Hobart Welding Products 2510 Welder User Manual
Contents
1. 1 ede LOM eek At 184671 WINDTUNNEL 0 0 cece mh m 1 e 1846583 PANEG aaj einen Re peut acevo sena tes dt 1 LIPS 184 665 BRACKET aat e ete etinrebee d ted ua 1 MEN ERE 188441 CHAIN safety 1 17 PLG20 187255 CORD SET 250V 1 zu d uie vates 178 126 CONNECTOR clamp cable 1 rat GS Mh 125 785 VALVE 24VAGO ne metro AE ERE eR DEA ME E 1 2900 40 NAE 134 464 LABEL warning general precautionary 1 184 660 WRAPPER ASSEMBLY 1 Sale adios acer sets 184 715 BRACKET bottle retainer 1 C 184 656 BASE 22 seis Wate E NE PE ee RE 1 Mr RE 106 879 AA E S tox tet oc tbc LL t tere tU HL ur t Sie c cet 1 d en MOD cc eter iet 09069337 WHEEL iet siete o a A er Det nt de at aS 2 Dueb viene alates 121 614 2 RETAING TID restet ea ER Gane elem x P PRATER er Ego d 2 dst P esse Ie i ee 184 664 lt PANEL Side uz rene e E UE E MU CER ER NR ete te Sy ERR 1 28 SR1 173713 RECTIFIER SCR main consisting of 1 HM 173 714 CLAMP spring thyristor2. GUN POLARITY CHANGEOVER CONNECTIONS Reverse Lead Connections For Electrode Negative DCEN For Gasless Flux Cored Wires FCAW Process Drive Assembly Becomes Negative Ref 194 425 Tools Needed 3 3 4in Ref ST 801 789 A OM 194 430 Page 12 2 8 Installing Gas Supply 3 Chain gas cylinder to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Regulator Flow Gauge Install so face is vertical 2 Hose Connection Fitting has 5 8 18 right hand threads 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturers recommended flow rate see Section 3 2 This flow gauge can be adjusted between 5 and 25 cfh 4 CO Adapter Customer Supplied 5 O Ring Install adapter with O ring between regulator flow gauge and CO cylinder Tools Needed 1 1 8 5 8 in Ref ST 801 789 Ref ST 149 827 B Ref ST 158 697 A 2 9 Installing Wire Spool And Adjusting Hub Tension P Small Spool Adapter Tools Needed When a slight force is needed to turn spool tension is set ST 801 790 OM 194 430 Page 13 2 10 Positioning Jumper Links T ih
3. 1 90 TP2 154244 THERMOSTAT NO 422 1 aed sees 143818 THYRISTOR SCR 500A 300V 2 onc S PERS 143852 FOOT mig rectifier 44 444 4 2 98 TP1 154 243 THERMOSTAT NC 1 94 C3 4 031 689 CAPACITOR cer disc 01uf 1000VDC 2 EL 166 667 CLAMP thyristor 1 does eter 008 999 CASTER dite aa e E Der RR at eet 2 ECT PON TRENT 146 149 lt CABLE WOM cec xe a Rete ex xn PRAE E Paler Egi ed 1 de OB ed etas 190 750 CLAMP WO K s esr tee rar an Eure PR Do 1 Loaded RA e oreet 192121 REGULATOR FLOWMETER 1 ee eee Les 144108 HOSE ce eee nn 1 sis OO ian siue 169 596 GUN 12ft 030 035 Fig 6 4 1 40 RC1 048 282 RECEPTACLE w SOCKETS 1 41 C9 C10 136 735 CAPACITOR 1uf 500VDC 2 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggeste
4. ACA Check input voltage available at site 1 Jumper Links Access Door Open door 2 Jumper Link Label 200 VOLTS 230 VOLTS 3 Input Voltage Jumper Links 3 lt RE a ESS Move jumper links to match input AA AR QR voltage Close and secure access door 230 VOLTS 460 VOLTS Close d ose door FRA fe 0 460 VOLTS 575 VOLTS ane of S 144 918 C S 144 916 A Tools Needed C HA Ref ST 801 789 A 2 11 Installing Work Clamp 1 Work Cable 2 Hardware 3 Work Clamp Tools Needed 1 2 in Route cable through clamp handle and secure as shown Ref ST 802 062 OM 194 430 Page 14 2 12 Electrical Service Guide Input Voltage 200 230 460 575 Input Amperes At Rated Output 50 44 22 17 AE Standard Fuse Or Circuit Breaker Rating In 80 70 35 25 Min Input Conductor Size In AWG Kcmil 8 8 10 12 Max Recommended Input Conductor Length In Feet Meters 93 28 124 38 329 100 313 95 Min Grounding Conductor Size In AWG Kcmil 8 8 10 12 Reference 1996 National Electrical Code NEC S 0092J 2 13 Selecting A Location And Connecting Input Power Have only qualified persons make this installation 1 Rating Label Supply correct input power Special instal
