Hobart Multi-Handler 200 Owner'S Manual Download Page 61

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OM-285922 Page 58

12-8. Troubleshooting

−

Excessive Spatter

Excessive Spatter

−

scattering of molten metal particles that

cool to solid form near weld bead.

S-0636

Possible Causes

Corrective Actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage range.

Electrode extension (stickout) too long.

Use shorter electrode extension (stickout).

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Incorrect polarity.

Check polarity required by welding wire, and change to correct polarity at welding power source.

12-9. 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.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas.

Use welding grade shielding gas; change to different gas.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

12-10. Troubleshooting

−

Excessive Penetration

Good Penetration

Excessive Penetration

−

weld metal melting through base metal

and hanging underneath weld.

Excessive Penetration

S-0639

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase travel speed.

Summary of Contents for Multi-Handler 200

Page 1: ...www HobartWelders com Description OM 285922B 2020 08 Processes Multiprocess Welding Arc Welding Power Source And Wire Feeder Hobart Multi Handler 200 t ...

Page 2: ...g Agreement 11 4 3 Information About Default Weld Parameters And Settings 11 4 4 Unit Specifications For MIG GMAW 11 4 5 Unit Specifications For TIG GTAW 11 4 6 Unit Specifications For Stick SMAW 11 4 7 Environmental Specifications 12 4 8 Dimensions And Weight 12 4 9 Duty Cycle And Overheating For MIG GMAW 13 4 10 Duty Cycle And Overheating For TIG GTAW 14 4 11 Duty Cycle And Overheating For Stick...

Page 3: ...ination Of Tungsten 50 10 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines 51 SECTION 11 GUIDELINES FOR TIG WELDING GTAW 52 11 1 Positioning The Torch 52 11 2 Torch Movement During Welding 53 11 3 Positioning Torch Tungsten For Various Weld Joints 53 11 4 Lift Arc And HF TIG Start Procedures 54 SECTION 12 GMAW WELDING MIG GUIDELINES 55 SECT...

Page 4: ...llow ing 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 semiautomati...

Page 5: ...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 6: ...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 7: ...cuments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Website www csagrou...

Page 8: ... 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 métalliques telles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitab...

Page 9: ...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 10: ...vant de 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 u...

Page 11: ...ards Institute Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents Website www global ...

Page 12: ...electric shock from wiring Safe94 2012 08 When power is applied failed parts can explode or cause other parts to explode Safe26 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned of...

Page 13: ...ating Single Phase Remote Circuit Breaker Positive Negative X Duty Cycle Line Connection S Suitable for Some Hazardous Locations Increase Hz Hertz Single Phase Static Frequency Converter Transformer Rectifier Gas Postflow Lift Arc Operation GTAW Gas Tungsten Arc Welding Wire Feed Spool Gun Self Shielded Flux Cored Arc Welding FCAW Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW Lift Arc...

Page 14: ...mplied warranty of fitness for a particular purpose 4 4 Unit Specifications For MIG GMAW Do not use information in unit specifications table to determine electrical service requirements See Sections 5 3 5 5 and 5 6 for information on connecting input power Input Voltage Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 50 60 Hz Single Phase 120 ...

Page 15: ...d or stored outside IP21S 2014 06 B Temperature Specifications Operating Temperature Range Storage Transportation Temperature Range 14 to 104 F 10 to 40 C Output is degraded at temperatures above 104 F 40 C 4 to 131 F 20 to 55 C Temp_2016 07 20 80 in 530 mm 4 8 Dimensions And Weight Ref 500578 A 10 60 in 270 mm 13 40 in 340 mm 38 4 lb 17 4 kg Weight ...

Page 16: ...age or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6 Minutes Resting 2 Minutes Welding 8 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 60 Duty Cycle At 80A 120V Input 240V Input 20 Duty Cycle At 185A 40 Duty Cycle At 145A 6 Minutes Welding 4 Minutes Resting 0 20 40 6...

Page 17: ...ge or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6 Minutes Resting 2 Minutes Welding 8 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 40 Duty Cycle At 95A 120V Input 240V Input 20 Duty Cycle At 200A 0 20 40 60 80 100 120 140 160 180 200 220 240 10 100 Output Amperes ...

Page 18: ... for unit to cool Reduce amperage or duty cycle before starting to weld again NOTICE Exceeding duty cycle can damage unit and void warranty 4 Minutes Welding 6 Minutes Resting 2 Minutes Welding 8 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 Ref Duty Cycle Charts 40 Duty Cycle At 80A 120V Input 240V Input 20 Duty Cycle At 170A 0 20 40 60 80 100 120 140 160 180 200...

