Hobart Welding Products Handler 135 Manual de usuario

TM-944C October 2003

Handler 135 (500 414) Eff. w/Serial No.

LB096205

Handler 175 (500 416) Eff. w/Serial No.

LB075197

Visit our website at

www.HobartWelders.com

Processes

Arc Welding Power Source And

Wire Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Handler 135 / 175

And H-10 Gun

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing Welding Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing Work Clamp 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Process/Polarity Table 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Changing Polarity 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Gas Supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 9. . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 10. . . . . . . . . . . . . . . . . . . . . . . .

3-8. Electrical Service Guide For 230 VAC Model 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing Wire Spool And Adjusting Hub Tension 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Threading Welding Wire 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld Parameter Chart For 115 VAC Model 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Weld Parameter Chart For 230 VAC Model 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − THEORY OF OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model) 22. . . . . . . . . . . . . . . . . .

6-3. Troubleshooting Circuit Diagram For Welding Power Source (230 VAC Model) 24. . . . . . . . . . . . . . . . . .

6-4. Control Board PC1 Testing Information (115 VAC Model) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Control Board PC1 Test Point Values (115 VAC Model) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Control Board PC1 Testing Information (230 VAC Model) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Control Board PC1 Test Point Values (230 VAC Model) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Overload Protection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Drive Motor Protection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Changing Drive Roll Or Wire Inlet Guide 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Replacing Gun Contact Tip 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Cleaning Or Replacing Gun Liner 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Replacing Switch And/Or Head Tube 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-944 Page 1Handler 135 / 175 ReturnTo Table Of Contents

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

safety_stm 5/97

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consultsymbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Servicing Hazards

YThe 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.

YOnly qualified persons should service, test, maintain, and re-

pair this unit.

YDuring servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using

linedisconnect switch, circuit breakers, or by removing plug from re-

ceptacle,or stop engine before servicing unless the procedure spe-

cifically requires an energized unit.

DInsulateyourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel

familiarwith and following standard safety practices do the job.

DWhentesting a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input

capacitorsaccording to instructions in Maintenance Section before

touchingany parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible

surfaces.

DDo not service unit near flammables.

FLYING METAL can injure eyes.

DWear safety glasses with side shields or face

shield during servicing.

DBe careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllowcooling period before working on welding

gun or torch.

EXPLODING PARTS can cause injury.

DFailedparts can explode or cause other parts to

explodewhen power is applied to inverters.

DAlways wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder

or stop engine before making or changing me-

ter lead connections.

DUse at least one meter lead that has a self-

retainingspring clip such as an alligator clip.

DRead instructions for test equipment.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

supportunit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep all doors, panels, covers, and guards

closed and securely in place.

TM-944 Page 2 Handler 135 / 175

Return To Table Of Contents

MOVING PARTS can cause injury.

DKeep away from moving parts.

DKeep away from pinch points such as drive

rolls.

MAGNETIC FIELDS can affect pacemakers.

DPacemakerwearers keep away from servicing

areas until consulting your doctor.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

startingto weld again.

DDo not block or filter airflow to unit.

H.F. RADIATION can cause interference.

DHigh-frequency(H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

DHave only qualified persons familiar with

electronicequipment install, test, and service

H.F. producing units.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipmentat once.

DHave the installation regularly checked and maintained.

DKeephigh-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimizethe possibility of interference.

READ INSTRUCTIONS.

DUse MILLER Testing Booklet (Part No. 150

853) when servicing this unit.

DConsultthe Owner’s Manual for welding safety

precautions.

DUse only genuine MILLER replacement parts.

1-3. California Proposition 65 Warnings

YWelding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

YBattery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

For Gasoline Engines:

YEngine exhaust contains chemicals known to the State of

Californiato cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

YDieselengine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Weldingcurrent, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is 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

weldingor 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 side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemakerwearers consult your doctor first. If cleared by your doctor,

thenfollowing the above procedures is recommended.

