FREE ENGLISH HOBART HANDLER 120 (01) PDF USER GUIDE
FREE ENGLISH HOBART HANDLER 120 (01) PDF USER MANUAL
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FREE ENGLISH HOBART HANDLER 120 (01) PDF OWNER MANUAL
FREE ENGLISH HOBART HANDLER 120 (01) PDF REFERENCE GUIDE
FREE ENGLISH HOBART HANDLER 120 (01) PDF INSTRUCTION GUIDE
FREE ENGLISH HOBART HANDLER 120 (01) PDF REFERENCE MANUAL
FREE ENGLISH HOBART HANDLER 120 (01) PDF INSTRUCTION MANUAL
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HOBART HANDLER 120 (01) PDF SUMMARY:
What are the different welding processes that this unit supports?
This unit supports MIG (GMAW) welding and Flux Cored (FCAW) welding.
What should I do to protect myself from potential hazards on the worksite?
Read the safety precautions in the Owner’s Manual to help protect yourself against potential hazards on the worksite.
What does the term MIG stand for?
MIG=GMAW.
What should I do before using this equipment?
Read the safety precautions before using this equipment.
What are some of the arc welding hazards?
Arc welding hazards include electric shock, fumes and gases, arc rays, fire and explosion, flying metal, buildup of gas, hot parts, magnetic fields, noise, and exploding cylinders.
What are some additional symbols for installation, operation, and maintenance?
Additional symbols for installation, operation, and maintenance include fire or explosion hazard, falling unit, overuse can cause overheating, static (ESD), moving parts, and welding wire can cause injury, H.F. radiation can cause interference, and arc welding can cause interference.
What are some principal safety standards?
Some principal safety standards are Safety in Welding and Cutting, ANSI Standard Z49.1, Safety and Health Standards, OSHA 29 CFR 1910, Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, National Electrical Code, NFPA Standard 70, Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Code for Safety in Welding and Cutting, CSA Standard W117.2, Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, and Cutting And Welding Processes, NFPA Standard 51B.
What are some of the considerations about welding and the effects of low frequency electric and magnetic fields?
Welding current flowing through cables causes electromagnetic fields and studies have not demonstrated that exposure to power-frequency electric and magnetic fields is a human health hazard. However, it is recommended that you minimize your exposure by keeping cables close together, arranging cables away from the operator, not coiling cables around your body, keeping the power source away from the operator, and connecting the work clamp as close to the weld as possible.
What are the warnings associated with electric shock?
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.
Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground. When making input connections, attach proper grounding conductor first. Frequently inspect input power cord for damage or bare wiring. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.
What are the warnings associated with fumes and gases?
Welding produces fumes and gases that can be hazardous to your health. Keep your head out of the fumes, and do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch-person nearby. Do not weld in locations near degreasing, cleaning, or spraying operations. Do not weld on coated metals, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator.
What are the warnings associated with arc rays?
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare. Warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
What are the warnings associated with fire or explosion?
Welding on closed containers can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers unless they are properly prepared. 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 and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments. Remove any combustibles from your person before doing any welding.
What are the warnings associated with flying metal?
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. Wear approved safety glasses with side shields even under your welding helmet.
What are the warnings associated with buildup of gas?
Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.
What are the warnings associated with hot parts?
Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.
What are the warnings associated with magnetic fields?
Pacemaker wearers keep away. Pacemaker wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.
What are the warnings associated with noise?
Wear approved ear protection if noise level is high.
What are the warnings associated with cylinders?
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application. Maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1.
What are the additional warnings for installation?
Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring. Be sure power supply system is properly sized, rated, and protected to handle this unit. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
What are the additional warnings for operation?
Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. Keep away from moving parts. Keep away from pinch points such as drive rolls. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place.
What are the additional warnings for maintenance?
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. 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. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
What should you do to reduce electromagnetic fields in the work environment?
To reduce electromagnetic fields in the work environment, you should:
- Keep cables together by twisting or taping them.
- Position all cables on the opposite side of the operator.
- Do not bend or wrap cables around your body.
- Keep the welding power source and cables as far away from you as possible.
- Connect the ground clamp as close as possible to the weld area.
What should people with pacemakers do before welding?
People with pacemakers should consult their doctor before welding. If cleared by their doctor, it is recommended that they follow the guidelines for reducing electromagnetic fields in the work environment.
What is the rated welding output of the 120 VAC model?
The rated welding output of the 120 VAC model is 90 amps at 19 volts DC, at a 30% duty cycle, and 75 amps at 19 volts DC at a 20% duty cycle.
What is the amperage range of the 120 VAC model?
The amperage range of the 120 VAC model is 30 – 130.
What is the maximum open-circuit voltage of the 120 VAC model?
The maximum open-circuit voltage of the 120 VAC model is 28 DC.
What is the input amperage of the 120 VAC model at rated load output?
