Hobart BETA-MIG 2250 Owner'S Manual Download

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BETA-MIG 2250

Processes

OM-192 440A

November 1998

Specifications Covered by this Manual:
903 702

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)
Welding

Description

Arc Welding Power Source and Wire
Feeder

Summary of Contents for BETA-MIG 2250

Page 1: ...BETA MIG 2250 Processes OM 192 440A November 1998 Specifications Covered by this Manual 903 702 Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Description Arc Welding Power Source and Wire Feeder ...

Page 2: ...e 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 parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particul...

Page 3: ... 9 2 3 Volt Ampere Curves 10 2 4 Installing Welding Gun 10 2 5 Installing Work Clamp 11 2 6 Setting Gun Polarity For Wire Type 11 2 7 Installing Gas Supply 12 2 8 Installing Wire Spool And Adjusting Hub Tension 12 2 9 Changing Input Voltage From 230 Volts To 200 Volts 13 2 10 Electrical Service Guide 13 2 11 Selecting A Location And Connecting Input Power 14 2 12 Threading Welding Wire 15 SECTION ...

Page 4: ......

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: ...9 mm D 36 1 2 in 927 mm 185 lb 84 kg 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm 030 045 in 0 8 1 2 mm D 36 1 2 in 927 mm While idling 6 Minutes Welding 4 Minutes Resting 2 2 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 for unit to c...

Page 14: ...92 436 2 4 Installing Welding Gun Ref ST 801 875 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew Insert gun end through opening until it bottoms against drive assembly Tighten thumbscrew 4 Gun Trigger Leads Insert leads one at a time through small grommet on front panel Con nect female friction terminals to matching male terminals in unit Polarity is not important Close door...

Page 15: ...p Route cable through clamp handle and secure as shown Close door Ref ST 802 285 Ref ST 801 566 Tools Needed 1 2 3 4 in 2 1 3 4 2 6 Setting Gun Polarity For Wire Type Tools Needed 3 4 in 1 1 Polarity Changeover Label 2 Positive Red Output Terminal 3 Negative Black Output Terminal Always read and follow wire manufacturer s recommended polarity Close door 3 2 Ref ST 801 875 Ref ST 192 432 ...

Page 16: ...g 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 8 Installing Wire Spool And Adjusting Hub Tension When a s...

Page 17: ...ead marked 200 VAC Slide tubing down and connect 200 volt lead stub to black switch lead that was just disconnected from the 230 volt lead and secure with exist ing hardware Slide tubing over connection and secure Tools Needed 1 2 4 5 16 3 8 in 230 VAC 200 VAC 3 2 10 Electrical Service Guide Input Voltage 200 230 Input Amperes At Rated Output 40 35 Max Recommended Standard Fuse Or Circuit Breaker ...

Page 18: ...rs Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 2 10 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 2 L1 L2 230 VAC 1 3 L1 L2 Y Always connect grounding conductor first GND PE 5 Y Do not move or operate unit where it could tip 18 in 457 mm of space for airflo...

Page 19: ... wire cut off end 4 in 102 mm Tighten Remove gun nozzle and contact tip Turn On WOOD Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire 7 ...

Page 20: ...rols 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide and Section 3 2 3 Power Switch 1 Ref ST 192 372 2 3 ...

Page 21: ...55 48 40 26 10 0 0 045 VOLTAGE 7 6 4 4 3 3 2 2 1 2MM WIRESPEED 60 55 50 45 46 40 30 22 030 VOLTAGE 5 5 4 2 2 1 1 0 8MM WIRESPEED 50 58 50 30 20 10 0 E71T GS 035 VOLTAGE 6 5 4 3 2 2 1 1 FLUXCORE 0 9MM WIRESPEED 50 40 38 30 20 10 0 0 045 VOLTAGE 5 5 4 3 2 2 1 2MM WIRESPEED 46 40 30 20 0 0 E71T GS 035 VOLTAGE 7 7 7 6 5 3 FLUXCORE 0 9MM WIRESPEED 80 78 72 68 60 55 75AR 25CO2 045 VOLTAGE 7 7 7 6 5 4 20...

Page 22: ...nd apply light coat of oil or grease to drive motor shaft 4 2 Circuit Breakers Ref ST 802 285 2 Y Turn Off unit 1 Circuit Breaker CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 Circuit Breaker CB2 CB2 protects the trigger circuit from overload If CB2 open...

Page 23: ... Tighten screw 3 Drive Roll Install correct drive roll for wire size and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 4 4 Replacing Gun Contact Tip Ref ST 801 987 Y Turn Off power before replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools N...

Page 24: ...ct plug and tighten setscrew s Cut liner off so that 7 16 in 11 mm 1 32 in 8 mm sticks out of head tube Install adapter contact tip insula tor and nozzle Lay gun cable out straight before installing new liner Head Tube 7 16 in Remove liner Remove nozzle contact tip and adapter Blow out gun casing Y Disconnect gun from unit Tools Needed Loosen setscrew in quick connect plug It may also be necessary...

