Hobart Welding Products Handler 125 Owner'S Manual Download Page 28 | Manualshive

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OM-283007 Page 26

SECTION 9

−

FCAW/GMAW WELDING GUIDELINES

9-1. Typical FCAW Process Connections (Electrode Negative)

Wire Feeder/

Welding Power Source

Workpiece

Gun

Work Clamp

FCAW/GMAW1 2018

−

01

−

Ref. 803444-A

Self-Shielding Flux

Core Wire

!

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.

.

Appearance of actual unit may
differ from that shown.

Workpiece

Gun

Work Clamp

!

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.

.

Appearance of actual unit may
differ from that shown.

9-2. Typical GMAW (MIG) Process Connections (Electrode Positive)

803444-A

Wire Feeder/

Welding Power Source

Regulator/

Flowmeter

Gas Hose

Shielding

Gas

Solid Wire

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Summary of Contents for Handler 125

Page 1: ...www HobartWelders com Description OM 283007B 2019 05 Processes File MIG GMAW Arc Welding Power Source And Wire Feeder Flux Cored FCAW Welding Handler 125 MIG GMAW Welding ...

Page 2: ... 1 Serial Number And Rating Label Location 10 4 2 Unit Specifications 10 4 3 Environmental Specifications 10 4 4 Duty Cycle And Overheating 11 4 5 Volt Ampere Curves 11 SECTION 5 INSTALLATION 12 5 1 Selecting A Location 12 5 2 Installing Work Clamp 12 5 3 Process Polarity Table 13 5 4 Changing Polarity 13 5 5 Installing Wire Spool And Adjusting Hub Tension 13 5 6 Installing Gas Supply 14 5 7 Conne...

Page 3: ... 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 semiautomatic DC con...

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: ... George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standa...

Page 7: ... nécessaire se servir 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 métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé...

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: ...e 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 unité s...

Page 10: ...g Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02169 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 10...

Page 11: ...tz Input Input Voltage Output Single Phase Transformer Rectifier Off On Work Connection Flux Cored Arc Welding FCAW FCAW Gun With Switch Do Not Switch While Welding Wire Feed Circuit Breaker Increase Percent Protective Earth Ground Temperature Indication Line Connection s Suitable For Welding In An Environment With Increased Risk Of Electric Shock X Duty Cycle I1 Rated Supply Current I2 Rated Weld...

Page 12: ...ions 80 A 18 Volts DC 25 Duty Cycle 55 A 16 75 Volts DC 60 Duty Cycle 40 A 16 Volts DC 100 Duty Cycle 25 130 28 5 21 3 2 59 2 23 57 5 lb 26 kg Length 19 4 in 493 mm Width 10 in 254 mm Height 13 1 2 in 343 mm Wire Type And Diameter Flux Cored Solid Wire Wire Feed Speed Range 030 035 in 0 8 0 9 mm 024 030 in 0 61 0 762 mm 88 545 ipm 2 2 13 8 mpm 4 3 Environmental Specifications A IP Rating IP Rating...

Page 13: ...ntinuous Welding 2 Minutes Welding 8 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 25 duty cycle at 80 amps Weld Amperes Duty Cycle 6 Minutes Welding 4 Minutes Resting rduty1 2013 04 284617 A 60 duty cycle at 50 amps 100 duty cycle at 40 amps 0 10 20 30 40 50 60 70 80 90 100 25 45 65 85 105 125 145 4 5 Volt Ampere Curves The volt ampere curves show the volt age and amperage ...

Page 14: ...in 460 mm 1 5 2 Installing Work Clamp Connectionhardware must be tight ened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and exces sive heating of the work clamp 1 Work Clamp 2 Work Cable From Unit 3 Insulator Grip Slide one insulating grip over work cable before connecting to clamp 4 Nut 5 Lock Washer 6 Flat Washer 7 Screw 8 Wo...

Page 15: ... cable is connected to the positive output Work cable is connected to the nega tive output 5 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 5 3 Close door Ref 210428 1 2 FCAW GMAW 5 5 Installing Wire Spool And Adjusting Hu...

Page 16: ...low rate should be set when gas is flowing through welding power source and welding gun Turn Range switch to Purge or Fan Only position Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate Tools Needed 802028 Ref 803379 A 11 16 1 1 8 in 6 4 5 7 1 2 3 Shielding Gas 5 7 Connecting 120 Volt Input Power Installation must me...

Page 17: ...ire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Use with solid or flux cored wire Push nozzle over contact tip and adapter until it is seated onto adapter Contact tip will be exposed approximately 7 16 in 11 3 mm when installed properly Push nozzle over contact tip and adapter until it is seated onto adapter End of contact tip will be fl...

Page 18: ...enough to prevent slipping Cut off wire Close door Press gun trigger until wire comes out of gun 2 Turn power on 6 in 150 mm Tighten Tighten Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Be sure that contact tip matches wire diameter Reinstall tip adapter if applicable contact tip and nozzle 3 5 4 Tip adapter may also require remo...