5. Ref S 0026 B 7 91 POWER PROTECTION 3 YEAR WARRANTY 1 General Hobart s products are warranted for three 3 years following date of shipment to the original user with the exceptions of items listed in paragraphs 2 through 8 2 Parts and Labor For Motor driven guns High frequency Capacitor Discharge units Running gears Trailers Field options are warranted for one 1 year 3 Expendable Items Primary and secondary switch contacts cable connectors carbon brushes fuses bulbs filters nozzles contact tips liners cutting tips and wire feed rolls are worn or consumed in the normal process of welding or cutting and are there fore warranted only if found to be defective prior to use 4 Replacement parts Replacement and exchange parts are warranted for the remainder of the original equipment warranty or for a period of ninety 90 days whichever is greater 5 Semiautomatic Items Mig welding guns and cables and plasma cutting torches tig torches and cables and remote controls and accessory kits are warranted for ninety 90 days 6 Engines Tires and Batteries Hobart does not warrant items furnished by Hobart but manufactured by others including with out limitation gasoline or diesel engines engine electrical equipment batteries and tires Such items are warranted directly by the manufacturer and Hobart may periodically inform customers of such warranty coverage however Hobart does not guarantee the accuracy
6. check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 5 97 e A i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact w
7. Information sur les champs lectromagn tiques SECTION 2 INSTALLATION 00 cc cece cette nnn nnn hh n n nn nnn 2 1 Specifications 2 2 Welding Power Source Duty Cycle And Overheating 2 3 Welding Gun Duty Cycle And Overheating 2 4 Volt Ampere Curves re 2 5 Installing Running Gear 2 6 Installing Welding Gun 2 7 Setting Gun Polarity For Wire Type 2 8 Installing Gas SUpply x eR x eee x RESET TET VETERES 2 9 Installing Wire Spool And Adjusting Hub Tension 2 10 Positioning Jumper Links 4 22 2 11 Installing Work Clamp 8 2 12 Electrical Service Guide 2 13 Selecting A Location And Connecting Input Power 2 14 Threading Welding Wire 2 SECTION 3 OPERATION 3 1 Controls 3 2 Weld Parameters 3 3 Installing Receptacle Module For Use With A Spool Gun Optional SECTION 4 MAINTENANCE AND TROUBLESHOOTI
8. cher des op rations de soudage l arc de gou geage ou de soudage par points OM 194 430 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn
9. circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage 5 3 DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux
10. rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour som nd fre 5 97 APA Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les p
11. 26 SECTION 6 PARTS LIST 17 Hardware is common and not available unless listed m 801 783 B Figure 6 1 Main Assembly OM 194 430 Page 27 Item Dia Part No Mkgs No Description Quantity Figure 6 1 Main Assembly l bobus 194 424 LABEL set nameplate amp side decals 1 184 670 z HANDLE nori ioni M en EN Re 1 ig ven PI 157 958 32 LIGHM Indi eae Dara Ar ASE nn ea ne 1 4 81 124 511 SWITCH tgl DPST 40A 600VAC On Off 1 5 R23 035897 POTENTIOMETER CP 1 T 2W 1K linear Voltage Control Wire Feed Speed 2 Gina 184783 KNOB in nn fe ee eh advil des tt ds mt nent 2 Lo nude se 184834 PANEL i iue us ee ouest ERR e ee de a RETE mean ated kgs 1 eut re 2148 6927 STABILIZERES reden cetus beech erie er antes 1 9 T1 174 553 TRANSFORMER pwr main 200 230 460 consisting of 1 9 T1 174554 TRANSFORMER pwr main 230 460 575 consisting of 1 v mous pes TP1 121497 THERMOSTAT NO 1 STO Ed oct fus Fig 6 2 CENTER BAFFLE w COMPONENTS 1 entente s 148 809 BLADE fan 9 000 5wg 34 deg w mtg hardware 1 12 FM 148 808 MOTOR fan 230V 50 60 HZ