TM-944 Page 3Handler 135 / 175 Return To Table Of Contents

SECTION 2 − SPECIFICATIONS

2-1. Specifications

A. 115 VAC Model

Rated Welding

Output Amperage

Range

Maximum Open-

Circuit Voltage

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*

30 − 135 28 20

15*

2.90

2.20*

2.50

1.77*

55 lb

(25 kg)

Length: 18-7/8 in

(479 mm)

Width: 10-5/8 in

(270 mm)

Height: 12-3/8 in

(314 mm)

Wire Type

Solid/

Stainless Flux Cored/

Aluminum Wire Feed Speed Range

Wire Type

And Dia .024 − .030 in

(0.6 − 0.8 mm) .030 − .035 in

(0.8 − 0.9 mm)/

.030

(0.8 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

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 30 19.5 4.60 3.75 65 lb

(29.5 kg)

Length: 18-7/8 in

(479 mm)

Width: 10-5/8 in

(270 mm)

Height: 12-3/8 in

(314 mm)

Wire Type

Solid/

Stainless Flux Cored/

Aluminum Wire Feed Speed Range

Wire Type

And Dia .024 − .035 in

(0.6 − 0.9 mm) .030 − .045 in

(0.8 − 1.2 mm)/

.030 − .035 in

(0.8 − 0.9 mm)

350 − 900 IPM (9.0 − 23.0 m/min) At No Load

50 − 850 IPM (1.3 − 20.3 m/min) Feeding Wire

TM-944 Page 4 Handler 135 / 175

Return To Table Of Contents

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

withoutoverheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

duty cycle before welding.

YExceeding duty cycle can

damageunit or gun and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes duty1 4/95 − 196 617 / 196 618

C. 115 VAC Model

D. 230 VAC Model

3 Minutes Welding 7 Minutes Resting

Duty Cycle %

Output Amperes

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 Minutes Resting

Duty Cycle %

Output Amperes

1410

20 40 60 100

26808

100

200

135

TM-944 Page 5Handler 135 / 175 ReturnTo Table Of Contents

2-3. Volt-Ampere Curves

The volt-ampere 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 − 196 608 / 196 609

E. 115 VAC Model

F. 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

TM-944 Page 6 Handler 135 / 175

ReturnTo Table Of Contents

SECTION 3 − INSTALLATION

3-1. Installing Welding Gun

Ref. 802 440-A

1 Drive Assembly

2 Gun Securing Thumbscrew

3 Gun End

Loosen thumbscrew. Insert gun

end through opening until it bottoms

against drive assembly. Tighten

thumbscrew.

4 Gun Trigger Leads

Insert leads, one at a time, through

gun opening on front panel.

Connectfemale friction terminals to

matching male terminals in unit.

Polarityis not important.

Close door.

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

Tools Needed:

3/8, 7/16 in

TM-944 Page 7Handler 135 / 175 Return To Table Of Contents

3-3. Process/Polarity Table

Process

Polarity

Cable Connections

Process

Polarity

Cable To Gun Cable To Work

GMAW − Solid wire with shield-

ing gas DCEP − Reverse polarity Connect to positive (+) out-

put terminal Connect to negative (−) 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 Negative

(DCEN)

2 Lead Connections For Direct

Current Electrode Positive

(DCEP)

Always read and follow wire

manufacturer’s recommended po-

larity, and see Section 3-3.

Close door.

Ref. 209 228 / Ref. 209 229

DCEN

DCEP

Electrode Negative

For Flux Core Wire

Electrode Positive

For Solid Wire

CHANGING

POLARITY

TM-944 Page 8 Handler 135 / 175

ReturnTo Table Of Contents

3-5. Installing Gas Supply

Obtain gas cylinder and chain to

running gear, wall, or other

stationary support so cylinder

cannotfall and break off valve.

1 Cap

2 Cylinder Valve

Removecap, stand to side of valve,

and open valve slightly. Gas flow

blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is 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

manufacturer’s recommended flow

rate.

Tools Needed:

Ref. 802 028-A / 802 441

5/8, 1-1/8 in

Argon Gas Or

Mixed Gas

.DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2shielding gas. See Parts List for optional

CO2gas regulator/flowmeter.

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