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OM-227 978 Page 32

SECTION 9

−

MIG WELDING (GMAW) GUIDELINES

mig1 2009

−

12

Wire Feeder/

Power Source

Workpiece

Gun

Regulator/

Flowmeter

Gas

Shielding Gas

Work Clamp

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.

Ref. 801 909-A

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Summary of Contents for Handler 210

Page 1: ...Processes OM 227 978D 2010 04 Handler 210 Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding R ...

Page 2: ...oducts 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 pa...

Page 3: ...rheating 12 4 3 Volt Ampere Curves 12 SECTION 5 INSTALLATION 13 5 1 Installing Nozzle Contact Tip And Adapter 13 5 2 Installing Welding Gun 13 5 3 Installing Work Clamp 14 5 4 Process Polarity Table 15 5 5 Changing Polarity 15 5 6 Installing Gas Supply 16 5 7 Serial Number And Rating Label Location 17 5 8 Selecting A Location And Connecting Input Power 17 5 9 Electrical Service Guide 18 5 10 Insta...

Page 4: ...tics 36 9 7 Good Weld Bead Characteristics 36 9 8 Troubleshooting Excessive Spatter 37 9 9 Troubleshooting Porosity 37 9 10 Troubleshooting Excessive Penetration 37 9 11 Troubleshooting Lack Of Penetration 38 9 12 Troubleshooting Incomplete Fusion 38 9 13 Troubleshooting Burn Through 38 9 14 Troubleshooting Waviness Of Bead 39 9 15 Troubleshooting Distortion 39 9 16 Common MIG Shielding Gases 40 9...

Page 5: ...olds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant vo...

Page 6: ...nless they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw ...

Page 7: ... panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing u...

Page 8: ... web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA 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...

Page 9: ...urant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou ...

Page 10: ... ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le co...

Page 11: ...ur D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonction...

Page 12: ...ecte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipement commandé par ordinateur tel que les robots D Veiller à ce que tout l équipement de la zone de soudage soit comp...

Page 13: ...n 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov N...

Page 14: ...OM 227 978 Page 10 ...

Page 15: ...ed Welding 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 And Diameter Solid Stainless Flux Cored Aluminum Wire Feed Speed Range 023 035 in 0 6 0 ...

Page 16: ...0 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 s...

Page 17: ...bscrew 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten thumbscrew Welding gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in MIG Gun position Close door Correct Incorrect Be sure that gun end is tight against d...

Page 18: ...eeves Slide one insulating sleeve over work cable before connecting to clamp Slide insulating sleeves over handles 802 456 A 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 Tools Needed 7 16 in 7 16 in 1 2 3 4 5 6 ...

Page 19: ...traight Polarity Connect to negative output terminal Connect to positive output terminal CHANGING POLARITY 5 5 Changing Polarity Turn off welding power source 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 4 Close door Ref 209 228 Ref 209 22...

Page 20: ...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 21: ... terminal first and never to a line ter minal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals Connect green or green yellow groundingconductor to disconnect device grounding terminal first Connect input conductors ...

Page 22: ...rcuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC ...

Page 23: ...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 24: ... WOOD Feed 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 se...

Page 25: ...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 6 Trigger Switch When pressed energized wire feeds and ...

Page 26: ...OM 227 978 Page 22 6 2 Weld Parameter Chart For 230 VAC Model ...

Page 27: ...OM 227 978 Page 23 227 949 B B ...

Page 28: ... Terminals l Damaged Gas Hose nl Weld Cables 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 release ...

Page 29: ... slide it out over the retaining pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate 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 t...

Page 30: ...atch wire size Tools Needed 8 mm 10 mm Lay gun cable out straight before installing new liner Remove nozzle contact tip and adapter Unscrew and remove liner Blow out gun casing Cut off wire and disconnect gun from feeder 5 8 in 16 mm Liner Stickout Install Liner Reassemble gun in reverse order from taking it apart 10 mm Head Tube 8 mm 1 3 2 Thread wire according to welding power source wire feeder...

Page 31: ...andle halves and install switch housing 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 end of figure 1 2 3 8 6 7 Remove screw on opposite side Secure head tube in vice Loosen jam nut Remove from vice and turn head tube out by hand 4 5 phi...

Page 32: ...nd if necessary replace gun trigger switch see Section 7 6 Check contact tip Check for kinks in gun cable Blow out liner and gun casing see Section 7 5 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 Adjust drive ro...

Page 33: ...OM 227 978 Page 29 Notes ...

Page 34: ...OM 227 978 Page 30 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 35: ...OM 227 978 Page 31 227 951 B ...

Page 36: ...wer Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp 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 Ref 801 909 A ...

Page 37: ...parameters 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...

Page 38: ... in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 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 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 Side View of Gun Angle FILLET WELDS ...

Page 39: ... electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage 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 ...

Page 40: ...nt 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 layer...

Page 41: ...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 42: ... 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 43: ...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 Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lowe...

Page 44: ...if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly...

Page 45: ...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 welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary ...

Page 46: ...OM 227 978 Page 42 Notes ...

Page 47: ...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 48: ...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 49: ... 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 57 233 346 PLATE stiffener base 1 58 229 793 WINDTUNNEL 1 221 037 REGULATOR FLOWMETER 10 50 CFH argon CO2 1 183 581 HOSE assembly gas 1 When ordering a component originally displaying a precau...

Page 50: ...716 ADAPTER contact tip 1 5 246 373 TUBE head 1 6 243 865 NUT jam 1 7 242 832 HANDLE 1 8 225 410 SWITCH trigger 1 9 079 878 HOUSING PLUG PINS 1 10 246 380 HOUSING power pin 1 11 245 927 CONNECTOR feeder 1 12 197 123 O RING 312 ID X 062 70 duro buna n 2 13 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 13 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 13 194 012 LINER monoco...

Page 51: ...gas 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 S...

Page 52: ...Notes ...

Page 53: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 54: ...Notes ...

Page 55: ...ables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumabl...

Page 56: ...utor retail 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 ...

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