The input amperage of the 120 VAC model at rated load output is 24 amps at 120 V, 60 Hz, Single-Phase, and 20 amps at 120 V, 60 Hz, Single-Phase (CSA Rating).
What is the weight of the 120 VAC model with the gun?
The weight of the 120 VAC model with the gun is 67 lb (30 kg).
What are the overall dimensions of the 120 VAC model?
The overall dimensions of the 120 VAC model are:
- Length: 19-1/8 in (489 mm)
- Width: 10-1/2 in (267 mm)
- Height: 14-1/2 in (368 mm)
What type of wire can be used with the 120 VAC model?
The 120 VAC model can use solid/stainless, flux-cored, and aluminum wire.
What is the wire feed speed range of the 120 VAC model at no load?
The wire feed speed range of the 120 VAC model at no load is:
- 160 – 870 IPM (4.1 – 22.5 m/min) for .023 – .030 in (0.6 – 0.8 mm) wire
- 160 – 870 IPM (4.1 – 22.5 m/min) for .030 – .035 in (0.8 – 0.9 mm) wire
What is the rated welding output of the 230 VAC model?
The rated welding output of the 230 VAC model is 130 amps at 20 volts DC, at a 30% duty cycle at 60 Hz input, and a 20% duty cycle at 50 Hz input.
What is the amperage range of the 230 VAC model?
The amperage range of the 230 VAC model is 30 – 175.
What is the maximum open-circuit voltage of the 230 VAC model?
The maximum open-circuit voltage of the 230 VAC model is 30 DC.
What is the input amperage of the 230 VAC model at rated load output?
The input amperage of the 230 VAC model at rated load output is 19.5 amps at 230 V, 50/60 Hz, Single-Phase.
What is the weight of the 230 VAC model with the gun?
The weight of the 230 VAC model with the gun is 70 lb (31.8 kg).
What are the overall dimensions of the 230 VAC model?
The overall dimensions of the 230 VAC model are:
- Length: 19-1/8 in (489 mm)
- Width: 10-1/2 in (267 mm)
- Height: 14-1/2 in (368 mm)
What type of wire can be used with the 230 VAC model?
The 230 VAC model can use solid/stainless, flux-cored, and aluminum wire.
What is the wire feed speed range of the 230 VAC model at no load?
The wire feed speed range of the 230 VAC model at no load is:
- 160 – 954 IPM (4.1 – 24 m/min) for .023 – .030 in (0.6 – 0.8 mm) wire
- 160 – 954 IPM (4.1 – 24 m/min) for .030 – .035 in (0.8 – 0.9 mm) wire
What is the duty cycle?
Duty cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating.
What happens if the unit overheats?
If the unit overheats, the thermostat(s) will open, the output will stop, and the cooling fan will run. You should wait fifteen minutes for the unit to cool down. Reduce the amperage or duty cycle before welding.
What can happen if the duty cycle is exceeded?
Exceeding the duty cycle can damage the unit or gun and void the warranty.
What is the duty cycle for the 120 VAC model at 90 amps?
The duty cycle for the 120 VAC model at 90 amps is 30%, which means 3 minutes of welding followed by 7 minutes of rest.
What is the duty cycle for the 230 VAC model at 130 amps?
The duty cycle for the 230 VAC model at 130 amps is 30% at 60 Hz input and 20% at 50 Hz input, which means 3 minutes of welding followed by 7 minutes of rest.
How do you install the welding gun?
To install the welding gun:
- Loosen the thumbscrew.
- Insert the gun end through the opening until it bottoms against the drive assembly.
- Tighten the thumbscrew.
- Insert the gun trigger leads, one at a time, through the small grommet on the front panel.
- Connect the female friction terminals to the matching male terminals in the unit. Polarity is not important.
- Close the door.
How do you change polarity?
To change polarity, connect the leads as follows:
- For Direct Current Electrode Positive (DCEP), follow the lead connections for DCEP.
- For Direct Current Electrode Negative (DCEN), follow the lead connections for DCEN. Always read and follow the wire manufacturer’s recommended polarity, and see Section 3-3. Close the door.
What is the polarity for GMAW using solid wire with shielding gas?
The polarity for GMAW using solid wire with shielding gas is DCEP (Direct Current Electrode Positive), also known as reverse polarity. The cable to the gun should be connected to the positive (+) output terminal, and the cable to the work should be connected to the negative (-) output terminal.
What is the polarity for FCAW using self-shielding wire with no shielding gas?
The polarity for FCAW using self-shielding wire with no shielding gas is DCEN (Direct Current Electrode Negative), also known as straight polarity. The cable to the gun should be connected to the negative (-) output terminal, and the cable to the work should be connected to the positive (+) output terminal.
How do you install a gas cylinder?
To install a gas cylinder:
- Obtain a gas cylinder and chain it to a running gear, wall, or other stationary support so it cannot fall and break off the valve.
