Hobart Welders Handler 210 Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Information EMF

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SECTION 3

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DEFINITIONS

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3-1. Symbols And Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Specifications

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4-2. Duty Cycle And Overheating

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4-3. Volt-Ampere Curves

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SECTION 5

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INSTALLATION

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5-1. Installing Welding Gun

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5-2. Installing Work Clamp

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5-3. Process/Polarity Table

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5-4. Changing Polarity

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5-5. Installing Gas Supply

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5-6. Selecting A Location And Connecting Input Power

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5-7. Electrical Service Guide

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5-8. Installing Wire Spool And Adjusting Hub Tension

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5-9. Installing Contact Tip And Nozzle

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5-10. Connecting Optional Spool Gun

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5-11. Threading Welding Wire

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SECTION 6

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OPERATION

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6-1. Controls

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6-2. Weld Parameter Chart For 230 VAC Model

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SECTION 7

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MAINTENANCE &TROUBLESHOOTING

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7-1. Routine Maintenance

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7-2. Overload Protection

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7-3. Drive Motor Protection

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7-4. Changing Drive Roll Or Wire Inlet Guide

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7-5. Replacing Gun Contact Tip

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7-6. Cleaning Or Replacing Gun Liner

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7-7. Replacing Switch And/Or Head Tube

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7-8. Troubleshooting Table

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SECTION 8

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ELECTRICAL DIAGRAM

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Summary of Contents for Handler 210

Page 1: ...Processes OM 227 978A 2006 12 Handler 210 Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding R ...

Page 2: ...ucts 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 proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The part...

Page 3: ... 2 Duty Cycle And Overheating 10 4 3 Volt Ampere Curves 10 SECTION 5 INSTALLATION 11 5 1 Installing Welding Gun 11 5 2 Installing Work Clamp 11 5 3 Process Polarity Table 12 5 4 Changing Polarity 12 5 5 Installing Gas Supply 13 5 6 Selecting A Location And Connecting Input Power 14 5 7 Electrical Service Guide 15 5 8 Installing Wire Spool And Adjusting Hub Tension 15 5 9 Installing Contact Tip And...

Page 4: ...tics 34 9 7 Good Weld Bead Characteristics 34 9 8 Troubleshooting Excessive Spatter 35 9 9 Troubleshooting Porosity 35 9 10 Troubleshooting Excessive Penetration 35 9 11 Troubleshooting Lack Of Penetration 36 9 12 Troubleshooting Incomplete Fusion 36 9 13 Troubleshooting Burn Through 36 9 14 Troubleshooting Waviness Of Bead 37 9 15 Troubleshooting Distortion 37 9 16 Common MIG Shielding Gases 37 9...

Page 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shield...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...ion selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du section...

Page 10: ...ble de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules ...

Page 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Page 12: ... Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans le...

Page 13: ...ding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 230 V 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 150 A 23 Volts DC 30 Duty Cycle 25 210 34 24 5 33 4 60 76 lb 34 kg Length 19 1 2 in 495 mm Width 10 5 8 in 270 mm Height 12 3 8 in 314 mm Wire Type Solid Stainless Flux Cored Aluminum Wire Feed Speed Range Wire Type And Diameter 023 035 in 0 ...

Page 14: ...15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 227 953 A 30 duty cycle at 150 amps 3 Minutes Welding 7 Minutes Resting 10 20 40 60 80 100 200 130 175 60 80 70 100 10 20 40 30 Output Amperes Duty Cycle 4 3 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 sho...

Page 15: ...rrect Be sure that gun end is tight against drive assembly 3 Gun Fully Seated 3 Gun Not Seated Exposed O rings will cause shielding gas leakage 5 1 3 2 Spool Gun MIG Gun 6 4 ÉÉÉ ÉÉÉ ÉÉÉ 5 2 Installing Work Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp ...

Page 16: ... no shielding gas DCEN Straight Polarity Connect to negative output terminal Connect to positive output terminal CHANGING POLARITY 5 4 Changing Polarity 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturer s recommended polarity and see Section 5 3 Close door Ref 209 228 Ref 209 229 1 2 ...

Page 17: ...regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate After flow is set close pressur...

Page 18: ...ing Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow groundingconductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Receptacle NEMA 6 50R Connect receptacle as shown 9 Over Current Protect...

Page 19: ...t breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 5 8 Installing Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool tension is set 1 2 in Tools Needed 803 012 803 013 B Ref 802 971...

Page 20: ...lux Nozzle MIG Nozzle Use with flux cored wire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Use with solid or flux cored wire Push nozzle over contact tip and adapter until it is seated onto adapter Contact tip will be exposed approximately 7 16 in 11 3 mm when installed properly Push nozzle over contact tip and adapter until it is seated...

Page 21: ...y connection see welding power source Owner s Manual Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriatesetting 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual or door chart for appropriatesetting...

Page 22: ...ed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Press gun trigger until wire comes out of gun Turn power on Be sure that Voltage range switch is set to range 1 2 3 4 5 6 or 7 to feed wire Rotate knob until it clicks into detent Wire will not feed if range switch is set between ranges 6 in 150 mm Tighten Use pressure indicator scale to set a desi...

