OM-249 498A 2011−02 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 210 MVP R File: MIG (GMAW)
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.
TABLE OF CONTENTS SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
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. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California Proposition 65 Warnings Welding or cutting equipment 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.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
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). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
OM-249 498 Page 10
SECTION 3 − DEFINITIONS 3-1.
SECTION 4 − SPECIFICATIONS 4-1. Specifications For 230 VAC Rated Welding Output Amperage Range Maximum OpenCircuit Voltage DC Amperes Input at Rated Load Output 230 V, 60 Hz, Single-Phase KVA KW Weight W/ Gun Overall Dimensions Length: 19-1/2 in. (495 mm) 150 A @ 23 Volts DC, 30% Duty Cycle 25 − 210 34 24 5.54 4.72 79 lb (36 kg) Width: 10-5/8 in. (273 mm) Height: 12-3/8 in. (314 mm) Wire Type And Diameter Solid/ Stainless Flux Cored .023 − .035 in. (0.6 − 0.9 mm) .030 − .045 in. (0.
4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 230 VAC Model If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit or gun and void warranty.
4-4. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 230 VAC Model 35 30 7 6 5 4 3 Voltage 25 20 2 1 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 Amperage 115 VAC Model 35 30 Voltage 25 20 15 4 5 6 7 10 5 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 Amperage ssb1.
SECTION 5 − INSTALLATION 5-1. Installing Nozzle, Contact Tip, And Adapter 2 3 Head Tube ! Turn off source. welding 1 Nozzle 2 Contact Tip 3 Tip Adapter power . Wire size stamped on tip − check and match wire size. 1 8 mm Tools Needed: 8 mm Ref. 243 839-A 5-2. Installing Welding Gun 1 2 3 4 Spool Gun 6 Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew.
5-3. Installing Work Clamp . Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. 1 2 3 4 5 Nut Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable. 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp. 3 1 Slide insulating handles. sleeves over 6 2 5 4 Tools Needed: 7/16 in.
5-4. Process/Polarity Table Process Cable Connections Polarity Cable To Gun Cable To Work GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) output terminal Connect to negative (−) output terminal FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative (−) output terminal Connect to positive (+) output terminal 5-5. Changing Polarity CHANGING POLARITY DCEN Electrode negative for flux cored wire ! Turn off source.
5-6. 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 with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 1 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 4 2 7 3 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical.
5-7. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
5-9. Multi−Voltage Plug (MVP) Connection Selecting Plug 2 1 3 4 5 ! 6 Do not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty. 7 Connecting Plug To Power Cord MVP Plug1 2010−10 / Ref. 805 390-C Selecting Plug 1 Power Cord Connector From Welding Power Source Select plug for power supply receptacle available at site.
5-10. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-11. Selecting A Location And Connecting Input Power 18 in. (457 mm) of space for airflow ! 1 Do not move or operate unit where it could tip.
5-12. Connecting 1-Phase Input Power For 230 VAC Input 1 5 =GND/PE Earth Ground 7 4 ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.
5-13. Connecting 1-Phase Input Power For 115 VAC Input ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. For 115 volts AC input power, a 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.
5-14. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter used with 8 in. (203 mm) spool only. When a slight force is needed to turn spool, tension is set. Tools Needed: Retaining ring used with 8 in. (203 mm) spool only. 1/2 in. OM-249 498 Page 24 803 012 / 803 013 -B / Ref.
5-15. Connecting Optional Spool Gun 1 2 3 4 7 Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew. Spool Gun ÇÇ ÇÇ Spool gun must be inserted completely to prevent leakage of shielding gas. 5 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 6 Spool Gun/MIG Gun Switch Place switch in Spool Gun position.
5-16. Threading Welding Wire 1 2 3 4 5 6 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. 6 Tools Needed: 1 2 3 5 . Hold wire and spool tightly to keep it from unraveling. 4 in (120 mm) 6 in (150 mm) Open pressure assembly. Make sure feed roll is set to correct groove to match wire size (see Section 7-4). Tighten Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. .
SECTION 6 − OPERATION 6-1. Controls 2 1 4 5 3 6 250 650-A 1 Wire Speed Control Control varies the rate of wire being fed through the welding gun. 2 Power Switch/Supplementary Protector Turns power on and off. Also, this switch functions as supplementary protector CB1. CB1 protects unit from overload. If CB1 opens, unit shuts down. Reset power protector. 3 switch/supplementary Voltage Control Control varies the voltage level of the welding arc.
