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OM-283007 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som 2018

01

7

Protect yourself and others from injury —

 

read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! 

 Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.
Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this equipment. A qualified person is defined as one

who, by possession of a recognized degree, certificate, or

professional standing, or who by extensive knowledge, train-

ing and experience, has successfully demonstrated ability to

solve or resolve problems relating to the subject matter, the

work, or the project and has received safety training to recog-

nize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks

or  severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D

Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on

unit.

D

Additional safety precautions are required when any of the follow-

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

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

D

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D

Always verify the supply ground 

 check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that 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

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D

Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or repaired cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D

Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in

use.

D

Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

D

Turn off unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on

equipment.

D

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

Содержание Handler 125

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 38: ...Notes ...

Страница 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...

Страница 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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