Hobart H100S2-10 Technical Manual Download Page 9

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TM-258 267 Page 7

Handler 140

4-4. Process/Polarity Table

Process

Polarity

Cable Connections

Cable To Gun

Cable To Work

GMAW

−

Solid wire with shielding

gas

DCEP

−

Reverse polarity

Connect to positive (+) output

terminal

Connect to negative (

−

) output ter-

minal

FCAW

−

Self-shielding wire

−

shielding gas

DCEN

−

Straight Polarity

Connect to negative (

−

) output

terminal

Connect to positive (+) output termi-

nal

4-5. Changing Polarity

Lead Connections For Direct

Current Electrode Negative

(DCEN)

Lead Connections For Direct

Current Electrode Positive

(DCEP)

Always read and follow wire

manufacturer’s recommended

polarity, and see Section 4-4.
Close door.

258 321-A

Summary of Contents for H100S2-10

Page 1: ...rtWelders com TM 258 267B 2013 03 Eff w Serial No MC370275Y Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding Handler 140 And H100S2 10 Gun R File MIG GMAW ...

Page 2: ... Hub Tension 10 4 10 Installing Contact Tip And Nozzle 11 4 11 Threading Welding Wire 12 SECTION 5 OPERATION 14 5 1 Controls 14 5 2 Weld Parameter Chart 15 SECTION 6 THEORY OF OPERATION 16 SECTION 7 TROUBLESHOOTING 18 7 1 Troubleshooting Table 18 7 2 Troubleshooting Circuit Diagram For Welding Power Source 20 7 3 Control Board PC1 Testing Information Use With Section 7 4 22 7 4 Control Board PC1 T...

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: ...abel Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 3 2 Specifications Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 115 V 60 Hz Single Phase...

Page 6: ...n damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 217 623 A 20 duty cycle at 90 amps 1 4 10 20 40 60 100 2 6 80 8 10 20 40 60 80 100 200 140 Duty Cycle Output Amperes 2 Minutes Welding 8 Minutes Resting 3 4 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source ...

Page 7: ... From Unit 2 Grounded Receptacle 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 2 258 641 A Do not move or operate unit where it could tip 1 18 in 460 mm 18 in 460 mm ...

Page 8: ...hing male terminals in unit Polarity is not important Close door Correct Incorrect Be sure that gun end is tight against drive assembly Gun Fully Seated 3 Gun Not Seated Exposed O rings will cause shielding gas leakage 4 1 2 3 4 3 Installing 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 hardw...

Page 9: ...to negative output ter minal FCAW Self shielding wire no shielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output termi nal 4 5 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 polarity and see Section 4 4 Clo...

Page 10: ...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 feedhead 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 clos...

Page 11: ... 20 A 115 volts AC 20 ampere individual circuit protected by time delay fuses or circuit breaker is required 1 Plug From Unit 2 Receptacle NEMA Type 5 15R Customer Supplied 2 Input6 2011 03 258 641 A Do not move or operate unit where it could tip 1 4 8 Selecting Extension Cord Use Shortest Cord Possible Single Phase AC Input Voltage Conductor Size AWG mm2 10 5 3 12 3 3 Maximum Allowable Cord Lengt...

Page 12: ...n is set 1 2 in Tools Needed 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 803 012 803 013 B Ref 802 971 C Align locking hole in spool with locking pin on spool hub ...

Page 13: ...Nozzle Optional MIG Nozzle Standard Use with flux cored wire 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 unti...

Page 14: ...raight Tools Needed Pull and hold wire cut off end Open pressure assembly Make sure feed roll is set to correct groove to match wire size see Section 8 4 Hold wire tightly to keep it from unraveling 6 in 150 mm 1 2 4 in 102 mm Straighten approximately 3 or 4 inches 76 or 102 mm of wire before inserting wire into guides Push wire thru guides into gun continue to hold wire 3 6 1 3 4 5 2 ...

Page 15: ... to range 1 2 3 or 4 to feed wire Rotate knob until it clicks into detent Wire will not feed if range switch is set between ranges Use pressure indicator scale to set a desired drive roll pressure Start with a setting of 2 on the scale Pressure Indicator Scale Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Be sure that tip matches ...

Page 16: ... 5 2 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 5 2 Do not switch under load Switch must click into detent position for weld output 4 Over Temperature Light Light illuminates if main transformer over heats 5 Gun Trigger Switch Pressing gun trigger energizes wire feed motor and ...

Page 17: ...TM 258 267 Page 15 Handler 140 5 2 Weld Parameter Chart 258 069 A ...

Page 18: ...d starting through the motor relay Provides a bleeder resistor for capacitor C1 8 Thermostat TP1 If main transformer overheats TP1 opens gun switch circuit stopping all weld output 9 Gun Trigger Receptacle RC3 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 Moto...

Page 19: ...olarity Changeover Block Wire Drive Motor 11 8 9 Thermostat TP1 Gun Trigger Receptacle RC3 10 Wire Speed Control R2 14 Output Capacitor C1 Smooths DC weld voltage from rectifier SR1 15 Stabilizer L1 Smooths DC weld current 16 Polarity Changeover Block Terminals allow changing between DCEP and DCEN processes 17 Over Temperature Light PL1 Indicates that the transformer is overheated ...

Page 20: ...ain rectifier SR1 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 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts see Section 8 6 Rea...

Page 21: ... 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 8 4 and or 8 6 Readjust wire reel hub tension Check voltage and connections of wire drive motor Replace motor if necessary Improper or no shielding ...

