Posted: 5/25/2014 12:17:00 PM EDT
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I have a Hobart Handler 210 and I can't get it to produce a consistent arc. It feeds wire fine and I can get the occasional weak arc, but can't weld. The ground seems good. Any help is greatly appreciated. Posted Via AR15.Com Mobile |
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If this is a flux or gas machine make sure the lead (+, -) wires are hooked up correctly inside. I'm using .030 flux cored wire with the polarity set correctly. I've used this exact setup before without issue. Literally just turned the machine on after having not used it for a few months and it doesn't work. Machine is also left unplugged when not in use. Posted Via AR15.Com Mobile |
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Did it ever work right? If so, what happened just before it quit working correctly? It worked fine when I last used it several months ago. Literally has just been sitting unplugged in the shop. Haven't changed wire or anything. Posted Via AR15.Com Mobile |
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Are you sure both legs of your 220 are hot? Are you running 115 or 230? I'm running 220. Both legs are hot cause the cooling fan won't turn on unless there is 240 volts. I also just put a VO meter on the plug and was getting 242v so that's not the issue. I currently have the machine opened up and there is nothing obvious. Posted Via AR15.Com Mobile |
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Your manual recommends:
Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 7-5). Check for proper polarity connections (see Section 5-4). Check thumbscrew securing gun end to feed head adapter and tighten if necessary. Don't know why not using the welder would change some of those things. |
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Open the cover where the wire feed mechanism is located and check that the internal leads are secure. I've had one work loose. Also check for any wire fouling in this area, brush/blow it out.
Is the wire itself rusty or corroded? Otherwise, just match your voltage/wire speed/material thickness. |
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Your manual recommends: Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 7-5). Check for proper polarity connections (see Section 5-4). Check thumbscrew securing gun end to feed head adapter and tighten if necessary. Don't know why not using the welder would change some of those things. One of the first things I did was find the manual and check those items. Still having no luck. I may just have to take the machine in yet again. Considering how much use this thing has had, it's had a lot of problems. Posted Via AR15.Com Mobile |
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220 at the machine?
Pull and plug in all the connections on the board. Pull the Voltage control plug and check for normal operation of the pot. IIRC the fan motor is also the control transformer. Don't remember what the normal output is. Good ground, solid wire connections, rusty liner/wire Bad diode or control board.  I've replaced a lot of control boards in the Handlers. There isn't really much else in there.
They really aren't meant for heavy use, more of a hobby machine. Made by miller though, maybe give them a call. ETA: have s/n ready |
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Like a bad bridge rectifier causing a not quite DC output? Maybe... Quoted:
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Bad diode or control board. I've replaced a lot of control boards in the Handlers. There isn't Like a bad bridge rectifier causing a not quite DC output? Maybe... After the main transformer is a 4-diode bridge rectifier that converts it to DC. Sometimes a diode opens or shorts. A short usually makes noise. An open diode can cause noodling like that. Only getting half power. Easiest way is to check the waveform with a 'scope. Otherwise use a meter to check that max output (open circuit - not welding) between output studs is better than 30VDC. Have you pulled the liner out and checked it yet? It may have corroded. If none of the above, it may be time to take it to a shop. |