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OM-944 Page 35

7-11. Troubleshooting – Lack Of Penetration

Lack Of Penetration – shallow
fusion between weld metal and
base metal.

Lack of Penetration

Good Penetration

S-0638

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.

Improper weld technique.

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc 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.

7-12. 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.

Improper welding technique.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

7-13. Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal
resulting in holes where no metal remains.

S-0640

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

Содержание H-10

Страница 1: ...Processes OM 944 196 639C October 2001 Handler 135 175 And H 10 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding ...

Страница 2: ...e 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 then help you to decide which exact part you may need to fix the problem Warranty and service information for your particul...

Страница 3: ...ATION 19 4 1 Controls 19 4 2 Weld Parameters For 115 VAC Model 20 4 3 Weld Parameters For 230 VAC Model 21 SECTION 5 MAINTENANCE TROUBLESHOOTING 22 5 1 Routine Maintenance 22 5 2 Overload Protection 22 5 3 Drive Motor Protection 22 5 4 Changing Drive Roll Or Wire Inlet Guide 23 5 5 Replacing Gun Contact Tip 23 5 6 Cleaning Or Replacing Gun Liner 24 5 7 Replacing Switch And Or Head Tube 25 5 8 Trou...

Страница 4: ......

Страница 5: ... 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 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...

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: ...aintained 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 interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area is ...

Страница 8: ...s a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one sid...

Страница 9: ...on 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 En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement s ...

Страница 10: ... D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à l...

Страница 11: ...ispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l installa ...

Страница 12: ...tiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de pre...

Страница 13: ...030 045 in 0 8 1 1 mm 030 035 in 0 8 0 9 mm 370 840 IPM 9 2 21 8 m min At No Load 50 800 IPM 1 3 20 3 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 Weight W Gun Overall Dimensions 130 A 20 Volts DC 30 Duty Cycle At 60 Hz Input 20 Duty Cycle At 50 Hz Input 30 175...

Страница 14: ...Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 196 617 196 618 A 115 VAC Model B 230 VAC Model 3 Minutes Welding 7 Minutes Resting Duty Cycle Output Amperes 10 20 40 60 80 100 200 10 20 30 40 50 60 70 80 100 130 20 duty cycle at 90 amps 30 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz 2 Minutes Welding 8 ...

Страница 15: ...between the curves shown ssb1 1 10 91 196 608 196 609 A 115 VAC Model B 230 VAC Model 0 0 5 0 10 0 15 0 20 0 25 0 30 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 LOAD AMPS OUTPUT VOLTS Range 4 Range 3 Range 2 Range 1 0 0 5 0 10 0 15 0 20 0 25 0 30 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 LOAD AMPS OUTPUT VOLTS Range 4 Range 3 Range 2 Range 1 ...

Страница 16: ...ainst drive assembly Tighten thumbscrew 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 3 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 802 456 1 2 3 4 5 Tools Needed 3 8 7 16 in...

Страница 17: ...tive output terminal FCAW Self shielding wire no shielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal 3 4 Changing Polarity 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturer s recommended po larity and see Section 3 3 Close door ...

Страница 18: ...vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufactur er s recommended flow rate 8 CO2 Adapter Customer Sup plied 9 O Ring Customer Supplied Install ...

Страница 19: ...dual branch circuit protected by time de lay fuses or circuit breaker is re quired 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 2 1 3 18 in 460 mm 18 in 460 mm 802 442 ...

Страница 20: ...eptacle 4 Line Disconnect Device See Section 3 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 94 802 443 Ref 802 085 1 18 in 457 mm of space for airflow L1 L2 L1 L2 2 230 VAC 1 Y Always connect grounding conductor first GND PE 4 3 Y Do not move or operate unit where it could tip ...

Страница 21: ...Max Recommended Input Conductor Length In Feet Meters 66 20 Min Grounding Conductor Size In AWG Kcmil 12 Reference 1996 National Electrical Code NEC S 0092 J 3 9 Installing Wire Spool And Adjusting Hub Tension S 0499 15 16 in Standard Wire Spool 8 in 1 Lb Wire Spool 4 in Turn wingnut When a slight force is needed to turn spool tension is set Tools Needed Adjusting Hub Tension Install spool so weld...

Страница 22: ...Tighten Remove gun nozzle and contact tip Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Hold wire tightly to keep it from unraveling Ref 802 444 Ref 205 837 WOOD Feed 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 Rein...

