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OM-227 978B 2007−04
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Handler 210
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From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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TABLE OF CONTENTS SECTION 9 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 9-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 9-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9-3. Holding And Positioning Welding Gun .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Nationa
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperage Voltage Hertz Negative V A Hz Direct Current Positive Single Phase Input (DC) Output Voltage Input Off On Do Not Switch Gas Metal Arc Flux Cored Arc Wire Feed While Welding Welding (GMAW) Welding (FCAW) SECTION 4 − SPECIFICATIONS 4-1. Specifications Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage KVA KW Output Range 230 V, 60 Hz, W/ Gun Dimensions DC Single-Phase Length: 19-1/2 i
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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 200 175 fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or 130 duty cycle before welding. 100 Exceeding duty cycle can 80 damage unit or gun and void warranty. 60 40 20 10 10 20 30 40 60 70 80 100 Duty Cycle % 30% duty cycle at 150 amps 3 Minutes Welding 7 Minutes Resting Overheating A or
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SECTION 5 − INSTALLATION 5-1. Installing Welding Gun 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. Tighten Spool Gun thumbscrew. Welding gun must be inserted 5 completely to prevent leakage of shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and ÉÉÉ tighten threaded collar. 6 Spool Gun/MIG Gun Switch ÉÉÉ Place switch in MIG Gun position. ÉÉÉ Close door. 6 MIG Gun 2 1 3 4 Be sur
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5-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output no shielding gas output terminal terminal 5-4. Changing Polarity 1 Lead Connections For Direct CHANGING Current Electrode Negative POLARITY
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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. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap with CO shielding gas. See Parts List for optional 2 1 2 Cylinder Valve CO gas regulator/flowmeter. 2 Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 4 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 2 5 Regulat
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5-6. Selecting A Location And Connecting Input Power Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Installation must meet all Na- tional and Local Codes − 18 in (457 mm) of have only qualified persons space for airflow make this installation. Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Always connect green or green/yellow conductor to supply grounding terminal fi
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5-7. Electrical Service Guide Input Voltage 230 Input Amperes At Rated Output 24 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 1 2 Circuit Breaker , Time-Delay 25 3 Normal Operating 35 4 Min Input Conductor Size In AWG 14 55 Max Recommended Input Conductor Length In Feet (Meters) (17) Min Grounding Conductor Size In AWG 14 Reference: 2005 National Electrical Code (NEC) (including article 630) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fus
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5-9. Installing Contact Tip And Nozzle Turn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 5-11). 3 2 Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. 1 Flux Nozzle MIG Nozzle Use with flux cored wire only. Use with solid or flux cored wire. Narrow design allows access in tight spaces and provides better visibility of puddle during welding. Push nozzle over contact tip and Push nozzle over
