Hobart 500559 MIG Welding Equipment User Manual

Handler 140
®
115V Wire Feed Welder
217919
March 2016
B
uilt with Hobart quality and durability, the
Handler 140 is a wire welding package with
industrial performance capable of operating on
standard 115/120 volt, 20 amp home circuits.
The broad output range of 25 –140 amps allows
you to weld 24 gauge up to 1/4 inch steel.
115 Volt
The Handler 140 is capable of running the following
wires: .023 –.035 in. (0.6 – 0.9 mm) mild steel
or stainless steel, .030 –.035 in. (0.8 – 0.9 mm)
flux-cored, and .030 in. (0.8 mm) aluminum.
Five output voltage settings with wire feed tracking
make the unit easy to set and adjust for different
materials and thicknesses.
500559
Includes:
Comfortable 10 ft. (3 m) H100S2-10 gun
10 ft. (3 m) work cable with clamp
Built-in gas solenoid valve and dual-gauge regulator with gas hose
Spool hub assembly accommodates 4 or 8 in. spools
Sample spool of .030 in. (0.8 mm) self-shielding flux-cored wire
.030 in. (0.8 mm) contact tips
Quick Select ™ drive roll for .024 in. (0.6 mm) or .030/.035 in.
(0.8/0.9 mm) solid wire, and .030/.035 in. (0.8/0.9 mm) flux-cored wire
Power cord with plug
Welding guide and material thickness gauge
Owner’s manual with installation, operation and maintenance guidelines
Applications:
Home, farm and ranch and light fabrication projects.
Mower Decks/Brackets
Fences/Gates
Kennels
Signs
Window Security Guards
Grills/Smokers
Firewood Racks
Metal Furniture
Machinery and
Auto Repair, etc.
Features
Benefits
Excellent arc performance
Smooth, stable arc on all thicknesses.
Industrial cast aluminum wire drive system
Professional and durable wire feed performance.
Five-position voltage control
Five voltage ranges allow you to fine-tune the arc.
Quick Select drive roll
Makes setup quicker by offering three grooves — two for different size solid wire and a third for flux-cored wire.
Weighs only 57 pounds
Easier to transport: increased ability to weld where you need to weld.
Convenient polarity changeover
Access makes it quick and easy to change polarity between solid or tubular wire.
Sloped control panel
Increased visibility to the user interface makes adjustments easier.
Self-resetting thermal overload protection
Protects power transformer from thermal overload to ensure reliability.
Hobart’s 5/3/1 industrial warranty
Five-year warranty on transformers, three years on electronics (drive motors, rectifiers) and one year on guns.
Designed, assembled and supported in
Troy, Ohio USA
Industrial-quality products with time-tested reliability since 1917.
Specifications (SUBJECT TO CHANGE WITHOUT NOTICE.)
Rated Output
90 A, 18.5 VDC,
at 20% duty cycle
Current
Range
Max. OpenCircuit Voltage
Wire Feed
Speed Range
Amps Input at Rated Output, 60 Hz, 1-Phase
115 V
KVA
KW
25 –140 A
28 V
40 – 700 IPM
50 – 740 IPM
at no load
20
2.9
Net
Weight
Dimensions
2.5
H: 12-3/8 in. (315 mm)
W: 10-5/8 in. (270 mm)
D: 19-1/2 in. (495 mm)
57 lb.
(26 kg)
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Handler 140 Welding Guide
Settings are approximate. Adjust as required. Thicker materials can be
welded using proper technique, joint preperation and multiple passes.
Recommended Voltage and Wire Speed Settings for thickness of metal being welded.
Number on left of slash is Voltage Setting/Number on right of slash is Wire Feed Setting.
CHANGING
POLARITY
Material
Being
Welded
Wire Type
and
Polarity Setting
Suggested
Shielding Gas
20–30 CFH Flow Rate
Diameter
of Wire
Being Used
24 ga.
.024 in.
(0.6 mm)
20 ga.
.036 in.
(0.8 mm)
18 ga.
.048 in.
(1.2 mm)
16 ga.
.060 in.
(1.6 mm)
12 ga.
.105 in.
(2.7 mm)
10 ga.
.135 in.
(3.4 mm)
3/16 in.
(4.8 mm)
1/4 in.
(6.4 mm)
No Shielding Gas
Required
Good for windy or
outdoor applications.
.030˝ (0.8 mm)
—
—
1/30
2/30
3/40
3/45
4/50
5/50*
Steel
Flux Core
E71T-11
(DCEN)
.035˝ (0.9 mm)
—
—
—
2/25
3/35
4/35
5/35
5/40*
Solid Wire
ER70S-6
(DCEP)
C25 Gas Mixture
75% Argon / 25% CO2
Produces less spatter.
