OM-230 261A 2006−10 Processes MIG (GMAW) Welding Description Wire Feeder Spool Gun Spool Gun DP 3035 File: Wire Feeder
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y 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. 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.
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 an approved welding helmet fitted with a proper shade of filter lenses 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. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y 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 procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints. Y Indique un message de sécurité particulier . Signifie NOTE ; n’est pas relatif à la sécurité. 2-2.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à 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 approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
2-3. 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 inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 3 − INSTALLATION 3-1. Specifications Wire Diameter Range .030 Thru .035 in (0.8 Thru 0.9 mm) Aluminum Wire Or Flux Cored Wire .023 Thru 035 in (0.6 Thru 0.9 mm) Solid Wire Approximate Wire Feed Range 115 To 715 ipm (4.1 To 20.4 mpm) Cooling Method Air Cooled Maximum Spool Size Weld Circuit Rating 4 in (102 mm) Diameter 100 Volts, 150 Amperes, 60% Duty Cycle Using Argon Shielding Gas Overall Dimensions Length: 11-1/2 in (291 mm) Width: 2-1/4 in (57 mm) Weight 7.5 lb (3.
3-3. Connecting Spool Gun To Handler 210 1 2 3 4 7 Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew. Spool Gun ÇÇ ÇÇ Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End 5 Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 6 6 7 1 3 2 4 3 Exposed O-rings will cause shielding gas leakage.
3-4. Installing Wire Spool And Threading Welding Wire Tools Needed: 6 7 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover. 8 3 4 5 Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool. 4 2 1 3 9 10 Hub Tension Nut Wire Spool 5 Push Roll/Lower Drive Roll 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever (Red) 8 Wire Inlet Guide 9 Contact Tip 10 Nozzle Remove nozzle and contact tip.
SECTION 4 − OPERATION 4-1. Controls . Spool Gun/MIG Gun switch on Handler 210 must be in Spool Gun position for spool gun to operate. 2 1 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 Valve Open valve on cylinder just before welding. Close valve on cylinder when finished welding. 3 Spool Gun/MIG Gun Switch Switch must be set in Spool Gun position for spool gun to operate.
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months l Unreadable Labels ~ Weld Terminals nl Cords nl Gun Cables Every 6 Months . Maintain more often during severe conditions.
5-2. Changing Drive Rolls Y Turn Off power at welding power source first. 1 Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer, and lift out drive roll. To install drive roll: 4 Slide drive roll onto shaft and secure with washer and screw. 3 2 It may be necessary to remove drive roll side of gun case to change lower drive roll.
5-3. Changing Liner Y Turn Off power at welding power source first. 1 2 3 Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. 3 2 1 Tools Needed: Ref. 804 687-A 5-4. Troubleshooting Trouble Gun tube assembly loose. Remedy Tighten nut at base of gun tube assembly. No weld output; gun/feeder does not Place Power switch on welding power source in the On position (see welding power source Owner’s work. Manual). Check Spool Gun/MIG Gun switch for correct position.
5-5. GMAW (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires different techniques than MIG welding mild steel. A. Before You Start Welding S Material thickness that can be welded with MIG process or aluminum are 14 ga. [0.074 in. (1.9 mm)] or heavier. (How heavy depends on the output capacity of the welder being used.) To MIG weld aluminum thinner than 14 ga.
S Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2. Gas Nozzle Contact Tube Recessed 1/8 in. (3.2 mm) Inside The Nozzle ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÉÉÉ ÉÉÉ Contact Tip To Work Distance 3/4 in. (19 mm) Figure 5-2. Contact Tube Position And Tip-To-Work Distance S Avoid large weave beads on aluminum.
SECTION 6 − ELECTRICAL DIAGRAMS 186 451 Figure 6-1.
Notes OM-230 261 Page 19
SECTION 7 − PARTS LIST . Hardware is common and not 20 13 12 14 28 42 41 40 39 32 38 36 35 37 34 1 2 33 31 45 30 29 27 15 26 16 4 22 5 21 6 17 18 7 19 23 8 2 3 24 25 43 11 44 9 4 10 available unless listed. 804 699-A Figure 7-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Complete Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 40 41 42 43 44 45 . . . PB1 . . . . . 186 416 . . TRIGGER SWITCH . . . . . . . . . . . . . . . . . . . . . .
Notes
Effective January 1, 2006 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface LG or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST Service You 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.
Owner’s Record Please complete and retain with your personal records. Model Name Protect Your Investment! Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Call 1-877-Hobart1 or visit our website at www.HobartWelders.
