Hobart Welders Handler 187 User Manual

Processes
OM-228 187D 2011−02
Handler 187
And H100S2−10 Gun
Arc Welding Power Source And
Wire Feeder
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
R
File: MIG (GMAW)

Hobart Welders Handler 187 Specifications

General

Input Voltage	230 V
Input Frequency	60 Hz
Input Phase	Single Phase
Duty Cycle	30% at 130A
Wire Feed Speed	50 - 700 in/min
Wire Size	0.023 - 0.035 in
Spool Size Capacity	4 in or 8 in spool

Summary

Safety Precautions

Symbol Usage and Electric Shock

Explains warning symbols, electric shock, and grounding precautions.

Arc Welding Hazards

Details hazards related to arc welding processes and equipment.

Specific Welding Hazards

Fume, Gas, Arc Ray, Fire, and Noise Hazards

Covers hazards from fumes, gases, arc rays, fire, flying metal, noise, and cylinder risks.

EMF and Medical Device Hazards

Discusses hazards related to EMF effects on medical devices.

Installation, Operation, and Interference Hazards

Installation, Operation, and Interference Hazards

Covers hazards during installation and operation, including fire, falling equipment, and interference.

Proposition 65, Safety Standards, and EMF

California Proposition 65 and Safety Standards

Lists California Proposition 65 warnings and principal safety standards.

EMF Information for Medical Implants

Provides detailed EMF information and precautions for individuals with medical implants.

Definitions

Symbols and Definitions

Defines various symbols used throughout the manual for clarity and safety.

Specifications

Technical Specifications Overview

Details the technical specifications of the welding unit, including output, weight, and dimensions.

Duty Cycle and Overheating

Explains duty cycle percentage, overheating warnings, and cooling procedures.

Volt-Ampere Curves

Displays volt-ampere curves illustrating output capabilities and parameter ranges.

Installation

Installing Gun Consumables

Provides steps for installing the nozzle, contact tip, and adapter on the welding gun.

Connecting the Welding Gun

Details the process of connecting the welding gun to the main unit, including lead connections.

Installing the Work Clamp

Guides on securely attaching the work clamp to the workpiece for proper electrical connection.

Process and Polarity Table

A table outlining polarity settings for different welding processes like GMAW and FCAW.

Changing Welding Polarity

Instructions on how to change the welding polarity by repositioning electrical connections.

Installing Shielding Gas Supply

Details the setup and connection of the shielding gas cylinder, regulator, and flowmeter.

Location Selection and Power Connection

Guidance on selecting an appropriate location and connecting the unit to the input power supply.

Electrical Service Guide

Provides recommendations for electrical service, including fuse/breaker ratings and conductor sizes.

Wire Spool Installation and Hub Tension

Steps for installing the wire spool and adjusting the hub tension for proper wire feeding.

Threading Welding Wire

Details the procedure for threading welding wire through the drive rolls and gun assembly.

Operation

Unit Controls Overview

Identifies and explains the function of each control on the welding unit's front panel.

Welding Parameter Chart

Offers a chart with recommended voltage and wire speed settings for various materials and wire types.

Wire Welding Package Settings

Provides recommended voltage and wire speed settings for different metal thicknesses and wire types.

Maintenance & Troubleshooting

Routine Maintenance Schedule

Outlines routine maintenance tasks to be performed periodically for optimal performance and longevity.

Overload and Drive Motor Protection

Explains overload protection and drive motor protection circuits and their reset procedures.

Drive Roll and Wire Inlet Guide Replacement

Provides instructions for changing drive rolls and wire inlet guides, including selecting correct grooves.

Welding Gun Maintenance

Guides on replacing gun consumables like nozzle, tip, adapter, liner, and cleaning the gun casing.

Welding Gun Switch and Head Tube Replacement

Details the procedure for replacing switches and head tubes on the welding gun.

Troubleshooting: Wire Feed and Output Issues

Lists common welding problems with their probable causes and recommended remedies for wire feed and output.

Troubleshooting: Porosity, Arc Stability, and Gas Flow

Continues troubleshooting for issues like porosity, arc stability, and gas flow.

Electrical Diagram

Main Circuit Diagram

Presents the main electrical circuit diagram for the welding unit.

Internal Circuit Diagram Details

Continues the electrical diagram, showing internal components and connections.

MIG Welding (GMAW) Guidelines

Typical MIG Process Connections

Illustrates a typical connection diagram for MIG welding processes.

MIG Process Control Settings

Provides general guidelines for setting controls for MIG welding processes based on material and wire.

Welding Gun Handling and Positioning

Offers guidance on proper techniques for holding and positioning the welding gun during operation.

Weld Bead Shape Factors

Explains various factors that influence the shape of the weld bead, such as gun angle and travel speed.

Gun Movement and Weld Bead Quality

Describes gun movements and illustrates characteristics of good and poor weld beads.

Good vs. Poor Weld Bead Characteristics

Illustrates and describes characteristics of good and poor quality weld beads.

Troubleshooting: Spatter and Porosity

Addresses causes and corrective actions for excessive spatter and porosity during welding.

Troubleshooting: Excessive Penetration

Addresses causes and corrective actions for excessive weld penetration.

Troubleshooting: Lack of Penetration and Fusion

Addresses causes and corrective actions for lack of penetration and incomplete fusion.

Troubleshooting: Burn-Through

Addresses causes and corrective actions for burn-through during welding.

Troubleshooting: Waviness and Distortion

Addresses causes and corrective actions for waviness in the weld bead and distortion.

Common MIG Shielding Gases

Provides a chart of common MIG shielding gases and their applications.

Troubleshooting Semiautomatic Welding Equipment

A guide for troubleshooting common problems with semiautomatic welding equipment and wire feeding.

Parts List

Main Assembly Parts Diagram

Illustrates the main assembly of the welding unit with labeled parts.

Main Assembly Parts List

Continues the illustration and listing of parts for the main assembly of the welding unit.

Welding Gun Parts Diagram

Illustrates the parts breakdown for the H100S2-10 welding gun.

Optional Drive Rolls

Lists optional drive rolls available for different wire diameters and feed head assemblies.

Optional Accessories

Lists optional accessories and their remarks, such as running gear and regulators.

Warranty Information

Warranty Contact and Service Information

Provides contact information for warranty questions, service, and general support.

Hobart 5/3/1 Limited Warranty Terms

Outlines the terms and conditions of the Hobart 5/3/1 limited warranty for welding equipment.

Warranty Limitations and Legal Rights

Details limitations, exclusions, and legal rights related to the warranty.

Owner's Record

Personal Equipment Record Keeping

A section for users to record their personal information and equipment details.

Available Resources and Support

Lists various resources available to users, including distributors, technical assistance, and manuals.