Hobart Welders Handler 210 Owner's Manual
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Hobart Welders Handler 210 Owner's Manual

Arc welding power source and wire feeder
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Handler 210
OM-227 978A
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
2006−12

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Summary of Contents for Hobart Welders Handler 210

  • Page 1 OM-227 978A 2006−12 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 210...
  • Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − MIG WELDING (GMAW) GUIDELINES ..........9-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperage Voltage Hertz Negative Direct Current Positive Single Phase Input (DC) Output Voltage Input Do Not Switch Gas Metal Arc Flux Cored Arc Wire Feed While Welding Welding (GMAW) Welding (FCAW) SECTION 4 − SPECIFICATIONS 4-1.

  • Page 14: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes 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 cool. Reduce amperage or duty cycle before welding.

  • Page 15: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Gun Drive Assembly MIG Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten Spool Gun thumbscrew. Welding gun must be inserted completely to prevent leakage of shielding gas.

  • Page 16: Process/Polarity Table

    5-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW −...

  • Page 17: Installing Gas Supply

    5-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. See Parts List for optional Cylinder Valve gas regulator/flowmeter.

  • Page 18: Selecting A Location And Connecting Input Power

    5-6. Selecting A Location And Connecting Input Power Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Y Installation must meet all Na- tional and Local Codes − 18 in (457 mm) of have only qualified persons space for airflow...

  • Page 19: Electrical Service Guide

    5-7. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker , Time-Delay Normal Operating Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) (17) Min Grounding Conductor Size In AWG Reference: 1999 National Electrical Code (NEC)

  • Page 20: Installing Contact Tip And Nozzle

    5-9. Installing Contact Tip And Nozzle Y Turn off welding power source. Nozzle Remove nozzle. Contact Tip Tip Adapter Thread welding wire through gun (see Section 5-11). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored wire only.

  • Page 21: Connecting Optional Spool Gun

    5-10. Connecting Optional Spool Gun Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end Spool Gun through opening until it bottoms against drive assembly. Tighten thumbscrew. Ç Ç Spool gun must be inserted completely to prevent leakage of Ç...

  • Page 22: Threading Welding Wire

    5-11. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in (120 mm) 6 in (150 mm) Open pressure assembly.

  • Page 23: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Ref. 227 950-A Wire Speed Control Power Switch Switch must “click” into detent Voltage Switch position. Use control to select a wire feed speed. As The higher the selected number, the Over Temperature Light Voltage switch setting increases, wire thicker the material that can be welded Light illuminates if main transformer...

  • Page 24: Weld Parameter Chart For 230 Vac Model

    6-2. Weld Parameter Chart For 230 VAC Model OM-227 978 Page 20...
  • Page 25 227 949-A OM-227 978 Page 21...

  • Page 26: Section 7 − Maintenance &Troubleshooting

    SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose...

  • Page 27: Changing Drive Roll Or Wire Inlet Guide

    7-4. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Retaining Pin To remove drive roll, push drive roll in and rotate it (1/4 turn) to the open slot and slide it out over the retaining pin.

  • Page 28: Cleaning Or Replacing Gun Liner

    7-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 8 mm / 10mm Head Tube Remove nozzle, contact tip, adapter, and gas diffuser. 8 mm 10 mm Remove liner. To Reassemble Gun: Insert new liner. Install wire outlet guide so that 1/8 Lay gun cable out straight in (3 mm) of liner sticks out.

  • Page 29: Replacing Switch And/Or Head Tube

    7-7. Replacing Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. 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.

  • Page 30: Troubleshooting Table

    7-8. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 5-6). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protector (see Section 7-2).
  • Page 31 Notes OM-227 978 Page 27...

  • Page 32: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-227 978 Page 28...
  • Page 33 227 951-A OM-227 978 Page 29...

  • Page 34: Section 9 − Mig Welding (Gmaw) Guidelines

    SECTION 9 − MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections 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. Regulator/ Flowmeter Wire Feeder/...

  • Page 35: Typical Mig Process Control Settings

    9-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in Convert Material Thickness to Amperage (A)

  • Page 36: Holding And Positioning Welding Gun

    9-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece...

  • Page 37: Conditions That Affect Weld Bead Shape

    9-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Push Use a Drag Technique with self-shielding flux Drag Perpendicular cored wire.

  • Page 38: Gun Movement During Welding

    9-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 39: Troubleshooting − Excessive Spatter

    9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 40: Troubleshooting − Lack Of Penetration

    9-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

  • Page 41: Troubleshooting − Waviness Of Bead

    9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.

  • Page 42: Troubleshooting Guide For Semiautomatic Welding Equipment

    9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.
  • Page 43 Notes OM-227 978 Page 39...

  • Page 44: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 804 691-A Figure 10-1. Main Assembly OM-227 978 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....199 566 DOOR, access ..........
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly (Continued) ....196 574 SWITCH, rocker DPST ......... .
  • Page 47 804 692-A Figure 10-2. H-14 Gun Item Part Description Quantity 231 204 Figure 10-2. H-14 Gun ......NOZZLE, slip type .500 orf flush (see Section 10-5) .
  • Page 48 10-3. Optional Drive Rolls For All Feed Head Assemblies WIRE DIAMETER PART NO. INCHES (mm) 202 925 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 10-4. Options PART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack...
  • 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 Effective January 1, 2006 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface LG or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
  • Page 52 Welding Process Handbooks Call 1-877-Hobart1 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2006 Hobart Welding Products. 2006−01...

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