12. Feed Speed 45 36 27 26 19 15 13 11 10 9 ER70S 6 08 Volts 22 5 22 0 20 5 20 0 20 0 19 5 19 0 19 0 18 5 18 5 035 Feed Speed 40 33 30 27 21 21 16 12 10 8 Volts 24 5 23 5 23 5 23 0 22 0 21 0 20 0 20 0 19 5 045 Feed Speed 27 25 22 19 18 17 15 11 10 Volts 19 5 19 5 19 0 18 5 18 0 18 0 16 5 16 5 16 5 023 Feed Speed 55 49 49 42 35 26 21 19 15 Volts 21 0 20 5 20 0 18 5 18 0 17 0 16 5 16 5 16 0 15 5 030 Mild Steel ER70S 6_ Feed Speed 58 43 41 33 28 22 21 15 13 10 75 Ar 25 CO Volts 21 5 21 5 20 5 20 0 19 5 19 0 18 5 17 5 17 5 16 5 20 cfh 035 Feed Speed 55 50 44 38 36 28 27 23 16 12 Volts 21 5 21 0 20 5 20 5 19 5 19 5 19 0 18 0 17 0 045 Feed Speed 33 30 28 26 24 21 19 12 10 Mild Steel Volts 29 5 29 0 29 0 28 5 26 5 98 Ar 2 O2 035 20 cfh Feed Speed 65 64 64 60 54 Volts 24 0 23 5 23 5 22 5 22 5 22 5 22 0 20 5 030 Stainless Steel Feed Speed 63 56 47 42 38 34 28 23 Roe Volts 26 0 25 0 24 0 24 0 22 5 21 5 21 5 21 5 20 0 19 5 035 Feed Speed 67 60 53 45 39 32 26 20 14 12 Stainless Steel Volts 28 5 27 5 26 5 25 5 25 0 98 Ar 2 O2 035 20 cfh Feed Speed 64 60 56 50 48 Volts 16 0 15 0 14 0 13 0 12 5 12 5 12 5 030 Feed Speed 30 26 20 12 11 9 9 Flux Cored Volts 16 0 14 5 13 5 13 0 12 5 12 5 12 5 E71T GS 035 No Gas Feed Speed 20 12 10 7 5 2 0 Vol
13. Riche M 1 Des tint 170467 RING retaining 42 1 170 468 v OF RING recie RO 1 Yes 169 730 WASHER shock 22 1 B vus 1697311 CUBE head En ee rate eve 1 bou sro 169 738 NUT locking handle 2 mr 194523 Ge NUT Jam sce ces rer P line ente de PORC up steer NP BR DECR CE 1 PEDEM 169 784 sa HANDLE n tem Rete eh ere eek og e ede eed re Dp tans 2 dat obe 169 741 STRAIN RELIEF cable 2 ule 180 433 CORD trigger assembly 1 ex descri 079 974 O RING 500 ID x 103CS rbr 2 15 194010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 194011 LINER monocoil 030 035 wire x 15ft consisting of 1 15 194012 LINER monocoil 035 045 wire x 15ft consisting of 1 AMG ui 079 975 O RING 187 ID x 103CS rbr 1 rece 196 255 SWITCH trigger ete pror erede Vs ci ede eee Ee eiue 1 Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replac
14. Ttt O HOUSING 3 1 Se REIS RC2 e D t ca 41 24VAC 38 c5 NEGATIVE p a P i STUD SRE Rc2 s gt Ze E 3 40 5 lt MT 4 T lt C MS 8 P RCI 3 RC2 o gt F A gt o e c7 RC2 T qH _ lt G PLG20 200v m lt 10 110 lt RCI PLGI 58 RC2 PLGI2 02 1 gt lt lt RC3 11 2 ciam coo lt e lt 803 12 2 lt u FED lt 2 3 Retas WHT lt R63 1 gt gt 32 10V REF OUT 32 RED lt lt RC 162 VOLT COMMAND IN JL A cw a JO IPM COMMAND IN 30 J gt 1 gt lt lt RC2 1 RC3 3 gt gt VOLT gt 3 gt lt lt RC6 7 Ross 1542 COMMAND COMMON 29 51 RC4 255 V TGR IN STD AK lt 9 gt 7 gt 23 r VRI a lt RC6 3 1 L MAIN RC4 11 gt WIRE TGR IN 19 iu _ gt 50 57 GRN LU 24N RC3 PLG4 Red TOS GAS CONT QUT R3 460V gt 4 gt lt lt Rce a RC4 PLG5 m R G PLGB uc gt GAS CONT IN J5 cw Ls PLG1 PLG2 2 lt lt RC6 1 230V 4 3 Le py Ss Lo 8 RC6 2 50 IPM REF OUT S18 LORS RC3 2 gt gt PLG20 aC er RC3 4 55 Z IPM REF COMMON ii 575V TP1 7 Y 19 29 RC1 ee lt 2 lt o 16 18608 18 230 460 575 OPTION ca 1 For Welding Power Source it Diagram Ircul Figure 5 1 C OM 194 430 Page 25 Notes OM 194 430 Page
15. all Safety Standards A Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away IE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground
16. de gaz protecteur contiennent du gaz Sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentair
17. fall be tween the curves shown 2 Overload Volt Ampere Curves When unit is used beyond capacity circuitry senses the overload and shuts down unit output Release trigger and lower weld voltage set ting before trying to weld This shut down circuitry protects internal circuits and parts from overload damage Approximate shutdown voltage amperage points shown for reference only ssb1 1 10 91 SB 144 925 A S 0700 A OM 194 430 Page 10 2 5 Installing Running Gear za Install running gear as shown Tools Needed ST 801 856 A 2 6 Installing Welding Gun s 1 Drive Assembly 2 Gun Securing Knob GunEnd Loosen securing knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert into receptacle and tighten threaded collar Close door Ref ST 801 789 A OM 194 430 Page 11 2 7 Setting Gun Polarity For Wire Type e ar 1 Polarity Changeover Label 2 Wire Drive Assembly 3 Positive Output Terminal 4 Negative Output Terminal Shown As Shipped Set For Electrode g Oo Positive DCEP For Solid Steel Or f a ack Al minum Wires GMAW Process polarity Wire Drive Assembly Work Clamp Lead Lead To Positive To Negative Close door Output Terminal Output Terminal
18. if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 194 430 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Weara welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this i