Page 22: ... 267 Page 20 Handler 140 7 2 Troubleshooting Circuit Diagram For Welding Power Source Test Equipment Needed V1 V2 V3 V4 V5 V7 R7 V6 R6 V10 V8 V9 R11 R9 R1 See also Section 7 3 for PC1 data R8 R10 R2 R3 R4 R5 ...

Page 23: ...nit turned on Voltage switch S2 in position 4 and gun trigger closed 27 4 volts DC with unit turned on Voltage switch S2 in position 5 and gun trigger closed V9 115 volts AC with unit turned on and gun trigger closed V10 2 9 to 15 4 volts DC with unit turned on Wire Speed control R2 from min to max with Voltage switch S2 in position 1 3 7 to 17 5 volts DC with unit turned on Wire Speed control R2 ...

Page 24: ...ler 140 7 3 Control Board PC1 Testing Information Use With Section 7 4 Be sure plugs are secure before testing See Section 7 4 for specific values during testing 1 Control Board PC1 Test Equipment Needed 803 717 A 256 988 A 1 ...

Page 25: ...RC2 1 30 volts DC reference to Pin 5 2 30 volts DC reference to Pin 5 gun trigger closed 3 30 volts DC reference to Pin 5 4 29 volts DC reference to Pin 5 gun trigger closed 5 Circuit common 6 27 volts DC reference to Pin 5 gun trigger closed 7 27 volts DC with Wire Speed control R2 at maximum reference to Pin 5 6 3 volts DC with Wire Speed control R2 at minimum reference to Pin 5 8 Not used 9 10 ...

Page 26: ...abels l Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals 6 Months OR Inside Unit 8 2 Overload Protection 802 441 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 8 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun trig...

Page 27: ... 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 stickout is 3 8 in 9 5 mm from gun tip Actual drive roll may differ from that shown See Section 11 3 for additional drive roll configurat...

Page 28: ...ide so that 1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tighten 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 and tip adapter gas diffuser Blow out gun casing 10 mm 1 2 3 ...

Page 29: ... hand Hand tighten head tube into cable connector Place head tube in vice and tighten until nuts are tight 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 4 5 6 7 Remove from vice install switch housing 8 Install handle...

Page 30: ...TM 258 267 Page 28 Handler 140 Notes ...

Page 31: ...nor 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 MC370275YAnd following 257 502 A 257 500 A Circuit Board PC1 115 VAC Model MC370275Y and following 256 987 A Not included in this manual ...

Page 32: ...TM 258 267 Page 30 Handler 140 Figure 9 1 Circuit Diagram Eff w MC370275Y And Following ...

Page 33: ...TM 258 267 Page 31 Handler 140 257 502 A ...

Page 34: ...TM 258 267 Page 32 Handler 140 Figure 9 2 Wiring Diagram Eff w MC370275Y And Following ...

Page 35: ...TM 258 267 Page 33 Handler 140 257 500 A ...

Page 36: ...RC2 1 RC2 2 RC2 12 RC2 10 RC2 9 RC2 11 RC2 C5 C4 2 3 1 Q3 R16 R13 R14 R15 R7 1 R4 R2 R18 R17 29V R12 30V PTC2 C3 4 8 A1 C2 C1 3 2 1 Q2 D6 D7 D14 D9 D10 D12 D8 D5 NC 1 4 3 CR2 5 2 CR2 1 2 CR1 30V 29V D13 Figure 9 3 Circuit Diagram For 115 VAC Model Control Board PC1 Eff w MC370275Y And Following ...

Page 37: ...er 140 256 987 A AGND AGND HEATSINK VERTICAL AGND CAP CAP MOTOR MOTOR R3 8 RC2 7 RC2 VOUT 6 RC2 2 RC1 1 RC1 5 RC2 4 RC2 D2 D11 R8 R1 5 6 7 A1 5AMP_50V D3 D1 D15 D4 R5 5AMP_50V VOUT HS1 5AMP_50V 4 5 3 CR1 2 1 3 Q1 PTC1 WFS_REF ...

Page 38: ...TM 258 267 Page 36 Handler 140 Notes ...

Page 39: ...rtWelders com TM 258 267B 2013 03 Eff w Serial No MC370275Y Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding Handler 140 And H100S2 10 Gun R File MIG GMAW ...

Page 40: ... 10 PARTS LIST Hardware is common and not available unless listed 258 385 A 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Figure 10 1 Main Assembly ...

Page 41: ...6 Z1 203 868 Reactor Assy 1 27 SR1 193 191 Rectifier Assy 1 28 193 193 Bus Bar Positive 1 29 217 831 Baffle Center 1 30 405 576 001 Bushing Terminal 1 31 193 144 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 257 585 Switch Rotary 1 36 R2 209 873 Potentiometer 1 37 258 234 Panel Front W Nameplate 1 38 257 796 Clamp Work 1 39 196 619 Ca...

Page 42: ...7 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 ...

Page 43: ...ning 1 4 169 716 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 9 246 380 HOUSING power pin 1 10 245 927 CONNECTOR feeder 1 11 197 123 O RING 312 ID X 062 70 duro buna n 2 12 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 12 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 12 194 012 LINER monocoil 035 045 wire x ...

Page 44: ...placement Liners 023 025 in 0 6 mm 196 139 194 010 030 035 in 0 8 0 9 mm 196 139 194 011 035 045 in 0 9 1 2 mm 196 140 194 012 Available at farm and tool supply retailers Available at Hobart Miller welding distributors 11 3 Replacement Drive Rolls For All Feed Head Assemblies PART NO WIRE DIAMETER INCHES mm 237 338 023 025 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 246 565...

Page 45: ...Notes ...

Page 46: ...Notes ...

Page 47: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

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 ...

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