Better appearance.
.024˝ (0.6 mm)
1/30
2/40
2/50
3/50
4/55
—
—
—
.030˝ (0.8 mm)
1/25
2/30
2/35
3/35
4/40
4/50
5/45
5/50*
5/45*
Steel
Steel
Stainless
Steel
Solid Wire
ER70S-6
(DCEP)
100% CO2
Tri-Mix
90% He / 7.5% Ar / 2.5% CO2
Stainless
Steel
(DCEP)
98% Ar / 2% CO2
Aluminum
Aluminum**
4043 AL (DCEP)
Aluminum**
5356 AL (DCEP)
—
—
2/30
3/30
4/35
4/40
5/40
.024˝ (0.6 mm)
1/25
2/35
3/30
3/40
4/50
5/50
—
—
.030˝ (0.8 mm)
—
2/30
3/30
3/35
4/30
4/35
5/35
5/40*
.035˝ (0.9 mm)
—
—
—
3/25
4/30
4/35
5/30
5/35*
.024˝ (0.6 mm)
—
—
3/30
4/50
—
5/50
—
—
.030˝ (0.8 mm)
—
—
3/20
4/40
—
5/40
—
—
.024˝ (0.6 mm)
—
—
1/45
2/60
—
4/70
—
—
.030˝ (0.8 mm)
—
—
1/40
2/50
—
4/60
—
—
.030˝ (0.8 mm)
—
—
—
3/90**
5/90**
—
—
—
.030˝ (0.8 mm)
—
—
—
2/100**
4/100**
—
—
—
100% Argon**
Match feed roll groove to diameter of wire being used.
Set tension knob setting to 3 at start.
Adjust tension per instructions in the manual.
*Multiple passes required.
.035˝ (0.9 mm)
CAUTION! Do not change voltage switch
position while welding. See owners manual
for more information.
Wire speed listed is a starting value only. Wire speed setting can be
fine-tuned while welding. Wire speed also depends on other variables
such as stick out, travel speed, weld angle, cleanliness of metal, etc.
**Aluminum wire is soft so feedability is not as good. Make sure that hub tension is not too tight and keep the torch as straight as possible. A “push angle” for the torch is recommended.
Control Panel
1
2
3
4
2
1.
2.
3.
4.
Power Switch
Wire Speed Control
Voltage Control Switch
Over Temp Light
DCEN
Electrode Negative
for Flux-Cored
Wire
DCEP
Electrode Positive
for Solid Wire
Performance Data
VOLT/AMP CURVE
DUTY CYCLE
30
200
25
100
80
20
VOLTAGE
OUTPUT AMPERES
140
60
40
15
1
10
2
3
4
5
20
5
10
1
2
4
6
8 10
20
40
60 80 100
0
0
10 20
30
DUTY CYCLE %
40 50
60
70
80 90 100 110 120 130 140 150 160
AMPERAGE
Accessories
H100S2-10 Replacement MIG Torch 245924
Comes in 10 ft. (3 m) length with liner for
.030 –.035 in. (0.8 – 0.9 mm) diameter wire.
Small Cart/Cylinder Rack 194776
Designed for portable MIG welders.
Accommodates large and small gas cylinders.
Protective Cover 195186
Weather-resistant nylon resists stains and
mildew while protecting the finish of your welder.
3
Consumables
Item
Hobart Package Part #
Miller Package Part #
.023/.025 in. (0.6 mm)
770174 (5 per package)
087299 (10 per package)
.030 in. (0.8 mm)
770177 (5 per package)
000067 (10 per package)
.035 in. (0.9 mm)
770180 (5 per package)
000068 (10 per package)
MIG Nozzle (Standard)
770404
169715
Gasless Flux-cored Nozzle
770487
226190
Tip Adapter
770402
169716
.023/.025 in. (0.6 mm)
196139
194010
.030/.035 in. (0.8/0.9 mm)
196139
194011
.035/.045 in. (0.9/1.2 mm)
196140
194012
Quick Select ™ drive roll for .024 in. (0.6 mm)
or .030/.035 in. (0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm) flux-cored wire
261157
261157
Dual-groove, V-knurled drive roll
for .030 – .035 in. (0.8 – 0.9 mm)
and .045 (1.2 mm) flux-cored wire
202926
202926
Contact Tips
Liners
Power Source Drive Rolls
Hobart Brothers Company
Troy, Ohio USA
An Illinois Tool Works Company
Service 800-332-3281
Sales 800-626-9420
hobartwelders.com