19. or completeness of its information regarding such warranties 7 Exclusive Remedies In case of Hobart s breach of warranty or any other duty with respect to the quality of any product or serv ice the sole and exclusive remedies therefore shall be As to PRODUCTS 1 repair 2 replacement or 3 where authorized by Hobart payment of or credit for the purchase price less reasonable depreciation based on its actual use upon return of the product and as to SERVICES including repair under war ranty the sole and exclusive remedies therefore shall be payment or credit for Hobart s actual charge therefore or in the absence of any actual charge the customary or reasonable charge for such services and if such breach also involves impairment of Hobart products the remedies available for breach of warranty with respect to the product 8 Modification and Misuse This warranty does not apply to products which have been modified in any way by any party other than Hobart nor to products which have not been installed and operated in accordance with applicable industry standards nor to products which have been used other than under the usual conditions for which designed nor to products that have not received proper care lubrication protection and maintenance under supervision of competent personnel Use of a product after discovery of a defect voids all warranties DISCLAIMER OF WARRANTIES THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCR
20. unit to cool Reduce amperage or voltage or duty cycle before welding A Exceeding duty cycle can damage unit warranty void Overheating Minutes p Aor V Reduce Duty Cycle duty1 4 95 SB 150 215 OM 194 430 Page 9 2 3 Welding Gun Duty Cycle And Overheating amp CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty Do not weld at rated load longer than shown below 9 Using gasless flux cored wire reduces gun duty cycle warn7 1 8 93 Definition 0 Minutes Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 100 Duty Cycle At 200 Amperes Using CO2 100 Duty Cycle At 150 Amperes Using Mixed Gases Continuous Welding 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 6096 Duty Cycle At 300 Amperes Using CO2 60 Duty Cycle At 200 Amperes Using Mixed Gases 6 Minutes Welding NJ 4 Minutes Resting SB1 1 8 93 2 4 Volt Ampere Curves 60 50 r 30 r DC VOLTS 20 F 10 100 150 DC AMPERES 200 DC VOLTS 250 DC AMPERES 250 400 1 Normal Volt Ampere Curves The volt ampere curves show the normal minimum and maximum voltage and amperage output capa bilities of the welding power source Curves of other settings
21. 150 227 C 4 5 Aligning Drive Rolls And Wire Guide Correct Incorrect Turn Off power View is from top of drive rolls look ing down with pressure assembly open 1 Drive Roll Securing Nut 2 Drive Roll eB 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Tools Needed Close pressure roll assembly Close door Ref ST 800 412 A 4 6 Replacing Gun Contact Tip pe Turn Off power before gt replacing contact tip 7 1 Nozzle amm 1 Ie 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new Tools Needed contact tip Reinstall nozzle CX TT Ref 800 797 C OM 194 430 Page 21 4 7 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing e A Turn off welding power Pu source wire feeder 1 Nozzle 1 2 2 Contact Tip 3 of i 3 Adapter q I Wire size stamped tip Remove nozzle check and match wire size contact tip adapter and wire outlet guide Cut off wire and disconnect 3 8 in gun from feeder Blow out gun casing Lay gun cable out straight before installing new liner Reassemble gun in reverse order from taking it apart Install Liner di 3 4 in 20 mm pe
22. 3 TERMINAL pwr output black 2 25 C7 8 186014 CAPACITOR ASSEMBLY 2 Fig 6 3 WIRE DRIVE ASSEMBLY 1 Mr AO cert 134201 STAND OFF SUPPORT PC card 4 vom 144 933 DOOR access changeover 1 pe D etat rte fos is 021469 LABEL danger high voltage 1 EUN INN PLG7 083526 CONNECTOR amp SOCKETS 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 194 430 Page 30 Item Dia Part No Mkgs No Description Quantity Figure 6 3 Wire Drive Assembly Fig 6 2 Item 26 on MESSER 172075 CARRIER drive roll w comp 1 Lg Panne 166072 SPACER gear 444 4444 eue 1 no di deis 174610 SCREW M 6 1 0 x 20 soc hd 3 RU PPM 173620 BUSHING motor mtg 3 010 224 spring rr Rete Beatie dene Re Re e win ae 1 ter 0
