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TABLE OF CONTENTS

SECTION 9

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MIG WELDING (GMAW) GUIDELINES

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9-1. Typical MIG Process Connections

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9-2. Typical MIG Process Control Settings

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9-3. Holding And Positioning Welding Gun

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9-4. Conditions That Affect Weld Bead Shape

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9-5. Gun Movement During Welding

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9-6. Poor Weld Bead Characteristics

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9-7. Good Weld Bead Characteristics

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9-8. Troubleshooting

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Excessive Spatter

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9-9. Troubleshooting

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Porosity

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9-10. Troubleshooting

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Excessive Penetration

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9-11. Troubleshooting

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Lack Of Penetration

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9-12. Troubleshooting

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Incomplete Fusion

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9-13. Troubleshooting

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Burn-Through

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9-14. Troubleshooting

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Waviness Of Bead

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9-15. Troubleshooting

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Distortion

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9-16. Common MIG Shielding Gases

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9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

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SECTION 10

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PARTS LIST

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WARRANTY

Содержание H-10 Gun

Страница 1: ...ocesses OM 925 217 694B August 2004 Handler 140 180 And H 10 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding Visit our website at www HobartWelders com R ...

Страница 2: ... take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will...

Страница 3: ...mpere Curves 11 SECTION 5 INSTALLATION 12 5 1 Installing Welding Gun 12 5 2 Installing Work Clamp 12 5 3 Process Polarity Table 13 5 4 Changing Polarity 13 5 5 Installing Gas Supply 14 5 6 Selecting A Location And Connecting Input Power For 115 VAC Model 15 5 7 Selecting A Location And Connecting Input Power For 230 VAC Model 16 5 8 Electrical Service Guide For 230 VAC Model 17 5 9 Installing Wire...

Страница 4: ...tics 35 9 7 Good Weld Bead Characteristics 35 9 8 Troubleshooting Excessive Spatter 36 9 9 Troubleshooting Porosity 36 9 10 Troubleshooting Excessive Penetration 36 9 11 Troubleshooting Lack Of Penetration 37 9 12 Troubleshooting Incomplete Fusion 37 9 13 Troubleshooting Burn Through 37 9 14 Troubleshooting Waviness Of Bead 38 9 15 Troubleshooting Distortion 38 9 16 Common MIG Shielding Gases 39 9...

Страница 5: ...hat cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not d...

Страница 6: ...elding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag ...

Страница 7: ...ing a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interf...

Страница 8: ...ne 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha g...

Страница 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D Pour exécuter les branchements d entrée fixer d abord le conducteur de mise à la terre adéquat et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation et s assurer qu il n est ni endommagé ni dénudé le remplacer immédiatement s il es...

Страница 10: ...ls que des gants en cuir une chemise en tissu épais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJETÉES peu vent blesser les yeux D Le soudage le burinage le passage de la pièce à la brosse métallique et le meulage provoquent l émission d étincelles et...

Страница 11: ...spositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de causer des interférences D Le rayonnement haute fréquence peut causer des interférences avec les équipements de radio navigation et de communication les services de sécurité et les ordinateurs D Ne demander qu à des personnes qualifiées familiarisées avec les équipements électroniques de faire fonctionner l installation D L util...

Страница 12: ...for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux Téléphone pour la Région 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs électromagnétiques Données sur le soudage électrique et les effe...

Страница 13: ... 314 mm Wire Type Solid Stainless Flux Cored Aluminum Wire Feed Speed Range Wire Type And Diameter 023 035 in 0 6 0 9 mm 030 035 in 0 8 0 9 mm 030 in 0 8 mm 50 740 IPM 1 3 18 8 m min At No Load 40 700 IPM 1 0 17 8 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 We...

Страница 14: ...ding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 217 623 A 217 757 A A 115 VAC Model B 230 VAC Model 20 duty cycle at 90 amps 30 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz 1 4 10 20 40 60 100 2 6 80 8 10 20 40 60 80 100 200 140 Duty Cycle Output Amperes 10 20 40 60 80 100 200 10 20 30 40 50 60 70 80 100 130 1...

Страница 15: ...ll between the curves shown ssb1 1 10 91 217 624 A 217 758 A A 115 VAC Model B 230 VAC Model RANGE4 RANGE3 RANGE2 RANGE1 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 0 0 5 0 10 0 15 0 20 0 25 0 30 0 Amperage Voltage RANGE1 RANGE 2 RANGE3 RANGE4 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 0 0 5 0 10 0 15 0 20 0 25 0 30 0 Amperage Voltage ...

Страница 16: ...ing gas 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 5 2 Installing Work Clamp 1 Insulating Sleeves 2 Nut 3 Work Cable From Unit Slide one insulating sleeve over work cable before connecting to clamp 4 Work Clamp 5 Screw 6 Work Clamp Tabs Bend tabs ...

Страница 17: ...o shielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal CHANGING POLARITY 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 polarity and see Section 5 3 Close door Ref 209 228 Ref 209 229 1 2 DC...

Страница 18: ...plied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Turn flow adjust screw to increase or decrease gas flow Flow 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 Ch...

