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TM-944C October 2003
Handler 135 (500 414) Eff. w/Serial No.
LB096205
Handler 175 (500 416) Eff. w/Serial No.
LB075197
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Handler 135 / 175
And H-10 Gun
Visit our website at
www.HobartWelders.com
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. California Proposi
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SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage safety_stm 5/97 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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Means “Note”; not safety related. 1-2. Servicing Haz
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MOVING PARTS can cause injury. H.F. RADIATION can cause interference. Keep away from moving parts. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and Keep away from pinch points such as drive communications equipment. rolls. Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units. The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting
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SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 115 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage KVA KW Output Range 115 V, 60 Hz, Single- W/ Gun Dimensions DC Phase Length: 18-7/8 in (479 mm) 90 A @ 19 Volts DC, 20 2.90 2.50 55 lb 20% Duty Cycle Width: 10-5/8 in (25 kg) 30 − 135 28 (270 mm) 63 A @ 21 Volts DC, 15* 2.20* 1.77* 20% Duty Cycle* Height: 12-3/8 in (314 mm) Solid/ Flux Cored/ Wire Feed Speed Range Stainless Alumin
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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) C. 115 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for 200 unit to cool. Reduce amperage or duty cycle before welding. 135 Exceeding duty cycle can 100 damage unit or gun and void warranty. 80 60 40 20 10 2 4168 80 40 600 100 1 20 Duty Cycle % 20% duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting D.
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2-3. Volt-Ampere Curves The volt-ampere curves show the E. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 30.0 25.0 20.0 Range 4 15.0 Range 3 Range 2 10.0 Range 1 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 LOAD AMPS F. 230 VAC Model 30.0 25.0 20.0 Range 4 Range 3 15.0 Range 2 Range 1 10.0 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 19
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SECTION 3 − INSTALLATION 3-1. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End 4 Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 Gun Trigger Leads 2 3 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. 1 Ref. 802 440-A 3-2. Installing Work Clamp 1 Nut 3 2 Work Cable From Unit 1 3 Work
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3-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output no shielding gas output terminal terminal 3-4. Changing Polarity 1 Lead Connections For Direct CHANGING Current Electrode Negative POLARITY
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3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap with CO shielding gas. See Parts List for optional 2 2 Cylinder Valve CO gas regulator/flowmeter. 2 Remove cap, stand to side of valve, 1 and open valve slightly. Gas flow 4 blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter 2 Install so face is vertical. 7 5 Regul
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3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual 2 18 in 1 branch circuit protected by time-de- (460 mm) 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 3 50 up to 200 ft (61 m). Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 18 in (460 mm) 802 4
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3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug (NEMA 6-50P) 3 Receptacle (NEMA 6-50R) Connect plug to receptacle. 4 Line Disconnect Device 18 in (457 mm) of space for airflow See Section 3-8. Special installation may be required where gasoline or volatile liquids are present − 4 see NEC Article 511 or CEC Section 20. L1 Always connect grounding conductor first. L2 = GND/PE 3 1 2 L1 L2 230 VAC, 1 Do not move or operat
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3-8. Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In AWG/Kcmil 14 66 (20) Max Recommended Input Conductor Length In Feet (Meters) 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 Installing 4 in (102 mm) Wire Spool When a slight force is needed to tu
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3-10. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. 4 6 Tools Needed: 1 2 3 5 Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Use pressure indicator Tighten scale to set a desired drive roll pressure. Pressure 1 2 Indicator 3 Scale 4 INPUT POWER
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SECTION 4 − OPERATION 4-1. Controls 1 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. 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 swi
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4-2. Weld Parameter Chart For 115 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Suggested Diameter Material Wire Type, Shielding Gas of Wire Being and Welded 20−30 cfh Flow Rate Being Used Polarity Setting .030” (0.8 mm) Steel Flux Core No Shielding Gas Required E71T −11 Good for Windy or .035” (0.9 mm) (DCEN) Outdoor Applications C25 Gas Mixture .024” (0.6 mm) Solid Wire ER70S
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for 115 Volt Wire Welding Package Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded. CHANGING Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. POLARITY DCEN 22 gauge 18 gauge 16 gauge 1/8 inch 3/16 inch Electrode Negative (.8 mm) (1.2 mm) (1.6 mm) (3.2 mm) (4.8 mm) For Flux Core Wire −−− 1/10 1/20 3/30 4/40 −−− −−− 1/10 3/10 4/30 1/10 1/20 2/30 4/65 −−− −−− 2/10 3/30 4/50 −−− −−− 2/10 2/15 4/40 −−− −−− 3/10 −−− DCEP 4/10 4/
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4-3. Weld Parameter Chart For 230 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Suggested Diameter Material Wire Type, Shielding Gas of Wire Being and Welded 20−30 cfh Flow Rate Being Used Polarity Setting .030” (0.8 mm) Steel Flux Core No Shielding Gas Required Good for Windy or .035” (0.9 mm) E71T −1 1 .045” (1.2 mm) (DCEN) Outdoor Applications C25 Gas Mixture .024” (0.6 mm)
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for 230 Volt Wire Welding Package Recommended Voltage and Wire Speed Settings for Thickness of Metal Being Welded. CHANGING Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting. POLARITY DCEN Electrode Negative 22 gauge 18 gauge 16 gauge 1/8 inch 3/16 inch 1/4 inch (.8 mm) (1.2 mm) (1.6 mm) (3.2 mm) (4.8 mm) (6.4 mm) For Flux Core Wire −−− 1/10 1/30 3/50 3/60 4/80 −−− −−− 1/20 3/40 3/50 4/60 −−− −−− −−− 2/20 3/40 4/50 1/20 1/45 2/85 3/90 4/100 −−− 1/10 1/30
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SECTION 5 − THEORY OF OPERATION 1 Circuit Breaker CB1 Protects unit from an over-current condition by opening primary power line. 2 Power Switch S1 Turns unit and fan motor FM on and 34 5 off. Fan Motor FM Thermostat Gun Trigger 3 Fan Motor FM And And Transformer TP1 Receptacle RC3 Transformer Controlled by power switch S1. Fan cools internal components, and transformer supplies control 2 voltage to PC1. Power Switch 4 Thermostat TP1 S1 If unit overheats, TP1 opens stopping all weld output. 5 Gu