Page 25: ...e speed Readjust front panel settings see Section 3 1 Change to correct size drive roll see Section 4 3 Readjust drive roll pressure see Section 2 12 Replace inlet guide contact tip and or liner if necessary see Sections 4 3 4 4 and or 4 5 4 7 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straightengun cable and or replace damaged pa...

Page 26: ...OM 192 440 Page 22 SECTION 5 ELECTRICAL DIAGRAM SC 192 433 Figure 5 1 Circuit Diagram For Welding Power Source ...

Page 27: ...OM 192 440 Page 23 Notes ...

Page 28: ...92 440 Page 24 SECTION 6 PARTS LIST ST 802 281 Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 Fig 6 2 10 Fig 6 3 11 12 13 14 15 16 17 Fig 6 4 18 19 20 Fig 6 5 Figure 6 1 Main Assembly ...

Page 29: ...BAFFLE w components 1 10 Fig 6 3 PANEL rear w components 1 11 PLG1 188 911 CORD SET 250V 1 12 192 831 BASE 1 13 135 390 AXLE 1 14 186 758 WHEEL 2 15 121 614 RING retaining 2 16 008 999 CASTER 2 17 Fig 6 4 PANEL front w components 1 18 146 149 CABLE work 1 19 130 750 CLAMP work 1 20 Fig 6 5 GUN 20 A Piecemaker 12 ft 1 When ordering a component originally displaying a precautionary label the label s...

Page 30: ...440 Page 26 ST 802 284 A Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 17 19 20 35 22 26 27 28 29 30 31 32 33 34 25 24 23 18 21 Figure 6 2 Center Baffle w Components ...

Page 31: ...erminal 2 17 CR1 072 817 RELAY encl 24VAC DPDT 1 18 CB2 180 912 CIRCUIT BREAKER man reset 1P 5A 250V 1 19 CB1 183 492 CIRCUIT BREAKER man reset 1P 10A 250V 1 20 PC1 171 986 CIRCUIT CARD ASSEMBLY control 1 21 097 416 TERMINAL pwr output black 1 22 C7 8 128 750 CAPACITOR ASSEMBLY 2 23 C9 10 193 205 CAPACITOR ASSEMBLY 2 24 RC2 184 734 BUSHING terminal 2 position 2 25 184 692 DRIVE ASSEMBLY wire consi...

Page 32: ...8 809 FAN 9 in 5wg 34 deg 1 3 M 188 706 MOTOR fan 230V 50 60 Hz 1 4 188 709 WINDTUNNEL 9in 1 5 125 785 VALVE 24VAC 2way custom port 1 6 143 810 PANEL rear 1 7 193 063 BRACKET support tank 1 8 188 441 CHAIN safety 1 9 605 227 NUT 750 14 knurled 1 10 178 126 CONN clamp cable 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and...

Page 33: ...witch 1 4 184 733 KNOB 1 5 035 897 POTENTIOMETER CP 1 T 2W 1K linear wire feed speed 1 6 S2 192 373 SWITCH selector 7 position 1 7 S1 128 755 SWITCH tgl DPST 40A 600 VAC 1 8 192 969 COVER module access 1 9 193 280 LABEL spoolmodule access 1 10 170 647 BUSHING snap in nyl 1 11 204 413 BUSHING snap in nyl 1 To maintain the factory original performance of your equipment use only Manufacturer s Sugges...

Page 34: ...art No Item No Figure 6 5 Gun And Cable Assembly Piecemaker 20 A Quantity 1 379 300 NOZZLE slip on assembly 1 2 379 587 TIP contact 023 1 2 379 304 TIP contact 030 1 2 379 314 TIP contact 035 1 2 379 315 TIP contact 045 1 3 379 596 DIFFUSER gas 1 4 SETSCREW 6 32 x 1 8 2 5 379 301 INSULATOR nozzle 1 6 177 483H TUBE gun assembly 1 7 W10904 012 O RING 2 ...

Page 35: ...ONNECTOR butt 2 21 WIRE lead assembly 1 22 TERMINAL quick connect 250 2 23 177 285H RING bayonet 1 24 WRENCH allen 1 8 in 1 25 WRENCH allen 1 16 in 1 26 177 490H SUPPORT cable feeder 1 27 177 286H ADAPTER support 1 28 W10904 014 O RING 1 2x5 8x1 16 in 2 29 SET SCREW 6 32x1 8 in Ref 30 379 427 004 LINER spring assembly 030 045 1 30 409 737 002 LINER spring assembly 024 035 1 31 177 503H KIT plug qu...

Page 36: ...Notes ...

Page 37: ...Notes ...

Page 38: ...Notes ...

Page 39: ...hat has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MA...

Page 40: ...r To locate a Distributor 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 th...

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