Страница 19: ...dual branch circuit protected by time delay fuses or circuit breaker is required 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 3 803 712 B 2 1 18 in 460 mm 18 in 460 mm ...

Страница 20: ...nect plug to receptacle 4 Line Disconnect Device See Section 5 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 94 803 713 B 18 in 457 mm of space for airflow L1 L2 230 VAC 1 Y Always connect grounding conductor first GND PE 3 Y Do not move or operate unit where it could tip 2 L1 L2 4 1 ...

Страница 21: ... circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 5 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 ...

Страница 22: ...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 Turn power on Be sure that Voltage range switch is set 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 or if set in the PURGE position 6 in 150 mm Tighten 1 2 3 4 Use pressur...

Страница 23: ... the selected number the thicker the material that can be welded see weld setting label in welding power source or Sections 6 2 and 6 3 as applicable Do not switch under load Switch must click into detent position 1 2 3 4 or purge for proper contact 4 Voltage Switch Purge Position In purge position fan runs but there is no weld output or wire feed Use PURGE setting when adjusting gas flow at the r...

Страница 24: ...OM 925 Page 20 6 2 Weld Parameter Chart For 115 VAC Model ...

Страница 25: ...OM 925 Page 21 217 618 A ...

Страница 26: ...OM 925 Page 22 6 3 Weld Parameter Chart For 230 VAC Model ...

Страница 27: ...OM 925 Page 23 217 754 B ...

Страница 28: ...ths 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 resets allowing dri...

Страница 29: ...ive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 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 Ref 803 714 A 023 025 Groove 030 035 Groove Stamped 024 Stamped 030 035 4 1 2 3 7 5 Replacing Gun Contact Tip Ref 802 399 A Y Turn Off power ...

Страница 30: ... 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 adapter gas diffuser and wire outlet guide Blow out gun casing 10 mm ...

Страница 31: ...hten 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 Reassemble in reverse order If replacing head tube continue to end...

Страница 32: ...nections see Section 5 4 Check thumbscrew securing gun end to feed head adapter and tighten if necessary 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 Electrode wire feeding stops during welding Straightengun cable and or replace damaged parts welding Adjust drive roll pressure see Section 5 10 Change to ...

Страница 33: ...OM 925 Page 29 SECTION 8 ELECTRICAL DIAGRAM 217 621 A Figure 8 1 Circuit Diagram For 115 VAC Model ...

Страница 34: ...OM 925 Page 30 217 755 A Figure 8 2 Circuit Diagram For 230 VAC Model ...

Страница 35: ...ns Y 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 Wire Feeder Power Source Workpiece Gun Regulator Flowmeter Gas Hose Shielding Gas Work Clamp light mig 5 97 Ref 803 715 A ...

Страница 36: ...ers 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in 3 5 in per ampere 2 in per ampere 1 6 in per ampere Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Low voltage wire stubs into work High voltage arc is unstab...

Страница 37: ...3 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 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 ...

Страница 38: ...ctrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WELD BEAD PROFILES 10 10 GUN TRAVEL SPEED S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast ...

Страница 39: ...ent Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 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 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or laye...

Страница 40: ...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 ...

Страница 41: ...elding power source 9 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 Imp...

Страница 42: ...pport hand on solid surface or use two hands 9 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 ...

Страница 43: ...ged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls wire feed rolls bird nesting Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into ...

Страница 44: ...cessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary ...

Страница 45: ...OM 925 Page 41 Notes ...

Страница 46: ...Hardware is common and not available unless listed 803 716 B 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 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 Figure 10 1 Main Assembly ...

Страница 47: ...063 MOTOR fan 115 VAC model 1 18 196 064 MOTOR fan 230 VAC model 1 19 409 953 001 BLADE fan cooling 1 20 217 096 TRANSFORMER power assy 115 VAC model 1 20 217 389 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 ...

Страница 48: ...del 1 50 221 079 LABEL weld chart 115 VAC model French 1 50 217 754 LABEL weld chart 230 VAC model 1 50 221 080 LABEL weld chart 230 VAC model French 1 51 204 711 LATCH 1 52 217 584 CONTACTOR 115 VAC model 1 52 217 585 CONTACTOR 230 VAC model 1 53 203 572 LABEL warn gen precaution EN FR models only 1 54 LABEL nameplate order by model and serial number 1 When ordering a component originally display...

Страница 49: ...head 1 6 169 738 NUT locking handle 1 7 169 719 NUT jam 1 8 079 975 O RING 187 ID x 103CS rbr 1 9 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 9 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 9 194 012 LINER monocoil 035 045 wire 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 2...

Страница 50: ...187 Running Gear Cylinder Rack For One Small Gas Cylinder 100 lb 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 lb 34 kg max 195 957 H 10 Replacement Gun 10 ft length 030 035 wire size 195 186 Protective Cover Weatherproof nylon 212 492 Regulator Flowmeter For use with CO2 shielding gas 10 50 CFH NOTE If individual parts are required see Parts List chapter of this...

Страница 51: ...3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines...

Страница 52: ...r To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact th...

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