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

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Handler 210
OM-227 978D
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
2010−04

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  • Page 1 OM-227 978D 2010−04 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 _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • 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 injure. 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-227 978 Page 10...

  • Page 15: 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 16: 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 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Nozzle, Contact Tip, And Adapter Turn off welding power source. Nozzle Contact Tip Tip Adapter Head Wire size stamped on tip − check Tube and match wire size. 8 mm Tools Needed: 8 mm Ref.

  • Page 18: Installing Work Clamp

    5-3. Installing Work Clamp Work Cable From Unit Work Clamp Screw Connection hardware must be tightened with proper tools. Do not just Work Clamp Tabs hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. Bend tabs around work cable.

  • Page 19: Process/Polarity Table

    5-4. Process/Polarity Table Cable Connections Process 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 − Self-shielding wire − DCEN −...

  • Page 20: Installing Gas Supply

    5-6. 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 21: Serial Number And Rating Label Location

    5-7. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-8.

  • Page 22: Electrical Service Guide

    5-9. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase...

  • Page 23: Connecting Optional Spool Gun

    5-11. Connecting Optional Spool Gun Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten Spool Gun thumbscrew. Spool gun must be inserted completely to prevent leakage of Ç...

  • Page 24: Threading Welding Wire

    5-12. 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 25: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Ref. 227 950-A / Ref. 246 668-A Wire Speed Control Voltage Switch Over Temperature Light The higher the selected number, the Light illuminates if main transformer Use control to select a wire feed speed. As thicker the material that can be welded overheats.

  • Page 26: Weld Parameter Chart For 230 Vac Model

    6-2. Weld Parameter Chart For 230 VAC Model OM-227 978 Page 22...
  • Page 27 227 949-B OM-227 978 Page 23...

  • Page 28: Section 7 − Maintenance &Troubleshooting

    SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often 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 29: Changing Drive Roll Or Wire Inlet Guide

    7-4. Changing Drive Roll Or Wire Inlet Guide Turn off welding power source. 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 30: Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing

    7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing Turn off welding power source. Nozzle Contact Tip Tip Adapter Head Wire size stamped on tip − check Tube and match wire size. Cut off wire and 8 mm disconnect gun from feeder.

  • Page 31: Replacing Switch And/Or Head Tube

    7-6. Replacing Switch And/Or Head Tube Turn Off welding power source /wire feeder and disconnect gun. Remove handle halves. Remove screws (5) and nuts (4). Remove switch housing. Install new Remove screw on switch and connect leads (polarity is opposite side. important).

  • Page 32: Troubleshooting Table

    7-7. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 5-8). No weld output; wire does not feed; fan 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 33 Notes OM-227 978 Page 29...

  • Page 34: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-227 978 Page 30...
  • Page 35 227 951-B OM-227 978 Page 31...

  • Page 36: Section 9 − Mig Welding (Gmaw) Guidelines

    SECTION 9 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 9-1. Typical MIG Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...

  • Page 37: Typical Mig Process Control Settings

    9-2. Typical MIG Process Control Settings 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 38: Holding And Positioning Welding Gun

    9-3. Holding And Positioning Welding Gun 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 39: Conditions That Affect Weld Bead Shape

    9-4. Conditions That Affect Weld Bead Shape 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 ° Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 40: Gun Movement During Welding

    9-5. Gun Movement During Welding 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 41: 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 42: 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 43: 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 44: Common Mig Shielding Gases

    9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 45 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
  • Page 46 Notes OM-227 978 Page 42...

  • Page 47: 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 43...
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....199 566 DOOR, access ..........
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly (Continued) ....196 574 SWITCH, rocker DPST ......... .
  • Page 50 243 842-A Figure 10-2. H100S4-10 Gun Item Dia. Part Mkgs. Description Quantity 245 926 Figure 10-2. H100S4-10 Gun ... . . 169 715 NOZZLE, slip type .500 orf flush ........
  • Page 51 .035/.045 in (0.9/1.2 mm) 196 140 194 012 *Available at farm and tool supply retailers. **Available at Hobart/Miller welding distributors. NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order. OM-227 978 Page 47...
  • Page 52 Notes...
  • Page 53 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 54 Notes...
  • Page 55 Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 56 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Hobart Welding Products. 2010−01...

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