- Remove the cap, stand to the side of the valve, and open it slightly to blow away dust and dirt.
- Close the valve.
- Install the regulator/flowmeter so its face is vertical.
- Connect the customer-supplied gas hose between the regulator/flowmeter gas hose connection and the fitting on the rear of the welding power source.
What is a typical gas flow rate?
A typical gas flow rate is 20 cubic feet per hour (cfh). You should check the wire manufacturer’s recommended flow rate.
How do you install a CO2 adapter?
Install the CO2 adapter with an O-ring between the regulator/flowmeter and the CO2 cylinder.
What are the input power requirements for the 120 VAC model?
The 120 VAC model requires a 120 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker. Select an extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m).
What are the input power requirements for the 230 VAC model?
The 230 VAC model requires a 230 volt input power. Always connect the grounding conductor first. Do not move or operate the unit where it could tip.
What is the electrical service guide for the 230 VAC model?
| Input Voltage | Input Amperes at Rated Output | Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes | Min Input Conductor Size in AWG/Kcmil | Max Recommended Input Conductor Length in Feet (Meters) | Min Grounding Conductor Size in AWG/Kcmil |
|---|---|---|---|---|---|
| 230 | 19.5 | 30 | 14 | 66 (20) | 14 |
How do you install the wire spool and adjust hub tension?
To install the wire spool and adjust hub tension:
- Install the spool so the welding wire feeds from the bottom.
- Turn the wingnut.
- When slight force is needed to turn the spool, the tension is set.
How do you thread the welding wire?
- Lay the gun cable out straight.
- Pull and hold the wire, and cut off the end.
- Remove the gun nozzle and contact tip.
- Open the pressure assembly.
- Push the wire through the guides into the gun while continuing to hold the wire.
- Close and tighten the pressure assembly, then let go of the wire.
- Hold the wire tightly to keep it from unraveling.
- Feed wire to check drive roll pressure. Tighten the knob enough to prevent slipping.
- Cut off the wire. Close and latch the door.
- Press the gun trigger until wire comes out of the gun.
- Reinstall the contact tip and nozzle.
- Turn the power on.
What does the Voltage Switch do?
The higher the selected number, the thicker the material that can be welded. Do not switch under load.
What does the Voltage Switch – Purge “0” Position do?
In purge position, the fan runs but there is no weld output.
What does the Wire Speed Control do?
Use the control to select a wire feed speed. As the Voltage switch setting increases, the wire speed range also increases.
What does the Power Switch do?
The power switch turns the unit On or Off. Do not switch while welding.
What are the weld parameters for the 120 VAC model for welding steel?
| Material Thickness | Wire Speed | Voltage |
|---|---|---|
| 18–24 GA. .022–.047 | 1–2 | 3–4 |
| 16 GA. .062 | 2–3 | 3–4 |
| 11 GA. .125 | 3 | 4–5 |
What are the weld parameters for the 120 VAC model for welding aluminum?
| To Weld: Type\Size | Thickness | Wire Speed | Voltage | Welding Polarity | Gas Flow (Cubic Ft/Hr) | Wire Stickout (Inches) |
|---|---|---|---|---|---|---|
| 5356 (.035) | 1/4" | 2 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 1/2" | 2 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 5/16" | 2 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 3/4" | 1 | 6-7 | DCEP | 20 | 3/4 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 3/4" | 1 | 4-5 | DCEP | 20 | 3/4 |
| 5356 (.035) | 1/4" | 1 | 4-5 | DCEP | 20 | 1/4 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 5/16" | 1 | 4-5 | DCEP | 20 | 5/16 |
| 5356 (.035) | 1/2" | 1 | 4-5 | DCEP | 20 | 1/2 |
| 5356 (.035) | 1/4" | 1 | 3-4 | DCEP | 20 | 1/4 |
| 5356 (.035) | 5/16" | 1 | 3-4 | DCEP | 20 | 5/16 |
| 5356 (.035) | 5/16" | 1 | 3-4 | DCEP | 20 | 5/16 |
| 5356 (.035) | 5/16" | 1 | 3-4 | DCEP | 20 | 5/16 |
| 5356 (.035) | 1/4" | 1 | 2-3 | DCEP | 20 | 1/4 |
| 5356 (.035) | 1/4" | 1 | 2-3 | DCEP | 20 | 1/4 |
What are the weld parameters for the 120 VAC model for welding with different wires?
