gun end is tight against drive assembly 4 Gun Fully Seated 4 Gun Not Seated Exposed O rings will cause shielding gas leakage Spool Gun ÉÉÉ ...

Page 8: ...per tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and excessive heating of the work clamp 1 Work Clamp 2 Work Cable From Unit 3 Screw 4 Flat Washer 5 Lock Washer 6 Nut Route work cable through hole in clamp handle Secure cable with hardware as shown Tools Needed 10 mm ...

Page 9: ...ng gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal 3 5 Changing Polarity Turn off welding power source 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturer s recommended polarity and see Section 3 4 Close door 260 459 A 1 2 CHANGING POLA...

Page 10: ... 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 welding gun Open pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate After flow is set...

Page 11: ...tput For future reference write serial number in space provided on back cover of this manual 1 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 3 8 Selecting A Location 1 18 in 460 mm 18 in 460 mm Location And Airflow 260 711 B ST 139 445 E Do not move or oper...

Page 12: ...s 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 When a slight force is needed to turn spool tension is set Retaining ring used with 8 in 203 mm spool only Adapter used with 8 in 203 mm spool only ...

Page 13: ...e 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 2011 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 comparable to the recomm...

Page 14: ...TM 260 273 Page 12 Handler 190 3 11 Connecting Input Power input4 2012 05 Ref 803 766 C 260 711 A L1 L2 230 VAC 1 7 9 Tools Needed 2 1 L1 L2 1 GND PE Earth Ground 6 5 3 4 7 ...

Page 15: ...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 terminal first Connect input conductors L1 and L2 to dis connect device line terminals 7 Over Current Protection Select type and size of over current protec ti...

Page 16: ...ty 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 appropriatesetting 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual or door chart for appropriatesettin...

Page 17: ...87 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 pressure indicator scale t...

Page 18: ... power source or Section 4 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 4 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 shielding gas flows Ref 248 84...

Page 19: ...TM 260 273 Page 17 Handler 190 4 2 Weld Parameter Chart For 230 VAC Model 248 827 B ...

Page 20: ...eder resistor for capacitor C1 8 Thermostat TP1 If main transformer overheats TP1 opens gun switch circuit stopping all weld output 9 Gun Trigger Receptacle RC7 Connects gun trigger circuit to welding power source 10 Wire Speed Control R2 Sets a wire feed motor speed by providing a reference voltage to motor control circuit on PC1 11 Wire Drive Motor Feeds wire at a speed set by R2 Motor is enable...

Page 21: ...r 11 8 9 Thermostat TP1 Gun Trigger Receptacle RC7 10 Wire Speed Control R2 Spool Gun Wire Drive Motor 18 16 Polarity Changeover Block Terminals allow changing between DCEP and DCEN processes 17 Wire Drive Selector Switch S3 Selects operation of integrated wire drive motor 11 or spool gun wire drive motor 18 18 Spool Gun Wire Drive Motor Feeds wire at speed set by R2 Motor is enabled when Wire Dri...

Page 22: ...1 and replace if necessary Check main transformer T1 for signs of winding failure Check continuity across windings and check for proper connections Check secondary voltages Replace T1 if necessary Check control board PC1 connections and voltages and replace if necessary Wire does not feed wire is not ener gized wire feeds unevenly Check contact tip Check for kinks in gun cable and liner Check gun ...

Page 23: ... that it is the proper size for the input voltage and amperage Low or erratic wire speed Readjust weld parameter settings Change to correct size drive roll Readjust drive roll pressure Clean or replace wire inlet guide or liner if dirty or plugged see Section 7 4 and or 7 5 Readjust wire reel hub tension Check voltage and connections of wire drive motor Replace motor if necessary Improper or no sh...

Page 24: ...536 604 Wire Diameter And Type All tests done with 030 035 liner in H 10 model 10 foot welding gun smooth groove drive roll Values are nominal depending on drive roll pressure and spool hub tension 030 035 Solid or Flux Core Wire Speed While Feeding 5 92 672 6 108 708 7 124 728 Min RPM Max RPM 1 2 3 4 13 17 21 25 125 142 161 177 All tests done with the pressure assembly open not feeding wire Value...