Page 19: ... or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Lifting Handle Use handle to lift unit 2 Line Disconnect Device Locate unit near correct input power supply 18 in 460 mm 18 in 460 mm 2 Do not move or operate unit where it could tip Movement Location And Airflow loc_smallmig2 2018 05 161 122 1 1 ...

Page 20: ...acle NEMA Type 6 50R Customer Supplied Follow electrical service guide for 240 VAC in Section 5 3 Do not use plug rating to size branch circuit protection Connecting Plug To Power Cord Align arrow on plug with arrow on power cord connector Push together Tighten threaded collar As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle MVP Plu...

Page 21: ...ize In AWG mm2 5 12 Reference 2020 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 recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and...

Page 22: ...n may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 See rating label on unit and check input voltage available at site For 120 volts AC input power a 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 1 Multi Voltage Plug And Power Cord Connector NEMA Type 5 15P Plug Shown For multi voltage plug ...

Page 23: ... never to a line terminal See rating label on unit and check input voltage available at site 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal 4 Disconnect Line Terminal 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 ...

Page 24: ...iliary power require ment at rated load is 10 KW continu ous 12 5 KW peak at 240 volts AC for full output Smaller generators will reduce output capability Engine Control Switch must be set at RUN position not RUN IDLE Set generator Fine Adjustment Control to 10 for maximum auxiliary power Generator settings if applicable Notes ...

Page 25: ...d or repaired cables 1 Negative Weld Output Terminal 2 Positive Weld Output Terminal 3 Stick Electrode Holder And Cable 4 Work Clamp And Cable Insert connectors fully into termi nals Rotate connector clockwise to lock in position Consult stick electrode manufac turer s guidelines for proper polarity and best results Ensure all connections are tight 4 1 2 3 3 4 ...

Page 26: ...inal 2 Positive Weld Output Terminal 3 TIG Torch And Cable 4 Work Clamp And Cable Connect TIG torch cable to the neg ative receptacle and connect work cable to the positive receptacle Turn connectors clockwise Ensure all connections are tight 5 Optional Foot Control with RJ 45 connector 6 RJ 45 Remote Control Receptacle Connect foot control to remote control receptacle 7 TIG Shielding Gas Connecti...

Page 27: ...sconnect input power before making connections 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Wire Drive Assembly Cable 4 Work Clamp And Cable Ensure all connections are tight 5 Gun End Connect gun end to drive assembly see Section 5 12 6 Trigger Control Cable 7 Four Pin Trigger Control Cable Receptacle Connect plug on end of cable to four pin receptacle on front of unit 8 M...

Page 28: ... Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide 4 Gun End Loosen knob Insert end of gun through opening in front panel until gun end bottoms against gun block Tighten knob 5 O Ring If o ring is visible the MIG gun is not inserted fully 6 Trigger Control Cable 7 Four Pin Trigger Control Cable Connection Connect plug on end of cable to four pin receptacle on front of unit 1 2 3 3 7 CORRECT INCORR...

Page 29: ...egulator flowmeter gas hose connection for gas type being used and the fitting on rear of welding power source Only one gas hose can be attached at a time 7 Flow Adjust Typical flow rate for CO2 shielding gas and MIG GMAW welding is 15 to 30 CFH cubic feet per hour 7 05 14 1 LPM and mixed gas is 25 to 45 CFH 11 75 21 15LPM Typical flow rate for Argon shielding gas and TIG GTAW welding is 15 to 25 ...

Page 30: ...2 4 in Wire Spool 3 8 in Wire Spool When a slight force is needed to turn spool tension is set 1 2 in Tools Needed Ref 287758A 803 012 803 013 B Ref 802 444 C Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool 2 1 When a slight force is needed to turn spool ten sion is set Align locking hole in spool with locking pin on spool hub Adapter and retainingring 3 ...

Page 31: ...e and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Ref 287758A 275167A 801 083 Ref 800 924 D Tighten 1 2 3 4 Pressure Indicator Scale Tighten 1 2 3 4 7 Use pressure i...

Page 32: ...essure Assembly Hold wire tightly to keep it from unraveling Rewind Wire Onto Spool Fasten End Of Wire To Spool Cut Off End Of Wire Loosen Knob Disconnect Gun Trigger Plug And Remove Gun From Unit 287758A Ref 802982A Ref 282722A Ref 282721A Knob Turn Off Power Tools Needed Insert Power Pin Connect Spool Gun Trigger Plug And Tighten Knob ...

Page 33: ...tive Output Receptacle 6 Negative Output Receptacle 7 TIG Remote Receptacle Connect optional foot control to unit 8 Process Select Button Press the button to select the desired process 9 Wire Feed Amperage Knob Controls wire feed speed in MIG process and amperage in the stick or TIG process See weld parameter chart for initial set tings 10 Power Switch 11 Shielding Gas Fitting 12 Circuit Breaker C...