| To Weld: Type\Size | Material Thickness | Wire Speed | Voltage | Welding Polarity | Gas Flow (Cubic Ft/Hr) | Wire Stickout (Inches) |
|---|---|---|---|---|---|---|
| HB–28 (.035) | 1/8" | 4 | 4 | DCEN | 20 | 3/8 |
| Fabshield 21B (.035) | 1/8" | 4 | 4 | DCEN | CO2 or C25 | 3/8 |
| HB–28 (.030) | 1/16" | 4 | 4 | DCEN | 20 | 1/4 |
| (.024) HB–28 (.024) | 1/16" | 4 | 4 | DCEN | 20 | 1/4 |
| HB–28 (.024) | .022” 24 GA | 2 | 2 | DCEN | 20 | 1/4 |
| HB–28 (.024) | 18 GA | 2 | 2 | DCEN | 20 | 1/4 |
| HB–28 (.024) | 16 GA | 3 | 3 | DCEN | 20 | 5/16 |
| HB–28 (.024) | 11 GA | 3 | 3 | DCEN | 20 | 5/16 |
| HB–28 (.030) | 16 GA | 1 | 1 | DCEN | 20 | 3/8 |
| HB–28 (.030) | 11 GA | 1 | 1 | DCEN | 20 | 3/8 |
| HB–28 (.035) | 16 GA | 2 | 2 | DCEN | 20 | 1/2 |
| HB–28 (.035) | 1/16” | 4 | 4 | DCEP | 20 | 1/2 |
| HB–28 (.035) | 1/8” | 2 | 2 | DCEP | 20 | 1/2 |
| HB–28 (.024) | 3/16” | 2 | 3 | DCEP | 20 | 1/2 |
| HB–28 (.024) | 1/8” | 2 | 3 | DCEP | 20 | 1/2 |
| HB–28 (.024) | 1/16” | 2 | 4 | DCEP | 20 | 1/2 |
| HB–28 (.024) | 3/64” | 2 | 2 | DCEP | 20 | 1/2 |
What are the weld parameters for the 230 VAC model for welding with different wires?
| To Weld: Type\Size | Material Thickness | Wire Speed | Voltage | Welding Polarity | Gas Flow (Cubic Ft/Hr) | Wire Stickout (Inches) |
|---|---|---|---|---|---|---|
| HB–28 (.024) | .022” 24 GA. | 1 | 4.5-5.5 | DCEN | 20 | 1/4 |
| HB–28 (.024) | 3/64” | 1 | 4.5-5.5 | DCEN | 20 | 1/4 |
| HB–28 (.024) | 1/16” | 2 | 4.5-5.5 | DCEN | 20 | 1/4 |
| HB–28 (.030) | 1/8” | 2 | 4.5-5.5 | DCEN | 20 | 1/4 |
| HB–28 (.030) | .187” | 2 | 4.5-5.5 | DCEN | 20 | 1/4 |
| HB–28 (.035) | 1/16” 16 GA. | 1 | 4-5 | DCEN | 20 | 1/4 |
| HB–28 (.035) | 1/8” | 1 | 4-5 | DCEN | 20 | 1/4 |
| HB–28 (.024) | 1/16” | 1 | 4-5 | DCEN | 20 | 1/4 |
| Solid Stainless (.030) | 16 GA. | 2 | 4-5 | DCEP | 20 | 5/16 |
| Solid Stainless (.030) | 11 GA. | 2 | 6-7 | DCEP | 20 | 5/16 |
| HB–28 (.024) | 16 GA. | 2 | 4-5 | DCEP | 20 | 1/4 |
| HB–28 (.024) | 18 GA. | 2 | 4.5-5.5 | DCEP | 20 | 1/4 |
| Fabshield 21B (.035) | 16 GA. | 1 | 4-5 | DCEP | CO2 or C25 | 3/8 |
| Fabshield 21B (.035) | 11 GA. | 1 | 6-7 | DCEP | CO2 or C25 | 3/8 |
| Fabshield 21B (.035) | 16 GA. | 1 | 7-8 | DCEP | CO2 or C25 | 3/8 |
| Fabshield 21B (.035) | 11 GA. | 1 | 4-5 | DCEP | CO2 or C25 | 3/8 |
| Fabshield 21B (.045) | 16 GA. | 1 | 5-6 | DCEP | CO2 or C25 | 1/2 |
| Fabshield 21B (.045) | 11 GA. | 1 | 4-5 | DCEP | CO2 or C25 | 1/2 |
What are the weld parameters for the 230 VAC model for welding aluminum?
| To Weld: Type\Size | Thickness | Wire Speed | Voltage | Welding Polarity | Gas Flow (Cubic Ft/Hr) | Wire Stickout (Inches) |
|---|---|---|---|---|---|---|
| 5356 (.035) | 3/16”to1/4” | 4 | 6-7 | DCEP | 20 | 3/8 |
| 5356 (.035) | 1/4” | 3 | 9-10 | DCEP | 20 | 1/2 |
| 5356 (.035) | 3/32” | 2 | 9 | DCEP | 20 | 1/2 |
What routine maintenance should be performed every 3 months?
- Disconnect power before maintaining.
- Replace unreadable labels.
- Repair or replace cracked weld cable.
- Clean and tighten weld terminals.
