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Hobart Welding Products 2510 manual

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Table of contents for the manual

  • Page 1

    BET A-MIG 2510 And M-25 Gun Processes OM-194 430A June 1999 Specifications Covered by this Manual: 500 430, 500 431, 500 432 Gas Metal Arc (MIG) W elding Flux Cored Arc (FCAW) W elding Description Arc Welding Power Source and Wire Feeder[...]

  • Page 2

    [...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

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  • Page 5

    OM-194 430 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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 message. . Means “Note”; not safety related. This group of symbols means W arning! W a[...]

  • Page 6

    OM-194 430 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 an[...]

  • Page 7

    OM-194 430 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-194 430 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 year[...]

  • Page 9

    OM-194 430 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-194 430 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-194 430 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-194 430 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for [...]

  • Page 13

    OM-194 430 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. OpenCir- cuit V oltage 200 V 230 V 460 V 575 V KV A KW 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle 32 50 2.3* 44 2* 22 1* 18 0.8* 10 0.46* 7.7 0.13* Wire T ype and Diameter Wire Feed Speed Dimensio[...]

  • Page 14

    OM-194 430 Page 10 2-3. W elding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RA TED DUTY CYCLE can damage gun and void warranty . • Do not weld at rated load longer than shown below . • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Duty Cycle is percentage of 10 minutes that gun can weld at rated load without[...]

  • Page 15

    OM-194 430 Page 1 1 2-5. Installing Running Gear ST-801 856-A Install running gear as shown. T ools Needed: 2-6. Installing Welding Gun Ref. ST-801 789-A 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun en d through opening until it bottoms against drive assembly . T ighten knob. 4 Gun Trigger Plug Insert into recepta[...]

  • Page 16

    OM-194 430 Page 12 2-7. Setting Gun Polarity For Wire T ype T ools Ne ed e d : 3/4 in Ref. 194 425 1 2 4 3 1 Polarity Changeover Label 2 Wire Drive Assembly 3 Positive (+) Output T erminal 4 Negative ( – ) Output T erminal Always read and follow wire manufacturer ’ s recommended polarity . Close door . Ref. ST-801 789-A[...]

  • Page 17

    OM-194 430 Page 13 2-8. Installing Gas Supply Ref. ST-801 789 / Ref. ST -149 827-B / Ref. ST-158 697-A 1 T ools Ne eded: 2 CO 2 Gas 4 5 1 Argon Gas OR 3 Chain gas cylinder to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection Fitting[...]

  • Page 18

    OM-194 430 Page 14 2-10. Positioning Jumper Links Ref. ST-801 789-A Check input voltage available at site. 1 Jumper Links Access Door Open door . 2 Jumper Link Label 3 Input V oltage Jumper Links Move jumper links to match input voltage. Close and secure access door . Close door . T ools Needed: 1 3/8 in 3 2 200 VOL T S 230 VOL T S 460 VOL T S S-14[...]

  • Page 19

    OM-194 430 Page 15 2-12. Electrical Service Guide Input V oltage 200 230 460 575 Input Amperes At Rated Output 50 44 22 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 80 70 35 25 Min Input Conductor Size In A WG/Kcmil 8 8 10 12 Max Recommended Input Conductor Length In Feet (Meters) 93 (28) 124 (38) 329 (100) 313 (95) Min Gro[...]

  • Page 20

    OM-194 430 Page 16 2-14. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 7 6 T ools Needed: Ref. ST-801 789-A / Ref. ST -802 064 / S-0627-A 6 in (150 mm) . Hold wire tightly to keep it from unraveling. 4 in (102 mm) T ig[...]

  • Page 21

    OM-194 430 Page 17 SECTION 3 – OPERA TION 3-1. Controls 1 Wire Speed Control Th e scale around the control is per- cent, not wire feed speed. 2 V oltage Control The scale around the control is actual voltage. See Section 3-2, or inside welding power source door , for weld param- eters chart. 3 Pilot Light 4 Power Switch 1 2 4 3[...]

  • Page 22

    OM-194 430 Page 18 3-2. W eld Parameters Wire T ype, Wire Operator Material Thickness Shielding Gas, And Flow Rate Diameter (inch) Operator Control Settings 3/8 in 5/16 in 1/4 in 3/16 in 10 ga 12 ga 14 ga 16 ga 18 ga 20 ga 22 ga 24 ga Volts ––– 20.0 19.5 19.0 18.0 18.0 18.0 17.5 17.0 17.0 .023 Feed Speed% ––– 38 34 32 24 19 15 14 12 12 [...]