23. 3 Months WARNIN Repair or replace cracked weld cable OL 59 Co oO Replace unreadable labels E i Clean and tighten weld terminals 6 Months Blow out or vacuum Remove drive roll and inside During heavy carrier Apply light coat service clean monthly of oil or grease to drive motor shaft 4 2 Circuit Breaker CB1 X 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow cooling period and reset breaker Close door Ref 57 801 789 Ref 800 797 C OM 194 430 Page 20 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 1 Securing Screw SO 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touch ing Tighten screw 3 Anti Wear Guide Install guide as shown 4 Drive Roll Install correct drive roll for wire size and type 5 Drive Roll Securing Nut Turn nut one click to secure drive roll Tools Needed 5 64 in 7 16in ST
24. 85242 FASTENER pinned aigu ange RR MEAE 1 pa eee 085 244 WASHER cupped 4 4 1 ah ONU 010 281 SS9PRING es ente ee Sen ct Qe ae ee Pe can Ae 1 uo O Wave uci easi 085 243 KNOB adjust tension 1 aO st rev RR 166071 LEVER mtg pressure 1 Ms ae 079 634 4 PIN as nece eR hte nes ne ne ERR RR OR a de 1 Sas ds sS 151828 PIN cotter 2 184 234 HOUSING drive motor 1 14 PM 173 435 MOTOR gear 24VDC consisting of 1 De th iare 193 633 KEY woodruff 118 x 380 1 xf stet M ates 193 634 WASHER wave 405 ID x 740 OD 2 NIE RUND 193 635 RING ext 394 shaft d und Octet ere sedis 079633 FITTING hose brs barbed nipple 1 acu LOM barata us 184 235 INSULATOR drive assembly 1 nb 145232 STOP COVER oco cese o aed aruit ed rental gad o tid etc D M Fede Ded 1 nes AB iced 182 788 HOUSING adapter gun feeder 1 m TS es
25. EMBLY consisting of 1 WAL eec 185643 STRIP mtg capacitor 2 mu Dates 082902 STRIP mtg center capacitor 1 AU S Lou 184 584 CAPACITOR elctit 15000uf 45VDC 8 IDEE 083 147 GROMMET scr No 8 10 6 Ped Mein oid 187 752 INSULATOR capacitor 1 17 PC1 184316 CIRCUIT CARD control 1 PLG3 115 094 CONNECTOR amp SOCKETS Included w rectifier 1 PLG4 131 052 CONNECTOR amp SOCKETS 1 MASSE PLG5 131 056 CONNECTOR amp SOCKETS 1 sg PLG6 115092 CONNECTOR amp SOCKETS 1 18 R1 119998 RESISTOR WW fxd 300W 5 ohm 1 sol Dee ye 038 618 LINK jumper 2 20 TE 158 406 TERMINAL ASSEMBLY pri 1ph 3V 1 p 010 199 TUBING Stl ut ete RI veer act cc alee ete AE AS 2 22 CR1 006 393 RELAY 24VAC 1 sad MAD oz 144425 VARISTOR Lis ouis neis epe teda PIE nie bp nn teens ante 1 ea 494 61
26. IPTION ON THE FACE HEREOF EXCEPT AS SPECIFI CALLY PROVIDED IN THE EXPRESSED WARRANTIES SET FORTH ABOVE ALL PRODUCTS ARE SOLD AS IS HOBART MAKES NO WARRANTIES EXPRESSED OR IMPLIED OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WARNING At all times safety is an important consideration in the installation servicing and operation of the product and skilled qualified technical assistance should be utilized at all times Specific recom mendations are included in Safety in Welding and Cutting American National Standard No Z 49 1 Hobart Brothers Company April 1997 Troy Ohio 45373 U S A 910516 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 Zip Eg Resources Available Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment PRINTED IN USA Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams File a claim for loss or damage during ship ment
27. NG 4 1 Routine Maintenance 4 2 Circuit Breaker CB1 4 3 Unit Overload 4 4 Changing Drive Roll And Wire Inlet Guide 4 5 Aligning Drive Rolls And Wire Guide 4 6 Replacing Gun Contact Tip 4422 4 7 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing 4 8 Replacing Switch And Or Head Tube 4 9 Troubleshooting SECTION 5 ELECTRICAL SECTION 6 PARTS LIST DIAGRAM Maece cn OPTIONS AND ACCESSORIES WARRANTY O1 O1 O1 N SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow
