Hobart Welding Products BETA-MIG 2510 Owner'S Manual Download Page 1

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BETA-MIG 2510

And M-25 Gun

Processes

OM-194 430A

June 1999

Specifications Covered by this Manual:

500 430, 500 431, 500 432

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)
Welding

Description

Arc Welding Power Source and Wire
Feeder

Summary of Contents for BETA-MIG 2510

Page 1: ... And M 25 Gun Processes OM 194 430A June 1999 Specifications Covered by this Manual 500 430 500 431 500 432 Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Description Arc Welding Power Source and Wire Feeder ...

Page 2: ......

Page 3: ...Spool And Adjusting Hub Tension 13 2 10 Positioning Jumper Links 14 2 11 Installing Work Clamp 14 2 12 Electrical Service Guide 15 2 13 Selecting A Location And Connecting Input Power 15 2 14 Threading Welding Wire 16 SECTION 3 OPERATION 17 3 1 Controls 17 3 2 Weld Parameters 18 3 3 Installing Receptacle Module For Use With A Spool Gun Optional 19 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 20 4 1 R...

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Page 5: ...is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not drape cables ov...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ... maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area i...

Page 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one s...

Page 9: ...rne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement s il est endommagé un câble dé...

Page 10: ...ct D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...nétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de p...

Page 13: ... 045 in 0 8 1 2 mm 1 2 1 7 m min W 15 1 8 in 384mm D 33 3 8 in 848 mm 89 kg While idling 4 Minutes Welding 6 Minutes Resting 6 Minutes Welding 4 Minutes Resting 2 2 Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes fo...

Page 14: ...Cycle At 300 Amperes Using CO2 60 Duty Cycle At 200 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting 2 4 Volt Ampere Curves ssb1 1 10 91 SB 144 925 A S 0700 A 1 Normal Volt Ampere Curves The volt ampere curves show the normal minimum and maximum voltage and amperage output capa bilities of the welding power source Curves of other settings fall be tween the curves shown 2 Overload Volt...

Page 15: ...ls Needed 2 6 Installing Welding Gun Ref ST 801 789 A 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert into receptacle and tighten threaded collar Close door 1 3 4 2 ...

Page 16: ...r Wire Type Tools Needed 3 4 in Ref 194 425 1 2 4 3 1 Polarity Changeover Label 2 Wire Drive Assembly 3 Positive Output Terminal 4 Negative Output Terminal Always read and follow wire manufacturer s recommended polarity Close door Ref ST 801 789 A ...

Page 17: ...ection Fitting has 5 8 18 right hand threads 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturer s recommended flow rate see Section 3 2 This flow gauge can be adjusted between 5 and 25 cfh 4 CO2 Adapter Customer Supplied 5 O Ring Install adapter with O ring between regulator flow gauge and CO2 cylinder 1 1 8 5 8 in 2 9 Installing Wire Spool And Adjusting Hub Ten...

Page 18: ... Voltage Jumper Links Move jumper links to match input voltage Close and secure access door Close door Tools Needed 1 3 8 in 3 2 200 VOLTS 230 VOLTS 460 VOLTS S 144 918 C 230 VOLTS 460 VOLTS 575 VOLTS S 144 916 A 2 11 Installing Work Clamp 1 Work Cable 2 Hardware 3 Work Clamp Route cable through clamp handle and secure as shown Ref ST 802 062 Tools Needed 1 2 in 1 3 2 ...

Page 19: ... 8 8 10 12 Reference 1996 National Electrical Code NEC S 0092J 2 13 Selecting A Location And Connecting Input Power Have only qualified persons make this installation 1 Rating Label Supply correct input power Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 801 788 A Ref 800 797 C 18 in 457 mm for airflow Size and ratings m...

Page 20: ... mm Hold wire tightly to keep it from unraveling 4 in 102 mm Tighten WOOD Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tigh...

Page 21: ...re Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The scale around the control is actual voltage See Section 3 2 or inside welding power source door for weld param eters chart 3 Pilot Light 4 Power Switch 1 2 4 3 ...

Page 22: ...lts 21 5 21 0 20 5 20 5 19 5 19 5 19 0 18 0 17 0 045 Feed Speed 33 30 28 26 24 21 19 12 10 Mild Steel Volts 29 5 29 0 29 0 28 5 26 5 98 Ar 2 O2 20 cfh 035 Feed Speed 65 64 64 60 54 Volts 24 0 23 5 23 5 22 5 22 5 22 5 22 0 20 5 Stainless Steel 308L 030 Feed Speed 63 56 47 42 38 34 28 23 308L HeArCO2 20 cfh Volts 26 0 25 0 24 0 24 0 22 5 21 5 21 5 21 5 20 0 19 5 20 cfh 035 Feed Speed 67 60 53 45 39 ...