What routine maintenance should be performed every 6 months?
- Blow out or vacuum inside. During heavy service, clean monthly.
What does the circuit breaker CB protect?
Circuit breaker CB protects the wire feed motor from overload. If the circuit breaker opens, the wire stops feeding.
What does the circuit breaker CB1 protect?
CB1 protects the unit from overload. If CB1 opens, the unit shuts down.
What does the circuit breaker CB2 protect?
Circuit breaker CB2 protects the wire feed motor from overload. If the circuit breaker opens, the wire stops feeding.
How do you reset the circuit breaker?
Reset the breaker.
How do you change the drive roll or wire inlet guide?
- Loosen the inlet wire guide securing screw.
- Slide the inlet wire guide tip as close to drive rolls as possible without touching.
- Tighten the screw.
- Secure drive roll with screw. Make sure the woodruff key is on the motor shaft, and not in the old drive roll.
How do you replace the gun contact tip?
- Turn off power before replacing contact tip.
- Cut off welding wire at contact tip.
- Remove the nozzle.
- Remove the contact tip and install new contact tip.
- Reinstall the nozzle.
How do you clean or replace the Piecemaker 14-A gun liner?
- Disconnect gun from the unit.
- Loosen liner set screw.
- Remove the liner.
- Remove nozzle, contact tip, adapter, and wire outlet guide.
- Blow out gun casing.
- Insert new liner.
- Push liner against quick-connect plug, and tighten set screw.
- Cut liner off so that 3/4 in (19.05 mm) sticks out of head tube.
- Install adapter, contact tip, and nozzle.
- Lay gun cable out straight before installing new liner.
What should you do if there is no weld output, the wire does not feed, and the fan does not run?
- Secure power cord plug in receptacle.
- Replace building line fuse or reset circuit breaker if open.
- Place Power switch in On position.
- Check circuit breaker CB (CSA model), and reset if necessary.
What should you do if there is no weld output, the wire does not feed, and the fan motor continues to run?
- Thermostat S3 is open due to overheating. Allow fan to run; the thermostat closes when the unit has cooled.
What should you do if there is no weld output, but the wire feeds?
- Connect work clamp to get good metal to metal contact.
- Replace contact tip.
- Check for proper polarity connections.
What should you do if there is low weld output?
- Connect unit to proper input voltage or check for low line voltage.
- Place voltage switch in desired position.
What should you do if the electrode wire feeding stops during welding?
- Straighten gun cable and/or replace damaged parts.
- Adjust drive roll pressure.
- Change to proper drive roll groove.
- Readjust hub tension.
- Replace contact tip if blocked.
- Clean or replace wire inlet guide or liner if dirty or plugged.
- Replace drive roll or pressure bearing if worn or slipping.
- Secure gun trigger leads or repair leads.
- Check circuit breaker CB or CB2 (depending on Model), and reset if necessary.
- Check and clear any restrictions at the drive assembly and liner.
- Have nearest Factory Authorized Service Agent check drive motor.
What is the typical MIG process connection?
The typical MIG process connections include a wire feeder/power source, a workpiece, a gun, a regulator/flowmeter, gas, and a work clamp.
What should you do before welding on a vehicle?
Disconnect both battery cables before welding on a vehicle because the weld current can damage electronic parts in vehicles.
Where should the work clamp be placed?
Place the work clamp as close to the weld as possible.
Are the provided control settings absolute or guidelines?
The provided control settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.
How does material thickness affect weld parameters?
Material thickness determines weld parameters.
How can you convert material thickness to amperage?
Convert material thickness to amperage using the formula .001 in = 1 ampere. For example, .125 in = 125 A.
What are the recommended amperage ranges for different wire sizes?
- .023 in wire: 30 – 90 A
- .030 in wire: 40 – 145 A
- .035 in wire: 50 – 180 A
What are the recommended wire speeds for different wire sizes?
- .023 in wire: 3.5 inches per ampere
- .030 in wire: 2 inches per ampere
- .035 in wire: 1.6 inches per ampere
How do you calculate wire speed based on amperage?
To calculate wire speed, multiply the amperage by the wire’s inches per ampere recommendation.
- For example, with 125 amps, the wire speeds are:
- .023 in wire: 3.5 x 125 A = 437 ipm
- .030 in wire: 2 x 125 A = 250 ipm
- .035 in wire: 1.6 x 125 A = 200 ipm
How do you set the voltage?
Set the voltage midway between the high and low voltage. Low voltage will result in the wire stubbing into the work and high voltage will result in an unstable arc and spatter.
What does voltage control?
Voltage controls the height and width of the weld bead.
What does wire speed (amperage) control?
Wire speed (amperage) controls weld penetration (wire speed = burn-off rate).
What should you ensure before lowering the helmet and pressing the trigger?