Page 19: ... a wire feed speed See weld setting label in welding power source or in Section 6 3 3 Power Switch Use switch to turn unit on and off 4 Over Temperature Light If unit overheats light turns on and output stops Allow unit to cool be fore attempting to weld Light goes out when unit has cooled and welding can resume Ref 284198 A 1 2 3 4 6 2 Operating The Gun Ref 804240 A 1 Trigger Switch Press and hol...

Page 20: ...OM 283007 Page 18 6 3 Weld Parameter Chart 283081 B ...

Page 21: ...air Or Replace Cracked Weld Cable 6 Months OR Drive Rolls Inside Unit 7 2 Overload Protection 161066 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 7 3 Replacing Gun Contact Tip Tools Needed Ref 804241 A Turn Off power before replacing contact tip 1 Nozzle Remove nozzle 2 Contact Tip 3 Tip Adapter Cut off welding wire at c...

Page 22: ...ing Reinstall plate and tighten screws 7 Retaining Knob Rotate counterclockwise and remove knob 8 Drive Roll The drive roll consists of two different sized grooves Each side is stamped with the proper size Select the groove that matches the wire size on the wire spool Install drive roll onto motor shaft so that correct groove size stamp faces out away from drive housing 9 Retaining Knob Opening In...

Page 23: ...ut liner Remove nozzle Cut off wire at contact tip and remove contact tip and tip adapter Reassemble drive cover and gun in reverse order from taking it apart Thread wire according to Section 5 9 Open pressure assembly Retract wire from liner onto spool Hold wire tightly to keep it from unraveling Secure end of wire at spool Remove four screws from cover and remove cover from wire drive assembly 8...

Page 24: ...own cable and top ring forward over head tube Separate gun handle halves Loosen liner setscrew Loosen and remove retaining nut from liner Pull liner out of gun cable If necessary twist cable to ease removal Turn Off welding power source Install retaining nut on one end of liner Lay gun cable straight on a flat surface Insert bare end of liner end without retaining nut into wire drive end of cable ...

Page 25: ... liner after cutting to length 3 8 in 10 mm Reassemble gun by placing head tube and cable into one half of handle Be sure trigger is properly installed into trigger slot Thread welding wire through gun see Section 5 9 Reinstall adapter contact tip and nozzle Reinstall cover onto wire drive assembly and secure with four screws Insert retaining nut into adapter and adjust liner stickout as shown Tig...

Page 26: ...ee Section 5 2 Replace contact tip see Section 7 3 Check that polarity leads are connected 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 Check cable connection at work clamp and tighten hardware if necessary see Section 5 2 If using an extension cord check that wire size and length is the proper size for ...

Page 27: ...OM 283007 Page 25 SECTION 8 ELECTRICAL DIAGRAM 284646 A Figure 8 1 Circuit Diagram ...

Page 28: ...re welding on a vehicle Place work clamp as close to the weld as possible Appearance of actual unit may differ from that shown Workpiece Gun Work Clamp 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 Appearance of actual unit may differ from that shown 9 2 Typical GMAW MIG Process Conn...

Page 29: ...ols weld penetration 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 or 0 0625 in 2 1 9 3 Typical Control Settings Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed 0 024 in 0 61 mm 30 90 A 3 5 in 89 mm per amp 3 5 x 62 5 A 21...

Page 30: ...y on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout Solid Wire 3 8 to 1 2 in 9 to 13 mm Flux Cored Wire 1 2 to 5 8 in 13 to 16 mm 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 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 4 Holding And Positi...

Page 31: ...mal Fast Electrode directed ahead of bead Electrode pointed back into bead Direction Of Welding The Drag or Pull technique is generally recommended when welding with flux cored tubular wire Weld bead shape depends on gun angle direction of travel electrode extension stick out travel speed thickness of base metal wire feed speed weld current and voltage 9 5 Conditions That Affect Weld Bead Shape Gu...

Page 32: ...se weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 6 Gun Movement During Welding 9 7 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 8 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer...

Page 33: ... wire and change to correct polarity at welding power source 9 10 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc GMAW Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for le...

Page 34: ...c on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 13 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld m...

Page 35: ...ses Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 9 16 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 Act...

Page 36: ...wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows GMAW 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 ...

Page 37: ...lacement Gun 8 ft 2 4 m length 030 035 0 8 0 9 mm Wire Size 268546 770198 Regulator Flowmeter For Argon and Argon mixed shielding gas Use with replace ment hose 269815 Available at farm and tool supply retailers Available at Hobart Miller welding distributors 10 3 Consumables Item Hobart Package Part No Miller Package Part No Contact Tips 023 025 in 0 6 mm 770174 5 per package 087299 10 per packag...

Page 38: ...Notes ...

Page 39: ...the product they are installed in or for a minimum of one year whichever is greater HF Units MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Water Cooling Systems 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...

Page 40: ...LC 2019 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...

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