Page 34: ... position 2 Display Three seconds into the power up process the screen will display the input voltage either 120V or 240V Ref 287758 A 1 2 6 3 Screen Wire Jog Mode 1 Display Jog mode is displayed when feed ing wire through the MIG gun 2 Wire Feed Knob Jog speed can be adjusted using the wire feed knob while in Jog mode Ref 287758 A 1 2 ...

Page 35: ... 5 11 for proper cable placement 2 Voltage Knob Adjust voltage knob per weld pa rameter chart for initial setting 3 Wire Feed Knob Adjust wire feed knob per weld pa rameter chart for initial setting 4 Display 5 Live Output Signal When the symbol is activated on the display the output is on The output is on in the MIG process when the trigger on the MIG gun or spoolgun is activated Ref 287758 A 1 2...

Page 36: ...ive and negative receptacles See section 5 11 for proper cable placement 2 Voltage Knob Adjust voltage knob per weld pa rameter chart for initial setting 3 Wire Feed Knob Adjust wire feed knob per weld pa rameter chart for initial setting 4 Display 5 Live Output Signal When the symbol is activated on the display the output is on The output is on in the Flux cored process when the trigger on the MI...

Page 37: ...o enter TIG process Check weld parameter chart for correct polarity at positive and negative receptacles See section 5 9 for proper cable placement 2 Amperage Knob Adjust amperage knob per weld pa rameter chart for initial setting 3 Display 4 Live Output signal When the symbol is activated on the display the output is on 5 Voltage Displayed The voltage is displayed only during welding Ref 287758 A...

Page 38: ...edal Push button to enter TIG process Check weld parameter chart for correct polarity at positive and negative receptacles See section 5 9 for proper cable placement 2 TIG Foot Pedal Connection 3 Amperage Knob Adjust amperage knob per weld pa rameter chart for initial setting 4 Display 5 Live Output signal When the symbol is activated on the display the output is on 6 Voltage Displayed The voltage...

Page 39: ...ative receptacles See section 5 8 for proper cable placement 2 Amperage Knob Adjust amperage knob per weld pa rameter chart for initial setting 3 Display 4 Live Output signal When the symbol is activated on the display the output is on The output is always on when the Stick process is selected 5 Voltage Displayed The voltage is displayed only during welding Ref 287758 A 1 2 3 4 5 ...

Page 40: ...ailable at www HobartWelders com OM 285922 Page 37 6 9 Screen Power Down Mode 1 Power Switch Push toggle to Off position 2 Display The screen displays the Powering Down message when the switch is powered off Ref 287758 A 1 2 Notes ...

Page 41: ...OM 285922 Page 38 SECTION 7 WELD PARAMETER CHARTS 7 1 Welding Parameters 120 Volt Ref 287984 B ...

Page 42: ... A complete Parts List is available at www HobartWelders com OM 285922 Page 39 Ref 287984 B ...

Page 43: ...OM 285922 Page 40 7 2 Welding Parameters 240 Volt Ref 287984 B ...

Page 44: ... A complete Parts List is available at www HobartWelders com OM 285922 Page 41 Ref 287984 B ...

Page 45: ... Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Every 6 Months OR Inside Unit Clean Drive Rolls 8 2 Overload Protection 500578A 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 ...

Page 46: ...he drive roll includes three different sized grooves The text aligned with the drive roll retaining pin indicates the selected groove 3 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retainingpin then rotate drive roll to desired slot See Section 14 2 for optional drive rolls 024 Groove 030 035 Groove 030 035 V Knurled Groove Groove Compatible Wire 024 030 ...

Page 47: ... the wire delivery circuit Check wire tension drive roll pres sure or obstruction in gun liner Fan Error Indicates a malfunction in the fan cooling sys tem Check for an obstruction in the fan blades or if the fan motor is not operating properly Shorted Trigger Indicates a malfunction in the MIG gun or spoolgun trigger circuit or the four pin recep tacle on front of the unit Shorted Trigger Indicat...

Page 48: ...Clear obstruction from fan The fan wiring harness is disconnected Connect the wiring harness The fan is damaged Contact Miller Electric Mfg LLC service department The control board is damaged Contact Miller Electric Mfg LLC service department Shorted trigger Release 4 pin trigger to clear error MIG gun or spool gun trigger is engaged on power up Release 4 pin trigger to clear error MIG gun trigger...

Page 49: ...o workpiece Fan not operating Unit not warmed up enough to require fan cooling Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor and control circuitry Stick welding problems Hard starts poor welding characteristics unusual spattering Use proper type and size of electrode Verify electrode polarity check and correct poor connections Make sure a...

