Hobart Welding Products H-10, Technical Manual

Page 1: ...ff w Serial No LB096205 Handler 175 500 416 Eff w Serial No LB075197 Visit our website at www HobartWelders com Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding Handler 135 175 And H 10 Gun ...

Page 2: ...TION 13 4 1 Controls 13 4 2 Weld Parameter Chart For 115 VAC Model 14 4 3 Weld Parameter Chart For 230 VAC Model 16 SECTION 5 THEORY OF OPERATION 18 SECTION 6 TROUBLESHOOTING 20 6 1 Troubleshooting Table 20 6 2 Troubleshooting Circuit Diagram For Welding Power Source 115 VAC Model 22 6 3 Troubleshooting Circuit Diagram For Welding Power Source 230 VAC Model 24 6 4 Control Board PC1 Testing Informa...

Page 3: ... power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters D Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts STATIC ESD can damage PC boards D Put on grounded wrist strap BEFORE handling boards or parts D...

Page 4: ...y 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 For Gasoline Engines Y Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Y Diesel engine exhaust and so...

Page 5: ... Dia 024 030 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 030 0 8 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...

Page 6: ...cle before welding Y 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 C 115 VAC Model D 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...

Page 7: ... other settings fall between the curves shown ssb1 1 10 91 196 608 196 609 E 115 VAC Model F 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 Ran...

Page 8: ...ng until it bottoms against 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 To...

Page 9: ...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 Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturer s recommended po larity and see Section 3 3 Close door Ref 209 228 Ref 209 229 DC...

Page 10: ...wmeter Install so face is 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 manufacturer s recommended flow rate Tools Needed Ref 802 028 A 802 441 5 8 1 1 ...

Page 11: ...olt 20 ampere individual 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 A ...

Page 12: ...e NEMA 6 50R Connect plug to receptacle 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 A Ref 802 085 18 in 457 mm of space for airflow L1 L2 2 230 VAC 1 Y Always connect grounding conductor first GND PE 3 Y Do not move or operate unit where it could tip L1 L2 4 ...

Page 13: ...ength 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 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 When a slight force is needed to turn spool ...

Page 14: ...s into gun continue to hold wire Hold wire tightly to keep it from unraveling 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 2 Turn power on INPUT POWER 6 in 150 mm Tighten 1 2 3 4 Use pressure indicator scale to set a desired drive roll pressure Pressure Indicator Scale Tighten 1 2 3 4 Be su...

Page 15: ...3 as applicable Do not 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 o...

Page 16: ...ake sure that hub tension is not too tight and CAUTION Do not change Voltage Switch Knob position while welding Wire Type and Polarity Setting Flux Core E71T 1 1 DCEN Solid Wire ER70S 6 DCEP Solid Wire ER70S 6 DCEP Stainless Steel DCEP Aluminum DCEP Material Being Welded Stainless Steel Aluminum Suggested Shielding Gas 20 30 cfh Flow Rate Tri Mix 90 He 7 5 Ar 2 5 CO2 100 Argon 100 CO2 No Shielding...

Page 17: ...t as possible A push angle for the torch is normally recommended Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded Number on Left of Slash is Voltage Setting Number on Right of Slash is Wire Feed Setting Electrode Negative For Flux Core Wire Electrode Positive For Solid Wire 1 10 4 40 4 30 1 10 1 20 2 10 2 10 3 10 2 30 2 15 1 20 1 10 2 30 3 30 2 15 4 10 3 40 3 10 3 30...

Page 18: ... not too tight and CAUTION Do not change Voltage Switch Knob position while welding Wire Type and Polarity Setting Flux Core E71T 1 1 DCEN Solid Wire ER70S 6 DCEP Solid Wire ER70S 6 DCEP Stainless Steel DCEP Aluminum DCEP Material Being Welded Stainless Steel Aluminum Suggested Shielding Gas 20 30 cfh Flow Rate Tri Mix 90 He 7 5 Ar 2 5 CO2 100 Argon 100 CO2 No Shielding Gas Required Good for Windy...

Page 19: ...d Wire Speed Settings for Thickness of Metal Being Welded Number on Left of Slash is Voltage Setting Number on Right of Slash is Wire Feed Setting Electrode Negative For Flux Core Wire Electrode Positive For Solid Wire 1 20 1 10 1 10 4 80 4 60 4 50 4 100 4 70 4 50 4 40 1 10 1 45 1 30 1 20 2 30 2 20 2 10 2 20 2 10 1 30 1 20 2 85 2 40 2 30 2 35 2 30 2 20 2 40 2 20 2 10 1 100 1 95 3 50 3 40 2 20 3 90...

