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Hobart Welding Products 210 manual

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Table of contents for the manual

  • Page 1

    Processes OM-227 978A 2006 − 12 Handler 210 Arc W elding Power Source And Wire Feeder Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding R[...]

  • 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 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 9 − MIG WELDING (GMA W) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical MIG Process Connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Control Settin[...]

  • Page 5

    OM-227 978 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me[...]

  • Page 6

    OM-227 978 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

  • Page 7

    OM-227 978 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-227 978 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W[...]

  • Page 9

    OM-227 978 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les utili sés Sy m bole g raphique d’avertis sement ! Attention ! Cett e pro - cédur e c omporte des risques poss[...]

  • Page 10

    OM-227 978 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

  • Page 11

    OM-227 978 Page 7 2-3 . Dangers s uppléme ntaires en relation avec l ’instal lation, le f onctionneme nt e t l a maintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l[...]

  • Page 12

    OM-227 978 Page 8 2-5. Princi pales norm es d e sécu rit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W [...]

  • Page 13

    OM-227 978 Page 9 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 Flux Cored Arc W elding (FCAW) SECTION 4 − SPECIFICA TIONS 4-1. Specifications Rated Wel[...]

  • Page 14

    OM-227 978 Page 10 4-2. 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. Y Exceeding duty cycle can damage unit or gu[...]

  • Page 15

    OM-227 978 Page 1 1 SECTION 5 − INST ALLA TION 5-1. Installing Welding Gun 804 686-A 1 Drive Assembly 2 MIG Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . T ighten thumbscrew . W elding gun must be inserted completely to prevent leakage of shielding gas. 5 Gun T rig[...]

  • Page 16

    OM-227 978 Page 12 5-3. Process/Polarity T able Process Polarity Cable Connections P rocess P o l ar i ty 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 − St[...]

  • Page 17

    OM-227 978 Page 13 5-5. 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 Insta[...]

  • Page 18

    OM-227 978 Page 14 5-6. Selecting A Location And Connecting Input Power Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tag- out in[...]

  • Page 19

    OM-227 978 Page 15 5-7. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 24 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Operating 3 35 Min Input Conductor Size In A WG 14 Max Recommended Input Conductor Length In Feet (Meters) 55 (17) Min Grounding Conductor [...]

  • Page 20

    OM-227 978 Page 16 5-9. Installing Contact Tip And Nozzle T ools Needed: Ref. 802 399-A Y T ur n off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 T ip Adapter Thread welding wire through gun (see Section 5-1 1). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. Flux Nozzle MIG Nozzle Use with flux core[...]

  • Page 21

    OM-227 978 Page 17 5-10. 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 . T ighten thumbscrew . Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun T rigger Plug In[...]

  • Page 22

    OM-227 978 Page 18 5-1 1. Threading Welding Wire 1 Wire Spool 2 W elding 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 23

    OM-227 978 Page 19 SECTION 6 − OPERATION 6-1. Controls 1 Wire Speed Control Us e control to select a wire feed speed. As V oltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2 , as applicable). 2 Power Switch 3 V oltage Switch The higher the selected number , the thicker t[...]

  • Page 24

    OM-227 978 Page 20 6-2. W eld Parameter Chart For 230 V AC Model[...]

  • Page 25

    OM-227 978 Page 21 227 949-A[...]

  • Page 26

    OM-227 978 Page 22 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y 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 l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl W [...]

  • Page 27

    OM-227 978 Page 23 7-4. Changing Drive Roll Or Wire Inlet Guide 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 slide it out over the retaining p[...]

  • Page 28

    OM-227 978 Page 24 7-6. Cleaning Or Replacing Gun Liner Ref. 804 692-A 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more. Cut liner of f so that 3/4 in (19 mm) sticks out of[...]

  • Page 29

    OM-227 978 Page 25 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Needed: 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tube in vice and tighten until nuts are tight. Remove from vic[...]

  • Page 30

    OM-227 978 Page 26 7-8. 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 5-6). d oes no t run. 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 protec[...]

  • Page 31

    OM-227 978 Page 27 Notes[...]

  • Page 32

    OM-227 978 Page 28 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram[...]

  • Page 33

    OM-227 978 Page 29 227 951-A[...]

  • Page 34

    OM-227 978 Page 30 SECTION 9 − MIG WELDING (GMA W) GUIDELINES 9-1. T ypical MIG Process Connections Y 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 s close to the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Shie[...]

  • Page 35

    OM-227 978 Page 31 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. NOTE 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 [...]

  • Page 36

    OM-227 978 Page 32 9-3. Holding And Positioning W elding Gun Welding 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 end of nozzle, and tip of wire is positioned correctly on seam. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Elect[...]

  • Page 37

    OM-227 978 Page 33 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. NOTE Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PR[...]

  • Page 38

    OM-227 978 Page 34 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 across gaps, a weave bead or multiple stringer beads works better . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 W eave Bead − Side T o Side Movement A[...]

  • Page 39

    OM-227 978 Page 35 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 40

    OM-227 978 Page 36 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 41

    OM-227 978 Page 37 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 ha[...]

  • Page 42

    OM-227 978 Page 38 9-17. T roubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, but wire does not feed T oo little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. w i re d oes no t f ee d . Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace[...]

  • Page 43

    OM-227 978 Page 39 Notes[...]

  • Page 44

    OM-227 978 Page 40 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 804 691-A 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 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 56 55 57 58 Figure 10-1. Main Assembly[...]

  • Page 45

    OM-227 978 Page 41 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 46

    OM-227 978 Page 42 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity 40 196 574 SWITCH, rocker DPST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 228 400 KNOB, pointer (voltage) 1 . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 47

    OM-227 978 Page 43 804 692-A 1 2 34 5 6 7 9 8 10 11 12 Figure 10-2. H-14 Gun Quantity Description Part No. 231 204 Item No. Figure 10-2. H-14 Gun 1 NOZZLE, slip type .500 orf flush (see Section 10-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NOZZLE, flux cored slip type (see Section 10-5) . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 48

    OM-227 978 Page 44 10-3. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 202 925 .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 49

    Notes[...]

  • Page 50

    Notes W o r k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual .[...]

  • Page 51

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2006 − 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 Hoba[...]

  • Page 52

    PRINTED IN USA © 2006 Hobart Welding Products. 2006 − 01 Hoba rt We lding Pr oducts An Illinois T ool W orks Compa ny 600 W est Main St r eet Tr oy , OH 45373 USA For T ech nical Assistan ce: Call1-800-332-3281 Fo r Liter atu re Or Ne ar est Dea le r: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was deliv[...]