Before lowering the helmet and pressing the trigger, be sure the wire is no more than 1/2 in (13 mm) past the end of the nozzle, and the tip of the wire is positioned correctly on the seam.
What is the proper electrode extension (stickout)?
The proper electrode extension (stickout) is 1/4 to 1/2 in (6 to 13 mm).
What affects weld bead shape?
Weld bead shape depends on the gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
What are the different gun angles and weld bead profiles for fillet welds?
The gun angle can be positioned in three ways during a fillet weld: Push, Perpendicular, and Drag. There are also three weld bead profiles: Short, Normal, and Long.
What are the different gun travel speeds and how do they affect the weld bead?
The gun travel speed can be Slow, Normal, or Fast, each of which affects the shape of the weld bead.
When is a stringer bead satisfactory?
A single stringer bead is satisfactory for most narrow groove weld joints.
When are weave beads or multiple stringer beads better?
For wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.
What is a stringer bead?
A stringer bead is a steady movement along a seam.
What is a weave bead?
A weave bead is a side-to-side movement along a seam.
What are some poor weld bead characteristics?
Poor weld bead characteristics include large spatter deposits, a rough, uneven bead, a slight crater during welding, bad overlap, and poor penetration.
What are some good weld bead characteristics?
Good weld bead characteristics include fine spatter, a uniform bead, a moderate crater during welding, no overlap, and good penetration into base metal.
How thick should each new weld bead or layer be?
Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded.
What is excessive spatter?
Excessive spatter is the scattering of molten metal particles that cool to solid form near the weld bead.
What are some possible causes of excessive spatter?
Possible causes of excessive spatter include:
- Wire feed speed too high
- Voltage too high
- Electrode extension (stickout) too long
- Workpiece dirty
- Insufficient shielding gas at welding arc
- Dirty welding wire
- Pickup of oil or lubricant on welding wire
What are some corrective actions for excessive spatter?
Corrective actions for excessive spatter include:
- Select lower wire feed speed
- Select lower voltage range
- Use shorter electrode extension (stickout)
- Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding
- Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc
- Use clean, dry welding wire
- Eliminate pickup of oil or lubricant on welding wire from feeder or liner
What is porosity?
Porosity is when small cavities or holes result from gas pockets in the weld metal.
What are some possible causes of porosity?
Possible causes of porosity include:
- Insufficient shielding gas at welding arc
- Spatter on the gun nozzle
- Leaks in gas hoses
- Nozzle too far from workpiece
- Holding the gun away from the bead before molten metal solidifies
- Wrong gas
- Dirty welding wire
- Pickup of oil or lubricant on welding wire
- Workpiece dirty
- Welding wire extends too far out of nozzle
What are some corrective actions for porosity?
Corrective actions for porosity include:
- 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
- Use welding grade shielding gas; change to different gas
- Use clean, dry welding wire
- Eliminate pickup of oil or lubricant on welding wire from feeder or liner
- Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding
- Use a more highly deoxidizing welding wire
- Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle
What is excessive penetration?
Excessive penetration is when weld metal melts through the base metal and hangs underneath the weld.
What are some possible causes of excessive penetration?
Excessive heat input.
What are some corrective actions for excessive penetration?
Corrective actions for excessive penetration include:
- Select lower voltage range and reduce wire feed speed
- Increase travel speed
What is lack of penetration?
Lack of penetration is shallow fusion between weld metal and base metal.
What are some possible causes of lack of penetration?
Possible causes of lack of penetration include:
- Improper joint preparation
- Improper weld technique
- Insufficient heat input
- Welding wire extends too far out of nozzle
What are some corrective actions for lack of penetration?
Corrective actions for lack of penetration include:
- Material too thick and joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics
- 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
- Select higher wire feed speed and/or select higher voltage range
- Reduce travel speed
What is incomplete fusion?
Incomplete fusion is the failure of weld metal to fuse completely with the base metal or a preceding weld bead.
What are some possible causes of incomplete fusion?
Possible causes of incomplete fusion include:
- Workpiece dirty
- Insufficient heat input
- Improper welding technique
What are some corrective actions for incomplete fusion?
Corrective actions for incomplete fusion include:
- Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding
- Select higher voltage range and/or adjust wire feed speed
- 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
What is burn-through?
Burn-through is when weld metal melts completely through the base metal, resulting in holes where no metal remains.
What are some possible causes of burn-through?
Excessive heat input.
What are some corrective actions for burn-through?
Corrective actions for burn-through include:
- Select lower voltage range and reduce wire feed speed
- Increase and/or maintain steady travel speed
What is waviness of bead?
Waviness of bead is weld metal that is not parallel and does not cover the joint formed by the base metal.
What are some possible causes of waviness of bead?
Possible causes of waviness of bead include:
- Welding wire extends too far out of nozzle
- Unsteady hand
What are some corrective actions for waviness of bead?
Corrective actions for waviness of bead include:
- Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle
- Support hand on solid surface or use two hands
What is distortion?
