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Handler 140 and H100S2-10 Gun Owner's Manual

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    Processes

    OM-925 217 694G2010 05

    Handler 140

    And H100S2-10 Gun

    Arc Welding Power Source AndWire Feeder

    Description

    MIG (GMAW) WeldingFlux Cored (FCAW) Welding

    R

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    Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local Hobartdistributor to receive the latest full line catalog or individual specification sheets.To locate your nearest distributor or service agency call 1-877-Hobart1 orvisit our website at www.HobartWelders.com.

    For Technical Help call 1-800-332-3281.

    Thank you and congratulations on choosing Hobart. Now you can get the

    job done and get it done right. We know you dont have time to do it anyother way.

    This Owners Manual is designed to help you get the most out of yourHobart products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

    Weve made installation and operation quickand easy. With Hobart you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that will helpyou figure out what the problem is. The partslist will then help you to decide the exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

    Hobart is registered to theISO 9001 Quality SystemStandard.

    Working as hard as youdo every power sourcefrom Hobart is backed bthe best warranty in thebusiness.

    From Hobart to You

    Hob_Thank 2009

    09

    Register your product at:HobartWelders.com

    Protect Your Investmen

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    OM-925 Page 1

    SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINsom _2010 03

    7

    Protect yourself and others from injury read and follow these precautions.

    1-1. Symbol Usage

    DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

    Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

    NOTICE Indicates statements not related to personal injury.

    . Indicates special instructions.

    This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid thehazards.

    1-2. Arc Welding Hazards

    The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

    Only qualified persons should install, operate, maintain, andrepair this unit.

    During operation, keep everybody, especially children, away.

    ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit is

    electrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.D Do not touch live electrical parts.

    D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating mats

    or covers big enough to prevent any physical contact with the workor ground.

    D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

    D Use AC output ONLY if required for the welding process.

    D If AC output is required, use remote output control if present onunit.D Additional safety precautions are required when any of the follow-

    ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

    D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

    D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

    D Always verify the supply ground check and be sure that input

    power cord ground wire is properly connected to ground terminal idisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

    D When making input connections, attach proper grounding conductor first double-check connections.

    D Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

    D Frequently inspect input power cord for damage or bare wiringreplace 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 drape cables over your body.D If earth grounding of the workpiece is required, ground it direct

    with a separate cable.D Do not touch electrode if you are in contact with the work, groun

    or another electrode from a different machine.D Do not touch electrode holders connected to two welding ma-

    chines at the same time since double open-circuit voltage will bepresent.

    D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

    D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiec

    or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to preven

    contact with any metal object.D Do not connect more than one electrode or work cable to any

    single weld output terminal.

    SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of inputpower.D Turn Off inverter, disconnect input power, and discharge inpu

    capacitors according to instructions in Maintenance Sectionbefore touching any parts.

    HOT PARTS can burn.D Do not touch hot parts bare handed.D Allow cooling period before working on equip-

    ment.D To handle hot parts, use proper tools and/or

    wear heavy, insulated welding gloves andclothing to prevent burns.

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    OM-925 Page 2

    Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

    FUMES AND GASES can be hazardous.

    D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at the

    arc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Material Safety Data Sheets (MSDSs)

    and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.D 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. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

    D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

    D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

    Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

    D Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

    D Wear approved safety glasses with side shields under yourhelmet.

    D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

    D Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

    ARC RAYS can burn eyes and skin.

    Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment c

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