Страница 23: ... switch under load Switch must click into detent position 1 2 3 4 or purge for proper contact 2 Voltage Switch Purge 0 Position In purge position fan runs but there is no weld output 3 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting in creases wire speed range also in creases see weld setting label in welding power source or Sections 4 2 or 4 3 as applicable 4 ...

Страница 24: ...OM 944 Page 20 4 2 Weld Parameters For 115 VAC Model 196 052 ...

Страница 25: ...OM 944 Page 21 4 3 Weld Parameters For 230 VAC Model 196 081 A ...

Страница 26: ...ths Blow out or vacuum inside During heavy service clean monthly Or 5 2 Overload Protection 802 441 1 Circuit Breaker CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset breaker 1 5 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 27: ...ide of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 3 10 NOTE when changing drive rolls make sure the woodruff key is on the motor shaft and not in the old drive roll 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 Ref 802 444 802 139 5 5 Replacing Gun Contact Tip Ref 802 399 A Y Turn Off power before replaci...

Страница 28: ...1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tight en 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 29: ...ten 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 Reas semble in reverse order If replacing head tube continue to end...

Страница 30: ...screw 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 4 1 Electrode wire feeding stops during Straightengun cable and or replace damaged parts welding Adjust drive roll pressure see Section 3 10 Change to proper drive roll groove see Section 5 4 Rea...

Страница 31: ...OM 944 Page 27 SECTION 6 ELECTRICAL DIAGRAM 194 324 NEUTRAL Figure 6 1 Circuit Diagram For 115 VAC Model ...

Страница 32: ...OM 944 Page 28 194 325 Figure 6 2 Circuit Diagram For 230 VAC Model ...

Страница 33: ...tions 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 Shielding Gas Work Clamp light mig 5 967 Ref 802 445 ...

Страница 34: ...35 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ipm 1 6 x 125 A 200 ipm 3 5 x 125 A 437 ipm Set voltage midway between high low voltage Low voltage wire stubs into work High voltage arc is unstable spatter 125 A based on 1 8 in Thickness to Amperage m...

Страница 35: ...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 GROOVE WELDS FILLET WELDS End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View Of Gun Angle 1 0 15 S 0421 A ...

Страница 36: ...trode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS STICKOUT FILLET WELD ELECTRODE EXTENSIONS STICKOUT Push Perpendicular Drag GUN TRAVEL SPEED Slow Normal Fast S 0634 ...

Страница 37: ...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 7 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 7 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or laye...

Страница 38: ...nsufficient 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 ...

Страница 39: ...n 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 Improper welding technique Place stringer bead in proper loc...

Страница 40: ...pport hand on solid surface or use two hands 7 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 41: ... most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Positions Argon 25 CO2 Flat Horizontal1 Fillet All Positions All Positions2 CO2 Flat Horizontal1 Fillet All Positions Tri Mix3 All Positions 1 Globular Transfer 2 Single Pass Welding Only 3 90 HE 7 1 2 AR 2...

Страница 42: ...IST Hardware is common and not available unless listed 802 449 B 3 4 9 8 32 35 13 5 34 33 11 12 24 26 2 17 6 18 10 38 37 42 1 31 14 16 36 29 30 15 27 28 41 25 23 22 19 21 20 7 39 40 47 46 45 44 43 48 49 50 51 Figure 8 1 Main Assembly ...

Страница 43: ...RD ASSY control 115 VAC model 1 13 195 887 CIRCUIT CARD ASSY control 230 VAC model 1 14 409 477 SWITCH rotary 25A 5 position 1 15 196 575 SWITCH rocker SPST 115 VAC model 1 15 196 574 SWITCH rocker DPST 230 VAC model 1 16 194 513 POTENTIOMETER 1 17 193 144 INSULATOR output stud 1 18 134 201 STAND OFF 1 19 203 556 SHAFT spool hub 1 20 409 615 002 WASHER spring finger 2 21 203 555 WASHER brake 1 22 ...

Страница 44: ...3 081 SCREW feed roll 1 47 196 052 LABEL weld chart 115 VAC model 1 47 196 081 LABEL weld chart 230 VAC model 1 48 010368 CLAMP work 1 49 089 899 LATCH 1 50 198 585 PLATE support 230 VAC model only 1 51 203 390 KEY woodruff 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only...

Страница 45: ...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 11 196 255 SWITCH trigger 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Table 8 1 Optional Drive Rolls For All Feed Head ...

Страница 46: ...Notes ...

Страница 47: ...obart s 5 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 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warra...

Страница 48: ...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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