28. Remove gun nozzle and contact tip Turn On assembly and let go of wire WOOD A Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire comes out of gun Reinstall Tighten knob enough to prevent slipping Close door contact tip and nozzle OM 194 430 Page 16 SECTION 3 OPERATION 3 1 Controls A b ACRES e ar 1 Wire Speed Control 42m The scale around the control is per I cent not wire feed speed 2 Voltage Control The scale around the control is actual voltage See Section 3 2 or inside welding power source door for weld eters chart 3 Pilot Light 4 Power Switch OFF ON INPUT POWER olo 40 ii 60 30 70 80 20 10 90 0 100 WIRE FEED SPEED VOLTAGE CONTROL OM 194 430 Page 17 3 2 Weld Parameters Wire Type Wire Material Thickness Shielding Gas Diameter EE And Flow Rate inch 9 3 8in 5 16in 1 4in 3 16 10ga 12ga 14 16ga 18ga 20ga 22ga 24ga Volts 20 0 19 5 19 0 18 0 18 0 18 0 17 5 17 0 17 0 023 Feed Speed 38 34 32 24 19 15 14 12 12 Volts 21 5 20 5 19 0 19 0 19 0 19 0 18 5 18 5 18 0 17 5 030 Mild Steel
29. WELDING PRODUCTS 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 an Description a 2 KJ Arc Welding Power Source and Wire Feeder BETA MIG 2510 And M 25 Gun OWNER S MANUAL amp WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq OM 194 430A TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 1 2 Arc Welding Hazards 22 1 8 Additional Symbols For Installation Operation And Maintenance 1 4 Principal Safety Standards 1 5 EMF Information SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles 1 2 Dangers relatifs au soudage larc 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 1 4 Principales normes de s curit 1 5
30. d Replacement Parts Model and serial number required when ordering parts from your local distributor OM 194 430 Page 28 1 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 Item Dia Part No Mkgs No Description Quantity Figure 6 2 Center Baffle w Components Fig 6 1 Item 10 eet 170 201 NUT retaining w warning label HOBART 1 1847384 SPACER SpOOl een a bad bot ela eee ROT E apt pude 1 Era 374551 WASHER flat keyed 1 184 739 SPRING iranien RE 1 bte o ect 405 448 WASHER friction 1 mi D utetur oat 184708 BRACKET siters AR M nds aa D M Mu des 1 Mile riens 405 376 de hbo ded ah sac beak deed Ais hee Reet 1 374 546 SHAFT spool support 1 602 246 WASHER flat 22 4 1 SID esas 184666 REEE SUPPORT i ellus RE eau bade 1 11 CB1 123745 CIRCUIT BREAKER man reset 1P 4A 250VAC 1 184 667 BAFFLE center 422 1 13 C5 186 998 CAPACITOR ASS
31. dage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu
32. des Sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro
33. e le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INSTALLATION 2 1 Specifications Amps Input at Rated Output 60 Hz Single Phase Max OpenCir Rated Output cuit Voltage 200 V 230 V 460 V 575 V KVA KW 250 A at 28 VDC 200 A at 28 VDC 32 50 44 22 18 10 77 40 Duty Cycle 60 Duty Cycle 2 3 2 1 0 8 0 46 0 13 Wire Type and Diameter Wire Feed Speed Dimensions Weight Solid Steel Stainless Steel Flux Cored 50 670 IPM 29 7 8 in 759 mm 198 lb 1 2 1 7 m min W 15 1 8 in 384mm 89 kg 023 045 in 023 035 in 030 045 in D 33 3 8 in 848 mm 0 6 1 2 mm 0 6 0 9 mm 0 8 1 2 mm While idling 2 2 Welding Power Source Duty Cycle And Overheating 6 Minutes Welding WELD AMPERES 60 Duty Cycle At 200 Amperes 4 Minutes Resting 40 50 60 DUTY CYCLE 40 Duty Cycle At 250 Amperes SA 4 Minutes Welding 6 Minutes Resting and 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
34. ement Parts Model and serial number required when ordering parts from your local distributor OM 194 430 Page 33 Options BETA MIG 2510 and Accessories Olympic 30A Spool Gun 130 831 01 9 Ideal for aluminum welding jobs 200 Amp 100 duty cycle air cooled 1 Ib spool gun with 30 ft 9 1 m cable assembly Use with Spool Gun Module 043 084 Spool Gun Module 043 084 Required if welding with spool gun Provides a convenient way for you to plug in an Olympic 30A spool gun Spool Shaft for Use with 1 and 2 Ib 4 in 102 mm Welding Wire Spools 204 550 Double Gas Bottle Rack Kit 190 631 Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages 1 V Grooved rolls for hard wire 2 U Grooved rolls for soft and soft shelled cored wires 3 U Cogged rolls for extremely soft shelled wires usually hard surfacing types 4 V Knurled rolls for hard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Wire Diameter Drive Roll Inlet z E Kit No 1 1 Fraction Decimal Metric oe Part No Type Wire Guide 023 025 in 023 025 in 0 6 mm 087 131 087 130 V Grooved 056 192 030 in 030 in 0 8 mm 079 594 053 695 V Grooved 056 192 035 in 035 in 0 9 mm 079 595 053 700 V Grooved 056 192 045 in 045 in 1 2 mm 079 596 053 697 V Grooved 056 193