6-2.
SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. 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 l = Replace Reference l Damaged Gas Hose nl Weld Cables OR ~ Drive Rolls ~ Inside Unit 7-2.
7-4. Changing Drive Roll Or Wire Inlet Guide Tools Needed: ! Turn off source. 1 Inlet Wire Guide Securing Screw Inlet Wire Guide 2 welding power Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Retaining Pin To remove drive roll, push drive roll in and rotate it (1/4 turn) to the open slot and slide it out over the retaining pin.
7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing 2 3 Head Tube ! Turn off source. welding 1 Nozzle 2 Contact Tip 3 Tip Adapter power . Wire size stamped on tip − check and match wire size. 1 Cut off wire and disconnect gun from feeder. 8 mm Remove nozzle, contact tip, and adapter. Unscrew and remove liner. Blow out gun casing. Lay gun cable out straight before installing new liner. 10 mm Reassemble gun in reverse order from taking it apart.
7-6. Replacing Switch And/Or Head Tube ! Turn Off welding power source /wire feeder and disconnect gun. 1 Remove screws (5) and nuts (4). 2 Remove handle halves. 3 Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. Remove screw on opposite side. 4 Secure head tube in vice. 5 6 8 Loosen jam nut. Remove from vice and turn head tube out by hand.
7-7. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-11). does not 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 protector (see Section 7-2). No weld output; wire does not feed; fan Thermostat TP1 open (overheating).
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1.
249 315-A OM-249 498 Page 35
SECTION 9 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 9-1. Typical MIG Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/ Power Source Gun Shielding Gas Gas Workpiece Work Clamp Ref.
9-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) (0.001 in. = 1 ampere) 0.125 in. = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in. 30 − 90 A 0.030 in. 40 − 145 A 0.035 in.
9-3. Holding And Positioning Welding 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. 1 1 3 2 2 3 4 5 5 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) 1/4 to 1/2 in.
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. 10° Push 10° Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS (STICKOUT) Recommend that stickout be ⅜ in. ( mm) for solid wire and ½ in. for flux cored wire.
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. 1 1 2 2 3 Stringer Bead − Steady Movement Along Seam Weave Bead − Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 3 S-0054-A 9-6.
9-8. Troubleshooting − 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. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
9-11. Troubleshooting − 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 maintaining proper welding wire extension and arc characteristics. Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding 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 hand on solid surface or use two hands. 9-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move.
9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters. welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.
SECTION 10 − PARTS LIST . Hardware is common and 20 24 41 42 54 56 40 55 44 45 51 50 46 1 47 43 48 38 33 2 39 30 49 32 31 36 37 34 35 3 4 29 5 6 7 8 28 59 9 52 10 11 27 12 13 26 25 17 23 60 16 14 19 15 18 57 21 53 58 22 not available unless listed. 250 327-A Figure 10-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 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 30 31 32 33 34 35 36 37 38 39 . . . . . . . . . . . . . . . 199 566 . . . . . . . . . . . . . . . 196 006 . . . . . . . . . . . . . . . 211 887 . . . . . . . . . . . . . . . 204 608 . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Continued) . . . 40 . . . . . . . . . . . . . . . 248 732 . . Supplementary Protector, Man Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . . . 228 400 . . Knob, Pointer (Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . 211 338 . . Knob, Pointer (WFS) . . . . . . . . . . . . . . . . . . . . . . .
1 2 3 4 13 5 14 6 7 7 9 12 11 10 8 243 842-A Figure 10-2. H100S4-10 Gun Item No. Dia. Mkgs. Part No. 245 926 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 13 13 14 . . . . . . . . . . 169 715 . . . . . . . . . +226 190 . . . . . . . . . +087 299 . . . . . . . . . +000 067 . . . . . . . . . +000 068 . . . . . . . . . +000 069 . . . . . . . . . . 170 470 . . . . . . . . . . 169 716 . . . . . . . . . . 246 373 . . . . . .
10-3. Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER INCHES (mm) PART NO. 237 338 .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 PART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max. 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max. 245 926 H100S4-10 Replacement Gun 10 ft length/.030-.
Effective January 1, 2011 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MB or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 5 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.
