Hobart Welding Products Handler 135 User manual

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
DC
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
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 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
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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
0
15
A or V
OR
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
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 Minutes Resting
Duty Cycle %
Output Amperes
1410 20 40 60 100
26808
10
20
40
60
80
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
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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.
4
1
23
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

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
1
2

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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
6
1
2
3
Argon Gas Or
Mixed Gas
4
5
7
.DO NOT use Argon/Mixed gas regulator/flowmeter
with CO2shielding gas. See Parts List for optional
CO2gas regulator/flowmeter.