35. es en relation avec l installation le fonctionnement et la maintenance 5 Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn jt i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec v ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s 79 amp e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de
36. es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 194 430 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de mass
37. esser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 194 430 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles
38. heck position of input jumper links see Section 2 10 Have Factory Authorized Service Agent check main control board No wire feed Reset circuit breaker CB1 see Section 4 2 Turn Wire Speed control to higher setting see Section 3 1 Clear obstruction in gun contact tip or liner see sections 4 6 and or 4 7 Readjust drive roll pressure see Section 2 14 Change to correct size drive rolls see Section 4 4 Rethread welding wire see Section 2 14 Check gun trigger and leads Repair or replace gun if necessary Have Factory Authorized Service Agent check main control board Poor weld bead or welding wire is noodle welding Check polarity setting for type of welding wire being used see Section 2 7 OM 194 430 Page 24 SECTION 5 ELECTRICAL DIAGRAM SC 184 944 A 1 i vs cen TP2 RECT 1 1 200V 9 24VAC 15 CRV 7 ak an 17 PLG7 oto 4 Eh 9 c2 lae REMOTE 10 OPTION SPOOL GUN RC3 230V FM lt 3 3 POSITIVE c3 So j EM OUTPUT STUD 4 RC2 23 2 lt B 52 460V 4 44 ey 46 DRIVE PLG9 RC2 V MET PK
39. i ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixerle c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dan
40. il instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation reg
41. ith any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and
42. lation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 457 mm for airflow GND PE et Eel g GND PE Connect First L1 L2 Size and ratings must comply with ap E plicable codes Install conductors in conduit or equivalent into a deener gized line disconnect device see Section 2 12 801 788 A Ref 800 797 C OM 194 430 Page 15 2 14 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight Tools Needed oP WD Ref ST 801 789 A Ref ST 802 064 S 0627 A Hold wire tightly to keep it from unraveling 4 in 102 mm Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire 1 3 OFF ON Q INPUT POWER Close and tighten pressure
43. lve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Re LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards 79 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards N MOVING PARTS can cause injury Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger unt
44. oudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent bl
45. ove procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles 4 ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En sou
46. oved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over va
