Hobart Welding Products Handler 210 MVP Owner'S Manual Download

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Processes

OM-249 498B

2011

−

Handler 210 MVP

Arc Welding Power Source And

Wire Feeder

Description

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

File: MIG (GMAW)

Summary of Contents for Handler 210 MVP

Page 1: ...Processes OM 249 498B 2011 03 Handler 210 MVP Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding R File MIG GMAW ...

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: ...ION 15 5 1 Installing Nozzle Contact Tip And Adapter 15 5 2 Installing Welding Gun 15 5 3 Installing Work Clamp 16 5 4 Process Polarity Table 17 5 5 Changing Polarity 17 5 6 Installing Gas Supply 18 5 7 Electrical Service Guide 19 5 8 Extension Cord Data Use Shortest Cord Possible 19 5 9 Multi Voltage Plug MVP Connection 20 5 10 Serial Number And Rating Label Location 21 5 11 Selecting A Location ...

Page 4: ...Bead Characteristics 40 9 7 Good Weld Bead Characteristics 40 9 8 Troubleshooting Excessive Spatter 41 9 9 Troubleshooting Porosity 41 9 10 Troubleshooting Excessive Penetration 41 9 11 Troubleshooting Lack Of Penetration 42 9 12 Troubleshooting Incomplete Fusion 42 9 13 Troubleshooting Burn Through 42 9 14 Troubleshooting Waviness Of Bead 43 9 15 Troubleshooting Distortion 43 9 16 Common MIG Shie...

Page 5: ...lds 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 vol...

Page 6: ...less 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 f...

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 249 498 Page 10 ...

Page 15: ... GMAW Wire Feed Circuit Protector U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1max Rated Maximum Supply Current I2 Rated Welding Current X Duty Cycle Single Phase Transformer Rectifier Temperature Increase Percent Protective Earth Ground S Suitable For Welding In An Environment With Increased Risk Of Electric Shock I1 Rated Supply Current I1eff...

Page 16: ...0 9 mm 030 045 in 0 8 1 2 mm 030 035 in 0 8 0 9 mm 70 750 IPM 1 8 19 0 m min At No Load 40 680 IPM 1 0 17 3 m min Feeding Wire 4 2 Specifications For 115 VAC Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Out put 120 V 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 90 A 19 Volts DC 20 Duty Cycle 25 140 28 20 2 84 2 41 79 lb 36 kg Length 1...

Page 17: ...ops 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 Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 249 620 A 30 duty cycle at 150 amps 3 Minutes Welding 7 Minutes Resting 230 VAC 20 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting 115 VAC ...

Page 18: ...ng power source Curves of other settings fall between the curves shown ssb1 1 10 91 249 621 A 0 5 10 15 20 25 30 0 10 20 30 40 50 60 70 80 90 100 110 120 130140 150 160 170 180190 200 210 220 35 Voltage Amperage 1 2 3 4 5 6 7 230 VAC 0 5 10 15 20 25 30 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 35 Voltage Amperage 5 4 6 7 115 VAC ...

Page 19: ...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 20: ...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 21: ...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 22: ...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 23: ...ding article 630 1 If a circuit breaker is used in place of a fuse choose a circuit 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 excl...

Page 24: ... Supplied Follow electrical service guide for 230 VAC in Section 5 7 Do not use plug rating to size branch circuit protection Connecting Plug To Power Cord Align arrow on plug with arrow on power cord connector Push together Tighten threaded collar As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle MVP Plug1 2010 10 Ref 805 390 C Do n...

Page 25: ...t see NEC Article 511 or CEC Section 20 For 115 VAC input power a 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 5 13 For 230 VAC input power see Section 5 12 1 Rating Label Supply correct input power see Section 5 10 2 Power Cord Connector 3 Plug NEMA Type 5 15P 4 Receptacle NEMA Type 5 15R Customer Supplied 5 Plug NEMA Type 5 20P Opti...

Page 26: ...e 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 grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 7 Over Current ...

Page 27: ...ect 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 1 Multi Voltage Plug And Power Cord Connector NEMA Type 5 15P Plug Shown For multi voltage plug connections see Section 5 11 2 Receptacle NEMA Type 5 15R Customer Supplied ...

Page 28: ...ded to turn spool tension is set 1 2 in Tools Needed 803 012 803 013 B Ref 802 971 C Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set Retaining ring used with 8 in 203 mm spool only Adapter used with 8 in 203 mm spool only ...

Page 29: ... Changeover Terminal Block To make proper polarity connection see Section 5 5 Close door 8 Wire Feed Speed Control Wire feed speed control controls rate at which the is fed through the welding gun to the weld puddle 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see Section 6 2 or door chart for appropriatesetting 10 Trigger Press trigger to energize welding po...

Page 30: ...688 B 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 ...

Page 31: ...ens unit shuts down Reset power switch supplementary protector 3 Voltage Control Control varies the voltage level of the welding arc The voltage range is 4 minimum to 7 maximum on 115 VAC and 1 minimum to 7 maximum on 230 VAC Switch must click into detent position DO NOT switch under load 4 Over Temperature Light Light illuminates if main transformer overheats 5 Gun Trigger Receptacle 6 Trigger Sw...

Page 32: ...OM 249 498 Page 28 6 2 Weld Parameter Chart 250 015 A ...

Page 33: ... nl Weld Cables nl Cords nl Gun Cables Every 6 Months OR Drive Rolls Inside Unit 7 2 Overload Protection 250 653 A 1 SupplementaryProtector CB1 Power Switch CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector power switch CB1 also turns unit on and off 1 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive moto...

Page 34: ...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 the proper groove to thread see Section 5...

Page 35: ...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 36: ...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 37: ...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 roll pressure see Section ...

Page 38: ...OM 249 498 Page 34 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 39: ...OM 249 498 Page 35 249 315 A ...

Page 40: ...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 41: ...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 42: ... 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 43: ...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 Recommend that stickout be in mm for solid wire and in for flux cored wire ...

Page 44: ...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 45: ...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 46: ... 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 47: ...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 48: ...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 49: ...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 50: ...e is common and not available unless listed 250 327 A 56 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 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55 57 58 59 60 48 Figure 10 1 Main Assembly ...

Page 51: ...Power 1 16 010 290 Bushing Strain Relief 1 17 137 761 Nut Gas Valve 1 18 236 925 Motor Fan 1 19 409 953 001 Blade Fan Cooling 1 20 248 730 Transformer Power 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 Bar Positive 1 29 251 236...

Page 52: ...el 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 56 230 033 LED yellow 1 57 219 261 Adapter Power Cable 5 15P 115V 15A 1 58 219 258 Adapter Power Cable 6 50P 230V 50A 1 59 233 346 PLATE stiffener base 1 60 229 793 Windtunnel 1 221 037 Regulator Flowmeter 10 50 CFH Argon CO2 1 183 581 Hose Assembly Gas 1 219 259 Ad...

Page 53: ...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 54: ...ng 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 Nozzl...

Page 55: ... s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are...

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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