Page 25: ...osition 1 and gun trigger closed 19 7 volts dc with Voltage switch S2 in position 2 and gun trigger closed 21 8 volts dc with Voltage switch S2 in position 3 and gun trigger closed 23 9 volts dc with Voltage switch S2 in position 4 and gun trigger closed 26 0 volts dc with Voltage switch S2 in position 5 and gun trigger closed 28 1 volts dc with Voltage switch S2 in position 6 and gun trigger clos...

Page 26: ... Control Board PC1 Testing Information Be sure plugs are secure before testing See Section 6 4 for specific values during testing 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC4 Test Equipment Needed Ref 804 691 A 248 284 A 2 1 3 ...

Page 27: ...1 11 11 Not used PC board common 12 23 volts ac with gun trigger closed reference to RC1 15 13 33 volts dc reference to RC1 11 14 24 volts ac reference to RC1 6 15 23 volts ac with gun trigger closed reference to RC1 12 16 17 2 volts dc with gun trigger closed reference to RC1 8 17 MIG Gun Spool Gun switch S3 in Spool Gun position and gun trigger closed reference to RC1 20 4 8 volts dc with Wire S...

Page 28: ...erminals l Damaged Gas Hose nl Weld Cables nl Cords nl Gun Cables Every 6 Months OR Drive Rolls Inside Unit 7 2 Overload Protection 802 441 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gu...

Page 29: ...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 proper feeding Flux Core Wire Recommended stickout is 1 2 in 12 7 mm from gun tip Solid Wire Recommended stick...

Page 30: ... and match wire size Tools Needed 8 mm 10 mm Lay gun cable out straight before installing new liner Remove nozzle contact tip and adapter Unscrew and remove liner Blow out gun casing Cut off wire and disconnect gun from feeder 5 8 in 16 mm Liner Stickout Install Liner Reassemble gun in reverse order from taking it apart 10 mm Head Tube 8 mm 1 3 2 Thread wire according to welding power source wire ...

Page 31: ...tion handle halves and install switch housing Turn Off welding power source wire feeder and disconnect gun 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 1 2 3 8 6 7 Remove screw on opposite side Secure head tube in vice Loosen jam nut Remove from vice and turn head tube out by hand 4...

Page 32: ...TM 260 273 Page 30 Handler 190 Notes ...

Page 33: ...t be minor circuit differences from your machine Use circuit inside machine case or contact your distributor for further information Model Serial Or Style Number Circuit Diagram Wiring Diagram Welding Power Source MC420249Y and following 248 830 A 248 831 A Circuit Board PC1 MC420249Y and following 248 286 A Not included in this manual ...

Page 34: ...TM 260 273 Page 32 Handler 190 Figure 8 1 Circuit Diagram For Welding Power Source Eff w MC420249Y And Following ...

Page 35: ...TM 260 273 Page 33 Handler 190 248 830 A ...

Page 36: ...TM 260 273 Page 34 Handler 190 Figure 8 2 Wiring Diagram For Welding Power Source Eff w MC420249Y And Following ...

Page 37: ...TM 260 273 Page 35 Handler 190 248 831 A ...

Page 38: ... 1 4 3 CR2 5 2 CR2 1 2 CR1 PTC2 11 RC1 C1 C2 3 1 2 Q2 D6 C5 C4 D16 3 1 2 Q3 R18 R17 R16 R15 R14 R13 R12 R11 R2 30V R4 D8 D7 D14 D10 D9 D13 D12 3 2 1 A1 5 RC1 3 RC1 2 RC1 29V 9 RC1 1 RC1 4 RC1 30V 13 RC1 7 RC1 12 RC1 14 RC1 15 RC1 6 RC1 29V 1 8 CR3 30V D5 R7 29V Figure 8 3 Circuit Diagram For Control Board PC1 Eff w MC420249Y And Following ...