47. place 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 Check and replace Power switch if necessary Have Factory Authorized Service Agent check all board connections and main control board No weld output wire feeds Thermostat TP1 open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 2 2 Connect work clamp to get good metal to metal contact Replace contact tip see section 4 6 An overload condition occurred Release gun trigger see Section 4 3 Have Factory Authorized Service Agent check main control board and main rectifier Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 13 Check input voltage jumper links and correct position if necessary see Section 2 10 Have Factory Authorized Service Agent check main control board Fan motor does not run NOTE Fan only runs when cooling is necessary Have Factory Authorized Service Agent check fan on demand circuit Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct size drive rolls see Section 4 4 Readjust drive roll pressure see Section 2 14 Replace inlet guide contact tip and or liner if necessary see sections 4 6 and or 4 7 C
48. ropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de s
49. s Liner nr EN Stickout Tools Needed Thread wire according to welding power source wire Te feeder manual T T 38in Ref ST 800 797 C OM 194 430 Page 22 4 8 Replacing Switch And Or Head Tube ry E A Disconnect gun first 1 Remove handle locking nut O 3 Slide handle 2 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 4 Secure head tube in vice a j 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto 7 Place head tube in vice and tighten new head tube Hand tighten head until nuts are tight tube into connector cable JE Q 8 Remove from vice Reposition handle and install switch housing Secure with handle locking nut Tools Needed 6 3 4in t er Ref ST 800 795 C OM 194 430 Page 23 4 9 Troubleshooting Trouble Remedy No weld output wire does not feed Be sure line disconnect switch is On see Section 2 13 Re
50. s not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 194 430 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use appr
51. s un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 194 430 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre app
52. ses NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 194 430 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields 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 OM 194 430 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the ab
53. trena 124778 KNOB zm a se bets sae EEE aa eer VR ER 1 173619 CARRIER drive roll w comp 1 174 609 SCREW M 4 7 12 iia a d E a N RR Ra 1 192 029 WASHER flat 250 ID X 437 OD 3 Hardware is common and not available unless listed 21 20 19 77 ST 801 793 A Figure 6 3 Wire Drive Assembly To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 194 430 Page 31 Ref 800 792 B Figure 6 4 Gun And Cable Assembly M 25 OM 194 430 Page 32 Item Part No No Description Quantity Figure 6 4 Gun And Cable Assembly M 25 1 169 724 NOZZLE slip type 500 orf 125 recess 1 169725 NOZZLE slip type 625 orf 125 recess dicite 169 726 NOZZLE slip type 625 orf flush 1 1 169727 NOZZLE slip type 625 orf 125 stickout 2 087299 TIP contact scr 023 wire x 1 125 2 000067 TIP contact scr 030 wire x 1 125 2 000068 TIP contact scr 035 wire x 1 125 2 000 069 TIP contact scr 045 wire x 1 125 E D 169 728 ADAPTER contact tip eter RE ehe ated heut 1 4 169 729 s v ADAPTER NOZZE 2 5 run een erede AU een
54. ts 19 0 18 5 18 0 16 5 15 5 14 5 14 0 13 5 045 Feed Speed 22 20 16 12 10 9 7 0 035 Feed Speed 58 50 41 36 33 33 Flux Cored bos Volts 26 0 25 5 255 25 0 245 24 0 2 20 cfh 045 Feed Speed 33 28 26 21 20 19 Volts 25 5 24 5 24 0 21 5 20 0 19 5 035 Flux Cored CET Feed Speed 73 65 46 36 33 30 75 Ar 25 CO Volts 25 5 25 5 24 5 24 0 23 5 23 5 20 cfh 045 Feed Speed 33 28 26 21 20 19 Volts 26 0 25 0 24 0 22 5 21 0 16 0 15 5 Aluminum 5356 ATGGG 3 64 9 Feed Speed 70 64 58 50 36 34 31 S 185 221 OM 194 430 Page 18 3 3 Installing Receptacle Module For Use With A Spool Gun Optional SN EA 1 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 2 Module 3 Plug PLG9 4 Receptacle RC2 Locate receptacle RC2 in unit wir ing harness Connect plug PLG9 to RC2 Slide module in and secure with supplied screws Tools Needed 1 n ST 801 869 A OM 194 430 Page 19 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 Routine Maintenance e gt gt ESSO Disconnect power before maintaining
55. ularly checked and maintained 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Proces
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