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Hobart Welding Products BETA-MIG 2510 Owner's Manual

And m-25 gun
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BETA-MIG 2510
And M-25 Gun
OM-194 430A
June 1999
Specifications Covered by this Manual:
500 430, 500 431, 500 432
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder

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Summary of Contents for Hobart Welding Products BETA-MIG 2510

  • Page 1 OM-194 430A June 1999 Specifications Covered by this Manual: 500 430, 500 431, 500 432 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder BETA-MIG 2510 And M-25 Gun...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • 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 D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays 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: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

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

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Max. OpenCir- 200 V 230 V 460 V 575 V Rated Output cuit Voltage 250 A at 28 VDC, 200 A at 28 VDC, 40% Duty Cycle 60% Duty Cycle 2.3* 0.8*...

  • Page 14: Welding Gun Duty Cycle And Overheating

    2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. Do not weld at rated load longer than shown below. Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .045 in (0.6 To 1.1 mm) .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires...

  • Page 15: Installing Running Gear

    2-5. Installing Running Gear Install running gear as shown. Tools Needed: ST-801 856-A 2-6. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. Gun Trigger Plug Insert into receptacle, and tighten threaded collar.

  • Page 16: Setting Gun Polarity For Wire Type

    2-7. Setting Gun Polarity For Wire Type Polarity Changeover Label Wire Drive Assembly Positive (+) Output Terminal Negative (–) Output Terminal Always read and follow wire manufacturer’s recommended polarity. Close door. Ref. 194 425 Tools Needed: 3/4 in Ref. ST-801 789-A OM-194 430 Page 12...

  • Page 17: Installing Gas Supply

    2-8. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Regulator/Flow Gauge Install so face is vertical. Gas Hose Connection Fitting has 5/8-18 right-hand threads. Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour).

  • Page 18: Positioning Jumper Links

    2-10. Positioning Jumper Links Check input voltage available at site. Jumper Links Access Door Open door. Jumper Link Label Input Voltage Jumper Links 200 VOLTS 230 VOLTS Move jumper links to match input voltage. Close and secure access door. 230 VOLTS 460 VOLTS Close door.

  • Page 19: Electrical Service Guide

    2-12. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 93 (28) 124 (38) 329 (100) 313 (95) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC)

  • Page 20: Threading Welding Wire

    2-14. Threading Welding Wire Wire Spool Tools Needed: Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Ref. ST-801 789-A / Ref. ST-802 064 / S-0627-A Hold wire tightly to keep it from unraveling.

  • Page 21: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Wire Speed Control The scale around the control is per- cent, not wire feed speed. 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.

  • Page 22: Weld Parameters

    3-2. Weld Parameters Material Thickness Wire Type, Wire Operator Operator Shielding Gas, Diameter Control Settings And Flow Rate (inch) 3/8 in 5/16 in 1/4 in 3/16 in 10 ga 12 ga 14 ga 16 ga 18 ga 20 ga 22 ga 24 ga Volts –...

  • Page 23: Installing Receptacle Module For Use With A Spool Gun (Optional)

    3-3. Installing Receptacle Module For Use With A Spool Gun (Optional) Knockout Panel Pierce front panel label at corners of knockout and follow 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.

  • Page 24: Section 4 - Maintenance And Troubleshooting

    SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum Remove drive roll and inside.

  • Page 25: Unit Overload

    4-3. Unit Overload If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun trigger to reset this condition. 4-4. Changing Drive Roll And Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.

  • Page 26: Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing

    4-7. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Y Turn off welding power source/wire feeder. Nozzle Contact Tip Head Adapter Tube Wire size stamped on tip – check and match wire size. Remove nozzle, contact tip, adapter, and wire outlet guide.

  • Page 27: Replacing Switch And/Or Head Tube

    4-8. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 28: Troubleshooting

    4-9. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-13). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-6).

  • Page 29: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM SC-184 944-A Figure 5-1. Circuit Diagram For Welding Power Source OM-194 430 Page 25...
  • Page 30 Notes OM-194 430 Page 26...

  • Page 31: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. 801 783-B Figure 6-1. Main Assembly OM-194 430 Page 27...
  • Page 32 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ... . . 194 424 LABEL, set, nameplate & side decals ........
  • Page 33 Hardware is common and not available unless listed. 27 (Fig. 6–3) ST-801 786-B Figure 6-2. Center Baffle w/Components OM-194 430 Page 29...
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 10) ... . . 170 201 NUT, retaining w/warning label (HOBART) ......
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Wire Drive Assembly (Fig 6-2 Item 26) ... . . 172 075 CARRIER, drive roll w/comp ......... . .
  • Page 36 Ref. 800 792-B Figure 6-4. Gun And Cable Assembly, M-25 OM-194 430 Page 32...
  • Page 37 Item Part Description Quantity Figure 6-4. Gun And Cable Assembly, M-25 ..169 724 NOZZLE, slip type .500 orf .125 recess ..169 725 NOZZLE, slip type .625 orf .125 recess .

  • Page 38: Options And Accessories

    Options and Accessories BETA-MIG 2510 Olympic 30A Spool Gun #130 831-01-9 Ideal for aluminum welding jobs. 200 Amp, 100% duty cycle, air-cooled, 1 lb spool gun with 30 ft (9.1 m) cable assembly. Use with Spool Gun Module #043 084.
  • Page 40 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Welding Supplies and Consumables Contact your Distributor for: Options and Accessories Personal Safety Equipment...

This manual is also suitable for:

M-25 gun

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