Page 23: ...w groves in front panel The knockout is held in place by a thin metal section half way down each side Be sure to cut label across metal sections before removing knockout to avoid tear ing the label 2 Module 3 Plug PLG9 4 Receptacle RC2 Locate receptacle RC2 in unit wir ing harness Connect plug PLG9 to RC2 Slide module in and secure with supplied screws Tools Needed 1 2 3 4 ...

Page 24: ...t 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 Ref ST 801 789 Ref 800 797 C 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow cool...

Page 25: ...curing Nut Turn nut one click to secure drive roll 5 64 in 7 16 in 4 5 Aligning Drive Rolls And Wire Guide Y Turn Off power View is from top of drive rolls look ing down with pressure assembly open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly ...

Page 26: ...ip check and match wire size Head Tube Tools Needed 3 8 in Lay gun cable out straight before installing new liner Remove nozzle contact tip adapter and wire outlet guide Remove liner Blow out gun casing Cut off wire and disconnect gun from feeder 3 8 in 3 4 in 20 mm Liner Stickout Install Liner Thread wire according to welding power source wire feeder manual Reassemble gun in reverse order from ta...

Page 27: ...ecure with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch hous...

Page 28: ... if necessary see Section 2 10 Have Factory Authorized Service Agent check main control board Fan motor does not run NOTE Fan only runs when cooling is necessary Have Factory Authorized Service Agent check fan on demand circuit Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct size drive rolls see Section 4 4 Readjust drive roll pressure see Section 2 1...

Page 29: ...OM 194 430 Page 25 SECTION 5 ELECTRICAL DIAGRAM SC 184 944 A Figure 5 1 Circuit Diagram For Welding Power Source ...

Page 30: ...OM 194 430 Page 26 Notes ...

Page 31: ...ION 6 PARTS LIST Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 Fig 6 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 28 36 37 38 39 40 41 801 783 B Figure 6 1 Main Assembly ...

Page 32: ...24VAC 1 20 134 464 LABEL warning general precautionary 1 21 184 660 WRAPPER ASSEMBLY 1 22 184 715 BRACKET bottle retainer 1 23 184 656 BASE 1 24 186 879 AXLE 1 25 090 693 WHEEL 2 26 121 614 RETAING ring 2 27 184 664 PANEL side 1 28 SR1 173 713 RECTIFIER SCR main consisting of 1 29 173 714 CLAMP spring thyristor 1 30 TP2 154 244 THERMOSTAT NO 1 31 143 818 THYRISTOR SCR 500A 300V 2 32 143 852 FOOT m...

Page 33: ... 194 430 Page 29 ST 801 786 B Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 10 11 12 14 15 16 13 17 18 19 20 21 22 23 24 25 27 Fig 6 3 28 29 30 9 Figure 6 2 Center Baffle w Components ...

Page 34: ... CARD control 1 PLG3 115 094 CONNECTOR SOCKETS Included w rectifier 1 PLG4 131 052 CONNECTOR SOCKETS 1 PLG5 131 056 CONNECTOR SOCKETS 1 PLG6 115 092 CONNECTOR SOCKETS 1 18 R1 119 998 RESISTOR WW fxd 300W 5 ohm 1 19 038 618 LINK jumper 2 20 TE1 158 406 TERMINAL ASSEMBLY pri 1ph 3V 1 21 010 199 TUBING stl 2 22 CR1 006 393 RELAY encl 24VAC DPDT 1 23 VR1 144 425 VARISTOR 1 24 494 613 TERMINAL pwr outp...

Page 35: ...of 1 193 633 KEY woodruff 118 x 380 1 193 634 WASHER wave 405 ID x 740 OD 2 193 635 RING rtng ext 394 shaft 1 15 079 633 FITTING hose brs barbed nipple 1 16 184 235 INSULATOR drive assembly 1 17 145 237 STOP cover 1 18 182 788 HOUSING adapter gun feeder 1 19 124 778 KNOB 1 20 173 619 CARRIER drive roll w comp 1 21 174 609 SCREW M 4 7 x 12 1 22 192 029 WASHER flat 250 ID X 437 OD 3 ST 801 793 A 1 2...

Page 36: ...OM 194 430 Page 32 Ref 800 792 B 1 2 3 4 5 6 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6 4 Gun And Cable Assembly M 25 ...

Page 37: ... RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 194 523 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 180 433 CORD trigger assembly 1 14 079 974 O RING 500 ID x 103CS rbr 2 15 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 15 194 012 LI...

Page 38: ...f drive rolls upon the following recommended usages 1 V Grooved rolls for hard wire 2 U Grooved rolls for soft and soft shelled cored wires 3 U Cogged rolls for extremely soft shelled wires usually hard surfacing types 4 V Knurled rolls for hard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Ref S 0026 B 7 91...

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Page 40: ...l Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department Resources Available Owner s Record File a...

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