OM-194 430A June 1999 Specifications Covered by this Manual: 500 430, 500 431, 500 432 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder BETA-MIG 2510 And M-25 Gun
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, 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.) OM-194 430A SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch 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 Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. 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 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding 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 Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – INSTALLATION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Max. OpenCircuit Voltage Rated Output 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle 32 200 V 230 V 460 V 575 V KVA KW 50 2.3* 44 2* 22 1* 18 0.8* 10 0.46* 7.7 0.13* Wire Type and Diameter Solid Steel Stainless Steel Flux Cored .023 – .045 in (0.6 – 1.2 mm) .023 – .035 in (0.6 – 0.9 mm) .030 – .045 in (0.8 – 1.2 mm) Wire Feed Speed Dimensions Weight 50–670 IPM (1.2–1.
2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED 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. Definition warn7.1 8/93 .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires 0 .023 To .045 in (0.6 To 1.
2-5. Installing Running Gear Install running gear as shown. Tools Needed: ST-801 856-A 2-6. Installing Welding Gun 1 2 3 2 Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 3 4 1 Gun Trigger Plug Insert into receptacle, and tighten threaded collar. Close door. 4 Ref.
2-7. Setting Gun Polarity For Wire Type 1 2 3 4 Polarity Changeover Label Wire Drive Assembly Positive (+) Output Terminal Negative (–) Output Terminal Always read and follow wire manufacturer’s recommended polarity. 1 Close door. 3 4 Ref. 194 425 Tools Needed: 3/4 in OM-194 430 Page 12 2 Ref.
2-8. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection Fitting has threads. 3 1 Argon Gas Flow Adjust CO2 Adapter Customer Supplied 5 2 right-hand Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate (see Section 3-2). This flow gauge can be adjusted between 5 and 25 cfh.
2-10. Positioning Jumper Links Check input voltage available at site. 1 Jumper Links Access Door Open door. 200 VOLTS 230 VOLTS 230 VOLTS 460 VOLTS 460 VOLTS 575 VOLTS S-144 918-C 2 3 3 Jumper Link Label Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure access door. Close door. S-144 916-A 2 1 Tools Needed: 3/8 in Ref. ST-801 789-A 2-11. Installing Work Clamp 1 2 3 2 Work Cable Hardware Work Clamp Route cable through clamp handle and secure as shown.
2-12. Electrical Service Guide Input Voltage 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 AWG/Kcmil 8 8 10 12 93 (28) 124 (38) 329 (100) 313 (95) 8 8 10 12 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) S-0092J 2-13.
2-14. Threading Welding Wire Tools Needed: 4 2 3 5 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 7 1 1 2 3 4 5 6 7 Ref. ST-801 789-A / Ref. ST-802 064 / S-0627-A 6 . Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire.
SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Control The scale around the control is percent, not wire feed speed. 2 Voltage Control The scale around the control is actual voltage. 4 See Section 3-2, or inside welding power source door, for weld parameters chart.
3-2. Weld Parameters Wire Type, Shielding Gas, And Flow Rate Wire Diameter (inch) Material Thickness 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 Feed Speed% – – – 38 34 32 24 19 15 14 12 12 Volts – – 21.5 20.5 19.0 19.0 19.0 19.0 18.5 18.5 18.0 17.5 Feed Speed% – – 45 36 27 26 19 15 13 11 10 9 Volts 22.5 22.0 20.5 20.
3-3. Installing Receptacle Module For Use With A Spool Gun (Optional) 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 halfway down each side. Be sure to cut label across metal sections, before removing knockout, to avoid tearing the label. 2 Module 3 Plug PLG9 4 Receptacle RC2 Locate receptacle RC2 in unit wiring harness. Connect plug PLG9 to RC2. Slide module in and secure with supplied screws.
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. Apply light coat of oil or grease to drive motor shaft. 4-2. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens, wire feeding stops.
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 1 2 5 3 Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 2 3 Anti-Wear Guide Install guide as shown. 4 1 Drive Roll Install correct drive roll for wire size and type.
