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Hobart Welding Products 210 MVP manual

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Table of contents for the manual

  • Page 1

    Processes OM-249 498B 2011 − 03 Handler 210 MVP Arc W elding Power Source And Wire Feeder Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding R File: MIG (GMA W)[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 ................................. 1-1. Symbol Usage 1 ....................................................................... 1-2. Arc W elding Hazards 1 ................................................................. 1-3. Additional Symbols For Installation, Operation, And[...]

  • Page 4

    T ABLE OF CONTENTS SECTION 8 − ELECTRICAL DIAGRAM 34 ........................................................ SECTION 9 − MIG WELDING (GMA W) GUIDELINES 36 ............................................ 9-1. T ypical MIG Process Connections 36 ...................................................... 9-2. T ypical MIG Process Control Settings 37 ...[...]

  • Page 5

    OM-249 498 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 201 1 − 01 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols[...]

  • Page 6

    OM-249 498 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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 poo[...]

  • Page 7

    OM-249 498 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-249 498 Page 4 1-4. California Proposition 65 W arnings W elding 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.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-249 498 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2010 − 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

  • Page 10

    OM-249 498 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHA[...]

  • Page 11

    OM-249 498 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter l[...]

  • Page 12

    OM-249 498 Page 8 Les PIÈCES MOBILES peuvent causer des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistol[...]

  • Page 13

    OM-249 498 Page 9 2-5. P r i nc ip al es no r m es de s écu r ité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Socie[...]

  • Page 14

    OM-249 498 Page 10[...]

  • Page 15

    OM-249 498 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMAW) Wire Feed Circuit Protector U 0 Rated No Load V oltage (A verage) U 1 Primary V oltage U 2 Convent[...]

  • Page 16

    OM-249 498 Page 12 SECTION 4 − SPECIFICA TIONS 4-1. Specifications For 230 V AC Rated W elding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 230 V , 6 0 Hz, Single-Phase KV A KW W eight W/ Gun Overall Dimensions 150 A @ 23 V olts DC, 30% Duty Cycle 25 − 210 34 24 5.54 4.72 79 lb (36 kg) Length: 19-1/[...]

  • Page 17

    OM-249 498 Page 13 4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage u[...]

  • Page 18

    OM-249 498 Page 14 4-4. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 249 621-A 0 5 10 15 20 25 30 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 [...]

  • Page 19

    OM-249 498 Page 15 SECTION 5 − INST ALLA TION 5-1. Installing Nozzle, Contact T ip, And Adapter Ref. 243 839-A ! T urn off welding power source. 1 Nozzle 2 Contact Tip 3 Tip Adapter . Wire s ize stamped o n t ip − c heck and mat ch w ire s ize. T ools Needed: 8 mm Head T ube 8 mm 1 3 2 5-2. Installing W elding Gun 804 695-A 1 Drive Assembly 2 M[...]

  • Page 20

    OM-249 498 Page 16 5-3. Installing W ork Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp T ab s Bend tabs around work cable. 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp. Slide insulating sleeves over handles. 802 456-A . Connection hardware must be tightened with proper tools. Do [...]

  • Page 21

    OM-249 498 Page 17 5-4. Process/Polarity T able Process Polarity Cable Connections Cable T o Gun Cable T o Work GMA W − 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[...]

  • Page 22

    OM-249 498 Page 18 5-6. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Inst[...]

  • Page 23

    OM-249 498 Page 19 5-7. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase Input V oltage (V) 230 V olts AC 1 15 V ol[...]

  • Page 24

    OM-249 498 Page 20 5-9. Multi − V oltage Plug (MVP) Connection Selecting Plug 1 Power Cord Connector From W elding Power Source Select plug for power supply receptacle available at site. Not all plugs shown are provided as standard with unit. 2 Plug − NEMA T ype 5 − 15P 3 Receptacle − NEMA T ype 5 − 15R (Customer Supplied) 4 Plug − NEMA[...]

  • Page 25

    OM-249 498 Page 21 5-10. Serial Number And Rating Label Location Th e serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-1 1. Selecting A Location And Connecti[...]

  • Page 26

    OM-249 498 Page 22 5-12. Connecting 1-Phase Input Power For 230 V AC Input Ref. 250 332-A ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to supply [...]

  • Page 27

    OM-249 498 Page 23 5-13. Connecting 1-Phase Input Power For 1 15 V AC Input Ref. 250 332-A ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. Fo r 1 15 volts AC input power , [...]

  • Page 28

    OM-249 498 Page 24 5-14. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in. T ools Needed: 803 012 / 803 013 -B / Ref. 802 971-C Installing 8 in. (203 mm) Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Retaining ring used[...]

  • Page 29

    OM-249 498 Page 25 5-15. Connecting Optional Spool Gun 804 695-A / 804 696-A 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten thumbscrew . Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun Trigger Plug Inse[...]

  • Page 30

    OM-249 498 Page 26 5-16. Threading W elding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: Pull and hold wire; cut off end. Remove gun nozzle and contact tip. Open pressure assembly. Make sure feed roll is set to correct groove to match wire [...]