  • Page 23

    OM-194 430 Page 19 3-3. Installing Receptacle Module For Use With A Spool Gun (Optional) ST-801 869-A 1 Knockout Panel Pierce front panel label at corners of knockout and follow groves in front panel. The knockout is held in place by a thin metal section half- wa y down each side. Be sure to cut label across metal sections, before removing knockout[...]

  • Page 24

    OM-194 430 Page 20 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . OR Remove drive roll and carrier . Appl[...]

  • Page 25

    OM-194 430 Page 21 4-3. Unit Overload If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun trigger to reset this condition. 4-4. Changing Drive Roll And Wire Inlet Guide ST-150 227-C T ools Ne ed e d : 1 3 2 4 5 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close[...]

  • Page 26

    OM-194 430 Page 22 4-7. Removing Nozzle, Contact Tip, And Adapter , Changing Liner , And Cleaning Gun Casing Ref. ST-800 797-C Y T urn off welding power source/wire feeder . 1 Nozzle 2 Contact Tip 3 Adapter . Wire size stamped on tip – check and match wire size. Head T ube T ools Needed: 3/8 in Lay gun cable out straight before installing new lin[...]

  • Page 27

    OM-194 430 Page 23 4-8. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 1 Remove handle locking nut. 2 Remove switch housing. Note : If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue[...]

  • Page 28

    OM-194 430 Page 24 4-9. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-13). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-6). Check and replace Power s[...]

  • Page 29

    OM-194 430 Page 25 SECTION 5 – ELECTRICAL DIAGRAM SC-184 944-A Figure 5-1. Circuit Diagram For Welding Power Source[...]

  • Page 30

    OM-194 430 Page 26 Notes[...]

  • Page 31

    OM-194 430 Page 27 SECTION 6 – P ARTS LIST . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 (Fig. 6 – 2) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 28 36 37 38 39 40 41 801 783-B Figure 6-1. Main Assembly[...]

  • Page 32

    OM-194 430 Page 28 Description Part No. Dia. Mkgs. Item No. Quantity Figure 6-1. Main Assembly 1 194 424 LABEL, set, nameplate & side decals 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 670 HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 33

    OM-194 430 Page 29 ST-801 786-B . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 10 11 12 14 15 16 13 17 18 19 20 21 22 23 24 25 27 (Fig. 6 – 3) 28 29 30 9 Figure 6-2. Center Baffle w/Components[...]

  • Page 34

    OM-194 430 Page 30 Description Part No. Dia. Mkgs. Item No. Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 10) 1 170 201 NUT , retaining w/warning label (HOBART) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 738 SP ACER, spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 35

    OM-194 430 Page 31 Description Part No. Dia. Mkgs. Item No. Quantity Figure 6-3. Wire Drive Assembly (Fig 6-2 Item 26) 1 172 075 CARRIER, drive roll w/comp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 166 072 SP ACER, gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-194 430 Page 32 Ref. 800 792-B 1 234 56 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6-4. Gun And Cable Assembly , M-25[...]

  • Page 37

    OM-194 430 Page 33 Description Part No. Item No. Figure 6-4. Gun And Cable Assembly , M-25 Quantity 1 ♦ 169 724 NOZZLE, slip type .500 orf .125 recess . . . . . . . . 1 ♦ 169 725 NOZZLE, slip type .625 orf .125 recess . . . . . . . . 1 169 726 NOZZLE, slip type .625 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 38

    Options and Accessories BET A-MIG 2510 Olympic 30A Spool Gun #130 831-01-9 Ideal for aluminum welding jobs. 200 Amp, 100% duty cycle, air-cooled, 1 lb spool gun with 30 ft (9.1 m) cable assembly . Use with Spool Gun Module #043 084. Spool Gun Module #043 084 Required if welding with spool gun. Provides a convenient way for you to plug in an Olympic[...]

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  • Page 40

    PRINTED IN USA Model Name S erial/St yle Number Purch as e Date (Date which equipment was deli v ered to original customer.) Distr ibut or Ad dres s City State Z ip Please complet e and retain with your personal records. Always provide Model Name and Serial/St yle Number. Contac t your Distr i butor for: Welding Supplies and Consumables Options and[...]