4-7. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Y Turn off welding source/wire feeder. 1 2 3 Head Tube 1 Nozzle 2 Contact Tip 3 Adapter power . Wire size stamped on tip – check and match wire size. Remove nozzle, contact tip, adapter, and wire outlet guide. Cut off wire and disconnect gun from feeder. 3/8 in Blow out gun casing. Lay gun cable out straight before installing new liner. Remove liner.
4-8. Replacing Switch And/Or Head Tube Y Disconnect gun first. 1 Remove handle locking nut. 3 2 4 Slide handle. 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 to end of figure. Secure head tube in vice. 5 6 Loosen jam nut. Remove from vice and turn head tube out by hand.
4-9. Troubleshooting Trouble No weld output; wire does not feed. Remedy 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 switch if necessary. Have Factory Authorized Service Agent check all board connections and main control board. No weld output; wire feeds. Thermostat TP1 open (overheating).
SECTION 5 – ELECTRICAL DIAGRAM SC-184 944-A Figure 5-1.
Notes OM-194 430 Page 26
19 24 28 7 1 2 38 3 37 4 6 5 41 40 8 36 35 34 9 33 32 11 31 10 (Fig. 6–2) 30 29 12 23 13 22 25 21 26 14 27 20 15 18 16 17 SECTION 6 – PARTS LIST . Hardware is common and 39 not available unless listed. 801 783-B Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 1 . . . . . . . . . . 194 424 . . . 2 . . . . . . . . . . 184 670 . . . 3 . . . PL1 . . 157 958 . . . 4 . . . . S1 . . 124 511 . . . 5 . . . R2,3 . 035 897 . . . 6 . . . . . . . . . . 184 733 . . . 7 . . . . . . . . . . 184 834 . . . 8 . . . . Z1 . . 143 892 . . . 9 . . . . T1 . . 174 553 . . . 9 . . . . T1 . . 174 554 . . . . . . . . . TP1 . . 121 497 . . . 10 . . . . . . . . . . . Fig 6-2 . . . 11 . . . . . . . . . .
. Hardware is common and 1 not available unless listed. 2 3 4 5 6 7 8 10 9 11 30 12 13 29 14 28 15 16 27 (Fig. 6–3) 18 17 19 25 24 23 22 21 20 ST-801 786-B Figure 6-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 10) . . . 1 . . . . . . . . . . 170 201 . . . 2 . . . . . . . . . . 184 738 . . . 3 . . . . . . . . . . 374 551 . . . 4 . . . . . . . . . . 184 739 . . . 5 . . . . . . . . . . 405 448 . . . 6 . . . . . . . . . . 184 703 . . . 7 . . . . . . . . . . 405 376 . . . 8 . . . . . . . . . . 374 546 . . . 9 . . . . . . . . . . 602 246 . . . 10 . . . . . . . . . . 184 666 . . . 11 . . . CB1 . . 123 745 . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-3. Wire Drive Assembly (Fig 6-2 Item 26) ... 1 .......... ... 2 .......... ... 3 .......... ... 4 .......... ... 5 .......... ... 6 .......... ... 7 .......... ... 8 .......... ... 9 .......... . . . 10 . . . . . . . . . . . . . 11 . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 13 . . . . . . . . . . . . . 14 . . . PM . . ................ ................ ................ . . . 15 . . . . . . . . . . . . . 16 . . . . . . . . . . . . .
16 12 11 9 14 13 15 12 11 10 9 8 17 7 6 5 4 3 2 1 Ref. 800 792-B Figure 6-4.
Item No. Part No. Description Quantity Figure 6-4. Gun And Cable Assembly, M-25 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 15 16 17 . . . ♦169 724 . . . ♦169 725 . . . . . 169 726 . . . ♦169 727 . . . ♦087 299 . . . ♦000 067 . . . ♦000 068 . . . ♦000 069 . . . . . 169 728 . . . . . 169 729 . . . . . 170 467 . . . . . 170 468 . . . . . 169 730 . . . . . 169 731 . . . . . 169 738 . . . . .
Options and Accessories BETA-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 30A spool gun.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number.