  • Page 31

    OM-249 498 Page 27 SECTION 6 − OPERATION 6-1. Controls 1 Wire Speed Control Control varies the rate of wire being fed through the welding gun. 2 Power Switch/Supplementary Protector T urns power on and of f. Also, this switch functions as supplementary protector CB1. CB1 protects unit from overload. If CB1 opens, unit shuts down. Reset power swit[...]

  • Page 32

    OM-249 498 Page 28 6-2. W eld Parameter Chart 250 015-A[...]

  • Page 33

    OM-249 498 Page 29 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels ~ W eld T erminals l Damaged Gas H[...]

  • Page 34

    OM-249 498 Page 30 7-4. Changing Drive Roll Or Wire Inlet Guide ! T urn off welding power source. 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Retaining Pin T o remove drive roll, push drive roll in and rotate it (1/4 turn) to the open slot and[...]

  • Page 35

    OM-249 498 Page 31 7-5. Changing Nozzle, Contact T ip, Adapter And Liner , And Cleaning Gun Casing 243 839-A ! T urn off welding power source. 1 Nozzle 2 Contact Tip 3 Tip Adapter . Wire s ize stamped o n t ip − c heck and mat ch w ire s ize. T ools Needed: 8 mm, 10 mm Lay gun cable out straight before installing new liner . Remove nozzle, contac[...]

  • Page 36

    OM-249 498 Page 32 7-6. Replacing Switch And/Or Head T ube 243 840-A T ools Needed: 15 mm Remove screws (5) and nuts (4). Remove handle halves. Hand-tighten head tube into cable connector . Place head tube in vice and tighten until nuts are tight. Remove from vice. Reposition handle halves, and install switch housing. ! T urn Off welding power sour[...]

  • Page 37

    OM-249 498 Page 33 7-7. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-1 1). Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protector (see Sect[...]

  • Page 38

    OM-249 498 Page 34 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram[...]

  • Page 39

    OM-249 498 Page 35 249 315-A[...]

  • Page 40

    OM-249 498 Page 36 SECTION 9 − MIG WELDING (GMA W) GUIDELINES mig1 2009 − 12 Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shielding Gas W ork Clamp 9-1. T ypical MIG Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce wor k c la mp a[...]

  • Page 41

    OM-249 498 Page 37 9-2. T ypical MIG Process Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A C[...]

  • Page 42

    OM-249 498 Page 38 9-3. Holding And Positioning Welding Gun . W elding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger , be sure wire is no more than 1/2 in. (13 mm) past e nd of nozzl e, an d tip of wir e is p ositi oned corre ctly on sea m. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 [...]

  • Page 43

    OM-249 498 Page 39 9-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROF[...]

  • Page 44

    OM-249 498 Page 40 9-5. Gun Movement During Welding . Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Alon[...]

  • Page 45

    OM-249 498 Page 41 9-8. T roubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Us[...]

  • Page 46

    OM-249 498 Page 42 9-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintai[...]

  • Page 47

    OM-249 498 Page 43 9-14. T roubleshooting − W aviness Of Bead W aviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. Support h[...]

  • Page 48

    OM-249 498 Page 44 9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Short Cir[...]

  • Page 49

    OM-249 498 Page 45 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on welding power s[...]

  • Page 50

    OM-249 498 Page 46 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 250 327-A 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55 57 58 59 60 48 Figure 10-1. Main Assembly[...]

  • Page 51

    OM-249 498 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quantity 1 199 566 Door , Access 1 ... ............... .. .................................................. 2 196 006 Hinge, Door 2 ... ............... .. ................................................... 3 21 1 887 Hub, Nut 1 ... ............... .. ..........[...]

  • Page 52

    OM-249 498 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity 40 248 732 Supplementary Protector , Man Reset 1 ... ............... .. ............................. 41 228 400 Knob, Pointer (V oltage) 1 ... ............... .. ......................................... 42 21 1 338 Knob, Pointer (WFS) 1 ...[...]

  • Page 53

    OM-249 498 Page 49 243 842-A 1 23 4 5 6 7 8 7 12 9 13 14 11 10 Figure 10-2. H100S4-10 Gun Description Part No. Dia. Mkgs. 245 926 Item No. Figure 10-2. H100S4-10 Gun Quantity 1 169 715 Nozzle, Slip T ype .500 orf Flush 1 ... .......... .. ...................................... 1 +226 190 Nozzle, Flux Cored Slip T ype 1 ... ......... .. ............[...]

  • Page 54

    OM-249 498 Page 50 10-3. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 237 338 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 10-4. Options P ART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder , 100 lb (45 kg) max. 194 776[...]

  • Page 55

    Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 201 1 − 01 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hob[...]

  • Page 56

    ORIGINAL INSTRUCTIONS − PRINTED IN USA © 201 1 Hobart Welding Products. 201 1 − 01 Hoba rt We lding Pr oducts An Illinois T ool W orks Compa ny 600 W est Main Street Tr oy , OH 45373 US A For Technical Assi stance: Call1-800-332-3281 Fo r Liter atu re Or Ne ar est Dea le r: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date[...]