Page 50: ...OM 285922 Page 47 Notes ...

Page 51: ...OM 285922 Page 48 SECTION 9 ELECTRICAL DIAGRAM Figure 9 1 Circuit Diagram ...

Page 52: ...OM 285922 Page 49 287757 A ...

Page 53: ...ngstens 010 in 25 mm Up to 15 Up to 15 020 in 50 mm 5 20 5 20 040 in 1 mm 15 80 15 80 1 16 in 1 6 mm 70 150 70 150 3 32 in 2 4 mm 150 250 140 235 1 8 in 3 2 mm 250 400 225 325 5 32 in 4 0 mm 400 500 300 400 3 16 in 4 8 mm 500 750 400 500 1 4 in 6 4 mm 750 1000 500 630 Typical argon shielding gas flow rates are 10 to 25 CFH cubic feet per hour Figures listed are a guide and are a composite of recom...

Page 54: ...evel radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Ideal Tungsten Preparation Stable Arc 1 Grinding Wheel Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality 2 Tungsten Electrode A 2 ce...

Page 55: ...Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 10 2 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade quate shielding gas coverage For exa...

Page 56: ...rch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool Repeat process Remove rod Welding direction 15 11 3 Positioning Torch Tungsten For Various Weld Joints 162003 0792 75 70 90 20 20 10 15 75 20 40 30 15 75 90 15 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint ...

Page 57: ...trode and workpiece The solid state output contactor does not energize until after electrode is touching work piece This allows electrode to touch workpiece without overheating sticking or getting contaminated Application Lift Arc is used for the DCEN or AC GTAW process when HF Start meth od is not permitted or to replace the scratch method HF Start When HF Start button light is On start arc as fo...

Page 58: ...ess to amperage A 0 001 in 0 025 mm 1 ampere 0 0625 in 1 59 mm 0 001 62 5 A 2 Select Wire Size See table below 3 Select Wire Feed Speed Amperage Wire feed speed amperage controls weld pene tration 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 ...

Page 59: ...0 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 12 3 Holding And Positioning Welding Gun Slow Fillet Weld Electode Extensions Stickout Electrode Extensions Stickout Gun Angles And Weld Bead Profiles 10 10 S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Weld bead shape d...

Page 60: ... weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 12 5 Gun Movement During Welding 12 6 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 12 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or laye...

Page 61: ...s in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shieldin...

Page 62: ...welding power source 12 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed I...

Page 63: ...port hand on solid surface or use two hands 12 15 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 Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower ...

Page 64: ...GMAW P Stainless Steel Spray Arc Aluminum Short Circuiting Aluminum GMAW P Aluminum Argon All Positions All Positions All Positions All Positions Argon 1 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 2 O2 Flat Horizontal Fillet All Positions Flat Horizontal Fillet Argon 5 CO2 Flat Horizontal Fillet All Positions Argon 10 CO2 Flat Horizontal Fillet All Positions All Positions...

Page 65: ...ch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows 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 Lo...

Page 66: ... less current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound Correct arc length is related to electrode di ameter Examine the weld...

Page 67: ...ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER MED 13 3 Striking An Arc S 0049 S 0050 Weld current starts when elec trode touches workpiece 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift elect...

Page 68: ...To produce the best results hold a short arc travel at a uniform speed and feed the electrode downward at a constant rate as it melts 1 1 2 2 Groove Welds Fillet Welds 13 5 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 13 6 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Unifor...

Page 69: ...ross gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the elec trode Do not let weave width ex ceed 2 1 2 times diameter of electrode 1 2 3 13 8 Electrode Movement During Welding 13 9 Welding Lap Joints S 0063 S 0064 1 Electrode 2 ...

Page 70: ...re good welds The single or double V groove weld is good for materials 3 16 3 4 in 5 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thickness you can weld from one side only Create a 30 degree bevel with oxy acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels 30...

Page 71: ...ble Causes Remedy Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Remedy Amperage too high for electrode Decrease amperage or select larger electrode Arc...

Page 72: ...Increase and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Remedy Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Remedy ...

Page 73: ... s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 14 2 Recommended MIG Spare Parts Quantity Description Part No 261157 Roll Drive 024 030 035V Wire 035VK Wire 1 202926 Roll Drive VK 030 035 045 Wire 1 271493 Lens Cover Replaceable 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested...

Page 74: ...Notes ...

Page 75: ...mum of one year whichever is greater HF Units MIG Flowgauge Regulators No Labor MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers 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 apply to 1 Consumable components s...

Page 76: ...LC 2020 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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