Hobart Handler 135 ... HELP!

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Hi, and thanks in advance for any help! Today my welder died. I have no idea what happened and am hoping someone can point me in the right direction. First, I'm restoring a car... so my welding is confined to thin sheet metal - spot welding and plug welding (and always on the lowest setting). However, today I started building a rotisserie using 2" square stock 1/8th" thick. The welder was on the highest setting for the first time. Everything was going well. I welded a few pieces together while resting between each weld. Then when I let off the trigger, I heard the gas hissing out of the gun. I turned the welder off and it continued to hiss and the welder was buzzing. I unplugged the welder and it stopped. I let it rest for a while and plugged it back in. With the machine off and plugged in, the gas started flowing out of the gun and the welder started buzzing again. Whether the welder is on or off, It just buzzes and hisses gas. The wire won't feed, the fan doesn't run... nothing. Did i fry the welder somehow?Thanks for any help!
Reply:Judging from your description and the unit control schematics, my guess is control relay CR3 is stuck closed or at worse the control circuit to activate CR3 has failed on.If CR3 is on all the time, the gun tip/wire should be hot (weld voltage present) all the time.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Judging from your description and the unit control schematics, my guess is control relay CR3 is stuck closed or at worse the control circuit to activate CR3 has failed on.If CR3 is on all the time, the gun tip/wire should be hot (weld voltage present) all the time.
Reply:I need to make a correction.  I was looking at the wrong machine schematic so it would be control relay CR1 not relay CR3 as I originally stated.To answer your question, if just a failed relay or even a component failure within the control circuit on the board, it's repairable by one with the appropriate knowledge and skill.Do you have the manual for the machine?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I must be trying to do too many things at the same time lately. Actually, the only control "components" within the CR1 control circuit is the gun trigger which is apparently functioning properly based on your description.  If the gun trigger was failed closed, you'd also have wire feed at the same time as gas flow and transformer hum.  But if CR1 fails closed you'll only get gas flow and transformer output (hum).So, simply replacing CR1 should fix your problem rather than buying a complete board for over $110. http://miller4less.com/advanced_sear...15&search.y=12Last edited by duaneb55; 10-20-2013 at 11:34 AM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:From the schematic, looks like the fan should always run.  It also supplies power to the control board through an auxiliary coil in the fan. Though it does sound like a malfunctioning relay."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Thanks again. I'm going to call my local welding shop tomorrow and see what they can do. Hopefully it won't hurt to bad. Thanks again for all the help!!!