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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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ACCESSORIES/CONSUMABLES

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WARRANTY

Содержание H-10 Gun

Страница 1: ...Processes OM 925 217 694F 2010 04 Handler 140 And H 10 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding R ...

Страница 2: ...oducts Please 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 pa...

Страница 3: ...ONS 11 4 1 Specifications 11 4 2 Duty Cycle And Overheating 12 4 3 Volt Ampere Curves 13 SECTION 5 INSTALLATION 14 5 1 Installing Welding Gun 14 5 2 Installing Work Clamp 14 5 3 Process Polarity Table 15 5 4 Changing Polarity 15 5 5 Installing Gas Supply 16 5 6 Serial Number And Rating Label Location 17 5 7 Selecting A Location And Connecting Input Power 17 5 8 Installing Wire Spool And Adjusting ...

Страница 4: ... 9 7 Good Weld Bead Characteristics 36 9 8 Troubleshooting Excessive Spatter 37 9 9 Troubleshooting Porosity 37 9 10 Troubleshooting Excessive Penetration 37 9 11 Troubleshooting Lack Of Penetration 38 9 12 Troubleshooting Incomplete Fusion 38 9 13 Troubleshooting Burn Through 38 9 14 Troubleshooting Waviness Of Bead 39 9 15 Troubleshooting Distortion 39 9 16 Common MIG Shielding Gases 40 9 17 Tro...

Страница 5: ...ds 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 semiautomaticDC 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 volt...

Страница 6: ...ess they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw fr...

Страница 7: ...anels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing uni...

Страница 8: ...eb site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa 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 S...

Страница 9: ...ant électrique s avère 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 ...

Страница 10: ...u laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le cont...

Страница 11: ... D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonctionne...

Страница 12: ...te et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipement commandé par ordinateur tel que les robots D Veiller à ce que tout l équipement de la zone de soudage soit compat...

Страница 13: ...5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov NIO...

Страница 14: ...OM 925 Page 10 ...

Страница 15: ...g Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 115 V 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 90 A 19 Volts DC 20 Duty Cycle 63 A 21 Volts DC 20 Duty Cycle 25 140 28 20 15 2 90 2 20 2 50 1 77 57 lb 26 kg Length 19 1 2 in 495 mm Width 10 5 8 in 270 mm Height 12 3 8 in 314 mm Wire Type And Diameter Solid Stainless Flux Cored Aluminum Wire ...

Страница 16: ...hermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding 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 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 Weldi...

Страница 17: ...curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown ssb1 1 10 91 217 624 A 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 ...

Страница 18: ...le terminals in unit Polarity is not important Close door 4 1 2 3 Correct Incorrect Be sure that gun end is tight against drive assembly 3 Gun Fully Seated 3 Gun Not Seated Exposed O rings will cause shielding gas leakage 5 2 Installing Work Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable 6 Insulating Sleeves Slide one insulating sleeve over wo...

Страница 19: ...hielding wire no 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...

Страница 20: ...e between 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 i...

Страница 21: ...ded on back cover of this manual 5 7 Selecting A Location And Connecting Input Power 1 Grounded Receptacle A 115 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 2 Plug From Unit Select extension cord of 12 AWG for up to 50 ft 15 m or 10 AWG for 50 up to 100 ft 30 m Special installation may be required where gasoline or volatile liquids are pres...

Страница 22: ...ed to turn spool tension 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 ...

Страница 23: ...r Install nozzle Flux 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 contac...

Страница 24: ...le Lay gun cable out straight 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 7 4 Hold wire tightly to keep it from unraveling 6 in 150 mm 6 1 3 4 5 2 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 h...

Страница 25: ...e 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 Tighten 1 2 3 4 Use pressure indicator scale to set a desired drive roll pressure Start with a setting of 2 or 3 on the scale Pressure Indicator Scale Tighten 1 2 3 4 Be sure that wire is positioned in proper feed roll groove Clos...

Страница 26: ...increases wire speed range also increases see weld setting label in welding power source or Section 6 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 6 2 Do not switch under load Switch must click into detent position for weld output Ref 230 002 A 2 3 1 NE PAS CHANGER DE PROCÉDÉ ...

Страница 27: ...rtWelders com OM 925 Page 23 Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Страница 28: ... A complete Parts List is available at www HobartWelders com OM 925 Page 24 6 2 Weld Parameter Chart ...

Страница 29: ... A complete Parts List is available at www HobartWelders com OM 925 Page 25 217 618 A ...

Страница 30: ...onths l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals 6 Months OR Inside Unit 7 2 Overload Protection 802 441 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becom...

Страница 31: ... on the opposite side of the drive 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 ...

Страница 32: ...l wire outlet guide 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 adapter gas diffuser and wire outlet guide Blow out gun c...

Страница 33: ...head tube out by hand Hand tighten 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 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 replaci...

Страница 34: ...d 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 Adjust drive roll pressure see Section 5 10 Change to proper drive roll groove see Section 7 4 Readjust hub tension see...

Страница 35: ...OM 925 Page 31 SECTION 8 ELECTRICAL DIAGRAM 230 952 A Figure 8 1 Circuit Diagram ...

Страница 36: ...r Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp 9 1 Typical MIG Process Connections 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 Ref 801 909 A ...

Страница 37: ...rameters 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 u...

Страница 38: ...n 13 mm past end of nozzle and tip of wire is positioned correctly on seam 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 39: ...lectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage 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 40: ... 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 layer f...

Страница 41: ...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 42: ...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 43: ...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 44: ... damaged 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 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 drive housing properly L...

Страница 45: ...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 46: ... 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 10 3 Replacement Drive Rolls For All Feed Head Assemblies PART NO WIRE DIAMETER INCHES mm 202 925 023 025 6 and 030 035 8 and 9 202 926 030 035 8 and 9 and 045 1 2 VK Groove 10 4 Regulator Flowmeter PART N...

Страница 47: ... s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are...

Страница 48: ...utor 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 the Delivering Carrier ...

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