Page 23: ...ng power source or Section 6 2 as applicable 2 Power Switch 3 Voltage Switch The higher the selected number the thicker the material that can be welded see weld setting label in welding power source or Section 6 2 as applicable Do not switch under load Switch must click into detent position 4 Over Temperature Light Light illuminates if main transformer overheats 5 Gun Trigger Receptacle Ref 227 95...

Page 24: ...OM 227 978 Page 20 6 2 Weld Parameter Chart For 230 VAC Model ...

Page 25: ...OM 227 978 Page 21 227 949 A ...

Page 26: ...l Damaged Gas Hose nl Weld Cables Every 3 Months nl Cords nl Gun Cables Every 6 Months OR Drive Rolls Inside Unit 7 2 Overload Protection 802 441 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative rele...

Page 27: ...drive roll 1 4 turn to closed slot 4 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 5 11 Tools Needed Ref 803 714 A 023 025 Groove 030 035 Groove Stamped 024 Stamped 030 035 3 1 2 4 ...

Page 28: ...ide so that 1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tighten two full turns more Cut liner off so that 3 4 in 19 mm sticks out of head tube Install gas diffuser adapter contact tip and nozzle Head Tube 8 mm Remove liner Remove nozzle contact tip adapter and gas diffuser Blow out gun casing 10 mm Lay gun cable out straight before installing new liner ...

Page 29: ...ighten head tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle locking nut Y Turn Off welding power source wire feeder and disconnect gun Remove switch housing Install new switch and connect leads polarity is not important Reassemble in reverse order If replacing head tube continue to e...

Page 30: ...rity connections see Section 5 4 Check thumbscrew securing gun end to feed head adapter and tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during welding Straightengun cable and or replace damaged parts welding Adjust drive roll pressure see Section 5 11 Ch...

Page 31: ...OM 227 978 Page 27 Notes ...

Page 32: ...OM 227 978 Page 28 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 33: ...OM 227 978 Page 29 227 951 A ...

Page 34: ...ions Y 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 Wire Feeder Power Source Workpiece Gun Regulator Flowmeter Gas Hose Shielding Gas Work Clamp light mig 5 97 Ref 804 688 A ...

Page 35: ...eters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in 3 5 in per ampere 2 in per ampere 1 6 in per ampere Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Low voltage wire stubs into work High voltage arc is unst...

Page 36: ...re is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm Hold a shorter stickout when welding with solid wire and using a shielding gas 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Si...

Page 37: ...ravel speed thickness of base metal wire feed speed weld current and voltage NOTE Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WELD BEAD PROFILES 10 10 GUN TRAVEL SPEED S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Use a Drag Technique with self shielding flux cored wire ...

Page 38: ...ement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or la...

Page 39: ...s in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shieldin...

Page 40: ... welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed I...

Page 41: ...s Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds 9 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtu...

Page 42: ...nough so it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in g...

Page 43: ...OM 227 978 Page 39 Notes ...

Page 44: ...ware is common and not available unless listed 804 691 A 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 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 56 55 57 58 Figure 10 1 Main Assembly ...

Page 45: ...A 3 C 7ft SPT 3 jkt 1 16 010 916 CONNECTOR clamp cable 750 1 17 137 761 NUT gas valve 1 18 196 064 MOTOR fan 1 19 409 953 001 BLADE fan cooling 1 20 225 937 TRANSFORMER power assy 1 21 208 015 HANDLE carrying 1 22 196 005 WRAPPER 1 23 204 036 LABEL warning 1 24 203 491 CLAMP capacitor 1 25 226 191 CAPACITOR electrlt 100000uf 1 26 225 891 REACTOR ASSY 1 27 193 316 RECTIFIER ASSY 1 28 227 780 BUS BA...

Page 46: ... 1 50 227 949 LABEL weld chart 1 51 204 711 LATCH 1 52 217 585 CONTACTOR 1 53 203 572 LABEL warn gen precaution EN FR models only 1 54 LABEL nameplate order by model and serial number 1 55 048 282 RCPT W SKTS service kit 1 56 202 661 LED yellow 1 57 228 643 PLATE stiffener base 1 58 229 793 WINDTUNNEL 1 When ordering a component originally displaying a precautionary label the label should also be ...

Page 47: ... RING retaining 1 5 169 718 TUBE head 1 6 169 738 NUT locking handle 1 7 169 719 NUT jam 1 8 079 975 O RING 187 ID x 103CS rbr 1 9 LINER monocoil 023 025 wire x 15ft including see Section 10 5 9 LINER monocoil 030 035 wire x 15ft including see Section 10 5 9 LINER monocoil 035 045 wire x 15ft including see Section 10 5 9 194 014 LINER monocoil 4 64 AL wire x 10ft nyl including 1 10 197 123 O RING ...

Page 48: ...s 10 50 CFH 144 108 Gas hose 5 ft For use with regulator flowmeter 212 492 10 5 Consumables ITEM HOBART PACKAGE NO MILLER PACKAGE NO Contact Tips 023 025 in 0 6 mm 770 174 5 per package 087 299 10 per package 030 in 0 8 mm 770 177 5 per package 000 067 10 per package 035 in 0 9 mm 770 180 5 per package 000 068 10 per package 045 in 1 2 mm 770 183 5 per package 000 069 10 per package MIG Nozzle Sta...

Page 49: ...Notes ...

Page 50: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 51: ...ntact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warran...

Page 52: ... or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to Resource...

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