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Manual Hobart Welding Products OM-227 978B

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  • Hobart Welding Products OM-227 978B - page 1

    Processes OM-227 978B 2007−04 Handler 210 Arc W elding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding R ...

  • Hobart Welding Products OM-227 978B - page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H ...

  • Hobart Welding Products OM-227 978B - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Hobart Welding Products OM-227 978B - page 4

    T ABLE OF CONTENTS SECTION 9 − MIG WELDING (GMA W) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical MIG Process Connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Control Settin ...

  • Hobart Welding Products OM-227 978B - page 5

    OM-227 978 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me ...

  • Hobart Welding Products OM-227 978B - page 6

    OM-227 978 Page 2 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. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...

  • Hobart Welding Products OM-227 978B - page 7

    OM-227 978 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. ...

  • Hobart Welding Products OM-227 978B - page 8

    OM-227 978 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W ...

  • Hobart Welding Products OM-227 978B - page 9

    OM-227 978 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy m bole graphique d’avertis sement ! Attention ! Cette pro- cédur e c omport e des risques poss i ...

  • Hobart Welding Products OM-227 978B - page 10

    OM-227 978 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...

  • Hobart Welding Products OM-227 978B - page 11

    OM-227 978 Page 7 2-3 . Dangers s upplémenta ires en r elation ave c l ’installa tion, l e f onctionnement et l a maintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger ...

  • Hobart Welding Products OM-227 978B - page 12

    OM-227 978 Page 8 2-5. Prin cipales nor mes d e sécu rité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W el ...

  • Hobart Welding Products OM-227 978B - page 13

    OM-227 978 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMA W) Wire Feed Flux Cored Arc W elding (FCA W) SECTION 4 − SPECIFICA TIONS 4-1. Specifications Rated W ...

  • Hobart Welding Products OM-227 978B - page 14

    OM-227 978 Page 10 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. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit or gu ...

  • Hobart Welding Products OM-227 978B - page 15

    OM-227 978 Page 1 1 SECTION 5 − INST ALLA TION 5-1. Installing Welding Gun 804 686-A 1 Drive Assembly 2 MIG Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten thumbscrew . W elding gun must be inserted completely to prevent leakage of shielding gas. 5 Gun T rigg ...

  • Hobart Welding Products OM-227 978B - page 16

    OM-227 978 Page 12 5-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect to negative (−) output terminal FCAW − Self-shielding wire − no shielding gas DCEN − Straight Po ...

  • Hobart Welding Products OM-227 978B - page 17

    OM-227 978 Page 13 5-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter In ...

  • Hobart Welding Products OM-227 978B - page 18

    OM-227 978 Page 14 5-6. Selecting A Location And Connecting Input Power Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tag- out in ...

  • Hobart Welding Products OM-227 978B - page 19

    OM-227 978 Page 15 5-7. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 24 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Operating 3 35 Min Input Conductor Size In A WG 4 14 Max Recommended Input Conductor Length In Feet (Meters) 55 (17) Min Grounding Conducto ...

  • Hobart Welding Products OM-227 978B - page 20

    OM-227 978 Page 16 5-9. Installing Contact Tip And Nozzle T ools Needed: Ref. 802 399-A Y T urn off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 T ip Adapter Thread welding wire through gun (see Section 5-1 1). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored ...

  • Hobart Welding Products OM-227 978B - page 21

    OM-227 978 Page 17 5-10. Connecting Optional Spool Gun 804 695-A / 804 696-A 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten thumbscrew . Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun T rigger Plug Ins ...

  • Hobart Welding Products OM-227 978B - page 22

    OM-227 978 Page 18 5-1 1. Threading Welding Wire 1 Wire Spool 2 W elding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: Pull and hold wire; cut off end. Remove gun nozzle and contact tip. Open pressure assembly. Make sure feed roll is set to correct groove to match wire ...

  • Hobart Welding Products OM-227 978B - page 23

    OM-227 978 Page 19 SECTION 6 − O P E R A T I O N 6-1. Controls 1 Wire Speed Control Us e control to select a wire feed speed. As V oltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2 , as applicable). 2 Power Switch 3 V oltage Switch The higher the selected number , the t ...

  • Hobart Welding Products OM-227 978B - page 24

    OM-227 978 Page 20 6-2. W eld Parameter Chart For 230 V AC Model / ...

  • Hobart Welding Products OM-227 978B - page 25

    OM-227 978 Page 21 227 949-B B ...

  • Hobart Welding Products OM-227 978B - page 26

    OM-227 978 Page 22 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl W ...

  • Hobart Welding Products OM-227 978B - page 27

    OM-227 978 Page 23 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wi r e G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Retaining Pin T o remove drive roll, push drive roll in and rotate it (1/4 turn) to the open slot and slide it out over th ...