Page 20: ...alve GS1 Controls shielding gas flow Pressing gun trigger opens valve 8 Wire Speed Control R1 Controls wire feed motor speed by providing a reference voltage to motor control circuit on PC1 9 Range Switch S2 Allows selection of weld output voltage 10 Main Transformer T1 Supplies power to weld output circuit 11 Main Rectifier SR1 Changes the ac output from T1 to full wave rectified dc output 12 Out...

Page 21: ...To Table Of Contents AC Or DC Control Circuits Weld Current Circuit Welding Wire Work 12 Electrode 9 Range Switch S2 10 Main Transformer T1 11 Main Rectifier SR1 13 Stablizer L1 Capacitor C1 14 Polarity Changeover Block Wire Drive Motor 15 ...

Page 22: ...eck 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 Check the setting of Voltage switch S2 Machine will not weld if voltage control is set between range positions Rotate switch until it clicks into a detent position Electrode wire feeding stops during welding Strai...

Page 23: ...e switch S2 in desired position see Section 4 1 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 6 Readjust wire reel hub tension Check voltage and connections of wire drive motor Replace motor if necessary Improper or no shielding gas flo...

Page 24: ...5 175 Return To Table Of Contents 6 2 Troubleshooting Circuit Diagram For Welding Power Source 115 VAC Model Test Equipment Needed V1 V2 V3 V4 V5 V7 V6 V10 V8 R5 V9 R6 R8 V11 R9 R1 R2 R3 R4 See also Section 6 4 for PC1 data R7 ...

Page 25: ...rol R1 with Voltage switch S2 in position 2 15 to 23 volts dc from min to max of Wire Speed control R1 with Voltage switch S2 in position 3 17 to 26 volts dc from min to max of Wire Speed control R1 with Voltage switch S2 in position 4 Voltage Switch S2 Position Min RPM Max RPM Min IPM Max IPM 1 2 3 4 50 60 70 80 155 170 190 215 190 230 265 300 585 640 715 800 Wire Diameter And Type All tests done...

Page 26: ...5 175 Return To Table Of Contents 6 3 Troubleshooting Circuit Diagram For Welding Power Source 230 VAC Model Test Equipment Needed V1 V2 V3 V4 V5 V7 V6 V10 V8 R5 V9 R6 R8 V11 R9 R1 R2 R3 R4 See also Section 6 6 for PC1 data R7 ...

Page 27: ...rol R1 with Voltage switch S2 in position 2 12 7 to 24 0 volts dc from min to max of Wire Speed control R1 with Voltage switch S2 in position 3 15 5 to 27 0 volts dc from min to max of Wire Speed control R1 with Voltage switch S2 in position 4 Voltage Switch S2 Position Min RPM Max RPM Min IPM Max IPM 1 2 3 4 40 50 70 90 135 160 190 205 150 190 260 340 510 600 700 800 Wire Diameter And Type All te...

Page 28: ... 115 VAC Model Be sure plugs are secure before testing See Section 6 5 for specific values during testing 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6 TP A 7 TP B 8 TP C 9 TP D 10 TP E 11 TP F Test Equipment Needed 802 779 195 888 B 1 2 3 4 5 6 7 8 9 10 11 ...

Page 29: ...s dc with gun trigger closed reference to TP C 6 35 volts dc reference to TP C 7 15 0 volts dc reference to TP C 8 15 0 to 6 5 volts dc from min to max of Wire Feed speed control R1 Reference for TP C RC2 1 Negative welder output voltage 2 Not used 3 Positive output to wire drive motor 4 Negative output to wire drive motor RC4 Circuit common RC5 Positive welder output voltage with gun trigger clos...

Page 30: ... 230 VAC Model Be sure plugs are secure before testing See Section 6 7 for specific values during testing 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6 TP A 7 TP B 8 TP C 9 TP D 10 TP E 11 TP F Test Equipment Needed 802 779 195 889 B 1 2 3 4 5 6 7 8 9 10 11 ...