Distortion is the contraction of weld metal during welding that forces the base metal to move.
What are some possible causes of distortion?
Excessive heat input.
What are some corrective actions for distortion?
Corrective actions for distortion include:
- Use restraint (clamp) to hold base metal in position
- Make tack welds along joint before starting welding operation
- Select lower voltage range and/or reduce wire feed speed
- Increase travel speed
- Weld in small segments and allow cooling between welds
What are some common MIG shielding gases and their applications?
| Application | Gas |
|---|---|
| Spray Arc Steel | Argon |
| Spray Arc Steel | Argon + 25% CO2 |
| Spray Arc Steel | CO2 |
| Short Circuiting Steel | Argon + 25% CO2 |
| Short Circuiting Steel | CO2 |
| Short Circuiting Stainless Steel | Tri-Mix3 |
| Short Circuiting Aluminum | Argon |
- Note:
- 1 Globular Transfer
- 2 Single Pass Welding Only
- 3 90% HE + 7-1/2% AR + 2-1/2% CO2
What are some of the parts in the main assembly of the welder?
Some of the parts in the main assembly of the welder include:
- Top panel
- Warning label
- Interior panel
- Gas valve nut
- Solenoid valve
- Tygon gas line tube
- Hex KEPS nut
- Relay
- Motor control circuit breaker
- Circuit breaker (120 VAC CSA model)
- Terminal gun switch bushing
- Insulator output washer
- Insulator output bushing
- Rubber grommet
- Hub brake spring
- Hub spool shaft
- Spool hub
- Nylon shaft washer
- Non-rotating washer
- Hub spool nut
- Wing nut
- Brake washer
- Fan blade
- Rect heat sink diode assembly
- Wire output guide
- Power transformer assembly
- Fan motor and heat sink mounting bracket
- Fan motor
- Lifting handle
- Handle mount spring
- Side panel
- Reactor assembly
- End cap handle enclosure
- Plastic end cap panel
- Rubber grommet
- Gun connector insulator
- Front end cap label
- Wire feed speed (WFS) pointer knob
- Tray panel
- Barbed fitting
- Gun connector
- Thumb screw
- Feed roll
- Feed roll screw
- Wire input guide
- Feed head
- Wire feed motor
- Woodruff key
- Strain relief connector
- Rear plastic end cap panel
- Input contactor
- Rotary range switch
- Capacitor clamp
- Resistor assembly
- Electrolytic capacitor
- Input switch
- Rheostat
- Door hinge
- Door panel
- Door latch
- Power cable assembly
- Ground lead
- Door label
- Ground screw label
- Moving parts label
- Electric shock label
- Caution label
- Strain relief connector
- Push-button circuit breaker
- Electric shock label
- Voltage pointer knob
What are the parts of the Piecemaker 14-A gun and cable assembly?
The parts of the Piecemaker 14-A gun and cable assembly are:
- Slip-on nozzle assembly
- Nozzle adapter
- Contact tip
- Gas diffuser
- Switch trigger
- Insulator
- Small handle pair
- Square M4 nut
- Outer cover
- Contact switch pin
- O-ring
- Set screw
- Spring liner assembly
- Allen wrench tool
- Handle screw
What are the available gun and cable assemblies for the Piecemaker 14-A?
The available gun and cable assemblies for the Piecemaker 14-A include:
| Cable Length (Feet) | Wire Type & Size | Tip Part No. | Liner Part No. | Cable Part No. | Set Screw Part No. |
|---|---|---|---|---|---|
| 10 | .024 H | 379 587 | 379 427-4 | 177 314-1 | |
| 10 | .030 H/T | 379 304 | 379 427-4 | 177 314-1 | |
| 10 | .035 H/T | 379 314 | 379 427-4 | 177 314-1 | |
| 10 | .045 T | 379 315 | 379 427-4 | 177 314-1 | |
| 10 | .024 H | 379 587 | 379 601-1 | 177 314-1 | |
| 10 | .030 H/T | 379 304 | 379 599-1 | 177 314-1 | |
| 10 | .035 H/T | 379 314 | 379 429-1 | 177 314-1 | |
| 10 | .045 T | 379 315 | 379 429-1 | 177 314-1 | |
| 10 | .024 H | 379 587 | 379 601-1 | 177 314-1 | W-11525-1 |
| 10 | .030 H/T | 379 304 | 379 599-1 | 177 314-1 | W-11525-1 |
| 10 | .035 H/T | 379 314 | 379 429-1 | 177 314-1 | W-11525-1 |
| 10 | .045 T | 379 315 | 379 429-1 | 177 314-1 | W-11525-1 |
| 10 | .024 H | 379 587 | 379 601-1 | 177 314-1 | W-11525-1 |
| 10 | .030 H/T | 379 304 | 379 599-1 | 177 314-1 | W-11525-1 |
| 10 | .035 H/T | 379 314 | 379 429-1 | 177 314-1 | W-11525-1 |
| 10 | .045 T | 379 315 | 379 429-1 | 177 314-1 | W-11525-1 |
What is the optional liner for .024 wire for all feed head assemblies? The optional liner for .024 wire for all feed head assemblies is part number 379 597-4.