  • Hobart Welding Products OM-227 978B - page 28

    OM-227 978 Page 24 7-6. Cleaning Or Replacing Gun Liner Ref. 804 692-A 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more. Cut liner of f so that 3/4 in (19 mm) sticks out of ...

  • Hobart Welding Products OM-227 978B - page 29

    OM-227 978 Page 25 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Nee d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tube in vice and tighten until nuts are tight. Remove from ...

  • Hobart Welding Products OM-227 978B - page 30

    OM-227 978 Page 26 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-6). 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 protect ...

  • Hobart Welding Products OM-227 978B - page 31

    OM-227 978 Page 27 Notes ...

  • Hobart Welding Products OM-227 978B - page 32

    OM-227 978 Page 28 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram ...

  • Hobart Welding Products OM-227 978B - page 33

    OM-227 978 Page 29 227 951-B ...

  • Hobart Welding Products OM-227 978B - page 34

    OM-227 978 Page 30 SECTION 9 − MIG WELDING (GMA W) GUIDELINES 9-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close t o the weld as possible. Wire Fe eder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Ho ...

  • Hobart Welding Products OM-227 978B - page 35

    OM-227 978 Page 31 9-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 ...

  • Hobart Welding Products OM-227 978B - page 36

    OM-227 978 Page 32 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electr ...

  • Hobart Welding Products OM-227 978B - page 37

    OM-227 978 Page 33 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. NOTE Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD P ...

  • Hobart Welding Products OM-227 978B - page 38

    OM-227 978 Page 34 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 W eave Bead − Side T o Side Movement A ...

  • Hobart Welding Products OM-227 978B - page 39

    OM-227 978 Page 35 9-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. ...

  • Hobart Welding Products OM-227 978B - page 40

    OM-227 978 Page 36 9-1 1. T roubleshooting − 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 maintai ...

  • Hobart Welding Products OM-227 978B - page 41

    OM-227 978 Page 37 9-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support h ...

  • Hobart Welding Products OM-227 978B - page 42

    OM-227 978 Page 38 9-17. T roubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, bu t wire does not feed. T oo little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to m ...

  • Hobart Welding Products OM-227 978B - page 43

    OM-227 978 Page 39 Notes ...

  • Hobart Welding Products OM-227 978B - page 44

    OM-227 978 Page 40 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 804 691-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 56 55 57 58 Figure 10-1. Main Assembly ...

  • Hobart Welding Products OM-227 978B - page 45

    OM-227 978 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quanti ty 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 HINGE, door 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Hobart Welding Products OM-227 978B - page 46

    OM-227 978 Page 42 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quanti ty 40 196 574 SWITCH, rocker DPST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 228 400 KNOB, pointer (voltage) 1 . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Hobart Welding Products OM-227 978B - page 47

    OM-227 978 Page 43 804 692-A 1 2 34 5 6 7 9 8 10 11 12 Figure 10-2. H-14 Gun Quanti ty Description Part No. 231 204 Item No. Figure 10-2. H-14 Gun 1 NOZZLE, slip type .500 orf flush (see Section 10-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 NOZZLE, flux cored slip type (see Section 10-5) . . . . . . . . . . . . . . . . . . . . . ...

  • Hobart Welding Products OM-227 978B - page 48

    OM-227 978 Page 44 10-3. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 202 925 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 10-4. Options P ART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder , 100 lb (45 kg) max. 194 776 ...

  • Hobart Welding Products OM-227 978B - page 49

    Notes ...

  • Hobart Welding Products OM-227 978B - page 50

    Notes W o r k l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual . ...

  • Hobart Welding Products OM-227 978B - page 51

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2007−01 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart ...

  • Hobart Welding Products OM-227 978B - page 52

    PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 Hoba rt We lding Product s An I l li noi s T ool Works Company 600 W es t Main Street Troy , OH 45373 U SA For T echn i cal A ssistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered ...

Manufacturer Hobart Welding Products Category Welding System

Documents that we receive from a manufacturer of a Hobart Welding Products OM-227 978B can be divided into several groups. They are, among others:
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All of them are important, but the most important information from the point of view of use of the device are in the user manual Hobart Welding Products OM-227 978B.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Hobart Welding Products OM-227 978B, service manual, brief instructions and user manuals Hobart Welding Products OM-227 978B. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Hobart Welding Products OM-227 978B.

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A complete manual for the device Hobart Welding Products OM-227 978B, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Hobart Welding Products OM-227 978B by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Hobart Welding Products OM-227 978B.

A complete Hobart Welding Products manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Hobart Welding Products OM-227 978B - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Hobart Welding Products OM-227 978B, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Hobart Welding Products OM-227 978B, that we can find in the current document
3. Tips how to use the basic functions of the device Hobart Welding Products OM-227 978B - which should help us in our first steps of using Hobart Welding Products OM-227 978B
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Hobart Welding Products OM-227 978B
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Hobart Welding Products OM-227 978B in a specific country, if it was not possible to solve the problem on our own.

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