Page 31: ...s dc with gun trigger closed reference to TP C 6 35 volts dc reference to TP C 7 15 0 volts dc reference to TP C 8 15 0 to 6 5 volts dc from min to max of Wire Feed speed control R1 Reference for TP C RC2 1 Negative welder output voltage 2 Not used 3 Positive output to wire drive motor 4 Negative output to wire drive motor RC4 Circuit common RC5 Positive welder output voltage with gun trigger clos...

Page 32: ...erminals 6 Months Blow out or vacuum inside During heavy service clean monthly Or 7 2 Overload Protection 802 441 1 Circuit Breaker CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset breaker 1 7 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 reset...

Page 33: ... opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 3 10 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 Tools Needed 4 Ref 802 444 B 024 Groove 030 035 Groove Stamped 024 Stamped 030 035 1 2 3 7 5 Replacing Gun Contact Tip Ref 802 399...

Page 34: ... outlet guide so that 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...

Page 35: ... out by hand Hand tighten 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 hea...

Page 36: ...m your machine Use circuit inside machine case or contact your distributor for further information Model Serial Or Style Number Circuit Diagram Wiring Diagram 115 VAC Model KK213350 and following 194 324 C 196 637 A 230 VAC Model KK213350 and following 194 325 A 196 655 A Circuit Board PC1 115 VAC Model KK213350 and following 195 890 Circuit Board PC1 230 VAC Model KK213350 and following 195 891 ...

Page 37: ...TM 944 Page 35 Handler 135 175 Return To Table Of Contents 194 324 C Figure 8 1 Circuit Diagram For 115 VAC Model Effective With Serial No KK213350 And Following ...

Page 38: ...TM 944 Page 36 Handler 135 175 Return To Table Of Contents 194 325 A Figure 8 2 Circuit Diagram For 230 VAC Model Effective With Serial No KK213350 And Following ...

Page 39: ...TM 944 Page 37 Handler 135 175 Return To Table Of Contents 196 637 A Figure 8 3 Wiring Diagram For 115 VAC Model Effective With Serial No KK213350 And Following ...

Page 40: ...TM 944 Page 38 Handler 135 175 Return To Table Of Contents 196 655 A Figure 8 4 Wiring Diagram For 230 Model Effective With Serial No KK213350 And Following ...

Page 41: ...TM 944 Page 39 Handler 135 175 Return To Table Of Contents 195 890 A Figure 8 5 Circuit Diagram For 115 VAC Model Control Board PC1 Effective With Serial No KK213350 And Following ...

Page 42: ...TM 944 Page 40 Handler 135 175 Return To Table Of Contents 195 891 A Figure 8 6 Circuit Diagram For 230 VAC Model Control Board PC1 Effective With Serial No KK213350 And Following ...

Page 43: ... Handler 135 175 And H 10 Gun TM 944C October 2003 Handler 135 500 414 Eff w Serial No LB096205 Handler 175 500 416 Eff w Serial No LB075197 Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding ...

Page 44: ...nts SECTION 9 PARTS LIST Hardware is common and not available unless listed 802 449 E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 35 33 32 50 44 49 48 47 46 45 52 51 36 37 43 42 41 39 40 38 28 31 34 Figure 9 1 Main Assembly ...

Page 45: ...fan 230 VAC model 1 19 409 953 001 BLADE fan cooling 1 20 194 268 TRANSFORMER power assy 115 VAC model 1 20 194 277 TRANSFORMER power assy 230 VAC model 1 21 208 015 HANDLE carrying 1 22 196 005 WRAPPER 1 23 204 036 LABEL warning 1 24 203 491 CLAMP capacitor 1 25 193 039 CAPACITOR electlt 53000uf 115 VAC model 1 25 193 040 CAPACITOR electrlt 100000uf 230 VAC model 1 26 203 868 REACTOR ASSY 115 VAC...

Page 46: ...roll 115 VAC model Prior to LC175022 or 230 VAC model Prior to LC155844 1 47 196 009 FITTING gas barbed 1 48 202 925 ROLL feed 024 in 030 035 in 1 49 194 508 HEAD feed assy 1 50 203 025 GUIDE wire inlet 1 51 209 228 LABEL weld chart 115 VAC model 1 51 209 229 LABEL weld chart 230 VAC model 1 52 204 711 LATCH 1 212 492 REGULATOR FLOWMETER 10 50 CFH CO2 1 OPTIONAL When ordering a component originall...

Page 47: ...x 15ft consisting 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 9 3 Optional Drive Rolls For Al...

Page 48: ...003 Hobart Welding Products Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 ...