What are the part numbers for different feed rolls?
- 407 230-1: For .024 (.6) and .030/.035 (.8 and .9) inch wire
- 203 568: For .035 inch, 5356 Aluminum wire
- 407 230-4: For .024 (.6) and .045 (1.2) inch wire
What are the available kits to convert the Piecemaker 14-A gun and machine to optional wire sizes?
| Part No. | Wire Size (Inches) | Items Included in Kit |
|---|---|---|
| 202 858-4 | .045 (1.2) | 3 Contact Tips, 1 Gun Liner, and a 2 lb. Sample of HANDLER T-80 |
| 202 858-5 | .030 (.8) | 3 Contact Tips, 1 Gun Liner, 1 Drive Roll |
| 202 858-6 | .035 (.9) | 3 Contact Tips, 1 Gun Liner, 1 Drive Roll |
| 202 858-8 | .024 (.6) | 3 Contact Tips, 1 .024 Gun Liner |
| 202 858-9 | .035 Aluminum | 3 Contact Tips, 1 Gun Liner, 1 Drive Roll and 1 Outlet Guide |
What are the available options for the welding machine? The available options for the welding machine include:
- 202 992-2: Carry-All for one small gas cylinder
- 202 526-1: Carry-All for one large gas cylinder
What should you do if individual parts are required? If individual parts are required, see the Parts List chapter of the manual for part numbers to order.
Where can you call for warranty questions? Call 1-877-HOBART1 for your local Hobart distributor.
What kind of support is available? Contact your distributor or call 1-800-332-3281 for fast answers to welding questions. The expertise of the distributor and Hobart is there to help you.
What is covered under the limited warranty?
Hobart warrants to its original retail purchaser that new Hobart equipment is free of defects in material and workmanship. Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship within the warranty periods. Hobart must be notified in writing within 30 days of such defect or failure.
What are the different warranty periods for Hobart equipment? Hobart provides different warranty periods for various parts and equipment:
- 5 Years Parts – 3 Years Labor: Original main power rectifiers and Inverters (input and output rectifiers only)
- 3 Years — Parts and Labor: Transformer/Rectifier Power Sources, Plasma Arc Cutting Power Sources, Semi-Automatic and Automatic Wire Feeders, Inverter Power Supplies, Intellitig, and Engine Driven Welding Generators
- 1 Year — Parts and Labor: DS-2 Wire Feeder, Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250), Process Controllers, Positioners and Controllers, Automatic Motion Devices, RFCS Foot Controls, Induction Heating Power Sources, Water Coolant Systems, HF Units, Grids, Maxstar 140, Spot Welders, Load Banks, Hobart Cyclomatic Equipment, Running Gear/Trailers, Plasma Cutting Torches (except APT & SAF Models), and Field Options
- 6 Months — Batteries
- 90 Days — Parts: MIG Guns/TIG Torches, Induction Heating Coils and Blankets, APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches, Remote Controls, Accessory Kits, Replacement Parts (No labor), Spoolmate 185 & Spoolmate 250, and Canvas Covers
What is not covered under the warranty?
Hobart’s Limited Warranty does not cover:
- Consumable components such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays, or parts that fail due to normal wear
- Items furnished by Hobart but manufactured by others, such as engines or trade accessories
- Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated, or misused, or equipment that has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment
What are the available remedies in the event of a warranty claim?
In the event of a warranty claim, the remedies shall be, at Hobart’s option:
- Repair
- Replacement
- The reasonable cost of repair or replacement at an authorized Hobart service station
- Payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense
What is the F.O.B. point for repairs or replacements?
Hobart’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. No compensation or reimbursement for transportation costs of any kind will be allowed.
What is excluded from the warranty?
Any express warranty not provided in the warranty document, and any implied warranty, guaranty or representation as to performance, and any remedy for breach of contract, tort or any other legal theory which might arise by implication, operation of law, custom of trade or course of dealing, including any implied warranty of merchantability or fitness for a particular purpose, with respect to any and all equipment furnished by Hobart is excluded and disclaimed by Hobart.
Where can you find a Hobart distributor, retail or service location?
Call 1-877-Hobart1 or visit the website at http://www.HobartWelders.com.
What should you contact your distributor for?
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
Who should you contact for assistance in filing or settling claims for loss or damage during shipment?
Contact the delivering carrier. For assistance, contact your distributor and/or equipment manufacturer’s Transportation Department.
Where can you call for technical assistance?
Call 1-800-332-3281 for technical assistance.
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