Page 39: ... HEATSINK 2PIN 20PIN AGND CAP CAP MOTOR MOTOR 5AMP_50V VOUT D2 5AMP_50V 5AMP_50V 20 RC1 2 RC4 5AMP_50V 5AMP_50V 5AMP_50V HS1 5AMP_50V 4 5 3 CR1 D4 2 1 3 Q1 19 RC1 1 RC4 R10 R9 29V D11 R3 R8 C3 D3 R1 D1 5 6 7 A1 4 8 A1 16 RC1 8 RC1 17 RC1 10 RC1 18 RC1 VOUT 3 2 4 CR3 6 7 5 CR3 PTC1 R6 R5 WFS_REF ...

Page 40: ...TM 260 273 Page 38 Handler 190 Notes ...

Page 41: ...rtWelders com TM 260 273B 2013 02 Eff w Serial No MC420249Y Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding File MIG GMAW Handler 190 And H100S4 10 Gun R ...

Page 42: ... 9 PARTS LIST Hardware is common and not available unless listed 258 438 A 1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 19 20 11 12 13 14 15 16 17 18 29 30 31 32 33 34 35 36 37 38 39 40 49 50 41 42 43 44 45 46 47 48 Figure 9 1 Main Assembly ...

Page 43: ...196 005 Wrapper 1 23 204 036 Label Warning 1 24 203 491 Clamp Capacitor 1 25 C1 193 040 Capacitor Electrlt 100000uf 1 26 Z1 225 891 Reactor Assy 1 27 SR1 193 316 Rectifier Assy 1 28 193 193 Bus Bar Positive 1 29 228 706 Baffle Center 1 30 S3 196 575 Switch Rocker 1 31 TE1 193 144 Insulator Output Stud 1 32 193 194 Bus Bar Negative 1 33 216 830 Label Warning 1 34 134 201 Stand Off 4 35 S2 226 813 S...

Page 44: ...ts Service Kit 1 49 228 643 Plate Stiffener Base 1 50 229 794 Label Spoolgun Mig Gun 1 221 037 Regulator Flowmeter 10 50 CFH Argon CO2 1 183 581 Hose Assembly Gas 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 Manufacturer s Suggested Replacement Parts Model and serial ...

Page 45: ... hex hd 4 9 197 172 Screw 006 32 x 0 37 3 10 196 895 Knob Tension 1 11 234 200 Spring Compression 1 12 196 896 Cup Spring Tension 1 13 225 718 Fastener Pinned 1 14 257 792 Screw Shld Stl 10 32 x 60 1 15 256 960 Guide Inlet 023 052 1 16 257 865 Knob T 1 00 Bar W 10 32 x 375 1 17 246 565 Roll Drive V VK Groove 030 035 1 18 217 778 Motor Gear 1 19 230 012 Fitting Gas 1 20 196 109 Cable 1 21 602 154 S...

Page 46: ... 169 716 Adapter Contact Tip 1 5 246 373 Tube Head 1 6 243 865 Nut Jam 1 7 242 832 Handle 1 8 225 410 Switch Trigger 1 9 079 878 Housing Plug Pins 1 10 246 380 Housing Power Pin 1 11 245 927 Connector Feeder 1 12 197 123 O Ring 312 ID X 062 70 Duro Buna n 2 13 194 010 Liner Monocoil 023 025 Wire x 15ft Consisting Of 1 13 194 011 Liner Monocoil 030 035 Wire x 15ft Consisting Of 1 13 194 012 Liner M...

Page 47: ...er 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 9 6 Consumables ITEM HOBART PACKAGE NO MILLER PACKAGE NO Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 770 177 5 per package 000 067 10 per package 035 in 0 9 mm 770 180 5 per package 000 068 10 per pac...

Page 48: ...ORIGINAL INSTRUCTIONS PRINTED IN USA 2013 Hobart Brothers Co 2013 01 Hobart Brothers Co An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Assistance Call1 800 332 3281 ...