Hobart Welding Products 2510 User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
BETA-MIG 2510
Processes
OM-185 158A May 1997
Eff. w/Serial Number KH438994
Specifications Covered by this Manual:
903 533, 903 562, 903 563
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder
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1OM-185 158
1. Safety Precautions – Read Before Using
1.1 Symbol Usage
OM-185 158A - 5/97, safety_som 4/97
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
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.
1.2 Arc Welding Hazards
Y 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 all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
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.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D 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).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground – 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.
D When making input connections, attach proper grounding conduc-
tor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D 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.
D 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.
D 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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
2 OM-185 158
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 RAYS can burn eyes and skin.
D Wear a 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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
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.
WELDING can cause fire or explosion.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D 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).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D 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.
D Wear approved ear protection if noise level is
high.
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.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
3OM-185 158
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.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If 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.
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.
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 Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
4 OM-185 158
1.5 EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields – Background Paper,
OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May
1989): “. . . there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
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 the 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:
The above procedures are also recommended for pacemaker wearers.
Consult your doctor for complete information.
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8 OM-185 158
1.4 Principales normes de sécurité
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.
Règles de sécurité en soudage, coupage et procédés 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 électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
L’extrait suivant est tiré des conclusions générales du document intitulé
Biological Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA–BP–E–53 (Washington DC : U.S. Govern-
ment Printing Office, mai 1989), publié par le Office of Technology
Assessment du Congrès américain : «... il existe maintenant d’abon-
dantes données scientifiques compilées à la suite d’expériences sur la
cellule ou d’études sur des animaux et des humains, qui montrent clai-
rement que les champs électromagnétiques basse fréquence peuvent
avoir des effets sur l’organisme et même y produire des transforma-
tions. Même s’il s’agit de travaux de très grande qualité, les résultats
sont complexes. Cette démarche scientifique ne nous permet pas
d’établir un tableau d’ensemble cohérent. Pire encore, elle ne nous per-
met pas de tirer des conclusions finales concernant les risques
éventuels, ni d’offrir des conseils sur les mesures à prendre pour rédui-
re sinon éliminer les risques éventuels». (Traduction libre)
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2 Mettre tous les câbles du côté opposé de l’opérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
4 Garder le poste de soudage et les câbles le plus loin possible de
vous.
5 Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les consignes mentionnées précédemment font partie de celles desti-
nées aux personnes ayant recours à un stimulateur cardiaque. Veuillez
consulter votre médecin pour obtenir plus de détails.
9OM-185 158
2. Installation
2.1 Specifications
Amps Input at Rated Output, 60 Hz, Single-Phase
Rated Output
Max. OpenCir-
cuit Voltage
200 V 230 V 460 V 575 V KVA KW
250 A at 28 VDC,
40% Duty Cycle
200 A at 28 VDC,
60% Duty Cycle
32 50
2.3*
44
2*
22
1*
18
0.8*
10
0.46*
7.7
0.13*
Wire Type and Diameter Wire Feed Speed Dimensions Weight
Solid Steel Stainless Steel Flux Cored 50–670 IPM H: 37 in (940 mm) 198 lb
.023 – .045 in
(0.6 – 1.2 mm)
.023 – .035 in
(0.6 – 0.9 mm)
.030 – .045 in
(0.8 – 1.2 mm)
(1.2–1.7 m/min) W: 19 in (483 mm)
D: 30-1/4 in (768 mm)
(89 kg)
* While idling
4 Minutes Welding 6 Minutes Resting
6 Minutes Welding 4 Minutes Resting
2.2 Duty Cycle and Overheating
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
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
Overheating
0
15
A or V
OR
Reduce Duty Cycle
Minutes
duty1 4/95 – SB-150 215
40% Duty Cycle At 250 Amperes60% Duty Cycle At 200 Amperes
10 OM-185 158
2.3 Volt-Ampere Curves
ssb1.1 10/91 – SB-144 925-A / S-0700-A
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 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.
0
10
20
30
40
50
60
0 50 100 150 200 250 300 350 400
DC VOLTS
DC AMPERES
1
*
*
*Approximate shutdown voltage/amperage
points shown for reference only.
2
2.4 Installing Running Gear
ST-801 856-A
Install running gear as shown.
Tools Needed:
11OM-185 158
2.5 Installing Welding Gun
Ref. ST-801 789
1 Drive Assembly
2 Gun Securing Knob
3 Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
knob.
4 Gun Trigger Leads
Insert leads, one at a time, through
small grommet on front panel. Con-
nect female friction terminals to
matching male terminals in unit.
Polarity is not important.
Close door.
1
3
4
2
2.6 Setting Gun Polarity for Wire Type
Tools Needed:
3/4 in
Shown As Shipped – Set For Electrode Positive
(DCEP) For Solid Steel Or Aluminum Wires
(GMAW Process).
Reverse Lead Connections – For Electrode Negative
(DCEN) For Flux Cored Wires (FCAW Process). Drive
Assembly Becomes Negative
S-185 249
Wire Drive Assembly
Lead To Positive (+)
Output Terminal
Work Clamp Lead To
Negative (–) Output
Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
1
2
4
3
1 Polarity Changeover Label
2 Wire Drive Assembly
3 Positive (+) Output Terminal
4 Negative (-) Output Terminal
Always read and follow wire
manufacturer’s recommended
polarity.
Close door.
Ref. ST-801 789
12 OM-185 158
2.7 Installing Gas Supply
Ref. ST-801 789 / Ref. ST-149 827-B / Ref. ST-158 697-A
1
Tools Needed:
2
CO
2
Gas
4 5
1
Argon Gas
OR
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 Gas 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-
ufacturer’s recommended flow
rate (see Section 3.2). This flow
gauge can be adjusted between 5
and 25 cfh.
4CO
2
Adapter
Customer Supplied
5 O-Ring
Install adapter with O-ring between
regulator/flow gauge and CO
2
cylinder.
1-1/8, 5/8 in
2.8 Installing Drive Roll and Wire Inlet Guide
ST-150 227-C
Tools Needed:
1
3
2
4
5
1 Securing Screw
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.
5/64 in
7/16 in
13OM-185 158
2.9 Installing Wire Spool and Adjusting Hub Tension
ST-801 790
When a slight force is needed
to turn spool, tension is set.
9/16 in
Tools Needed:
Small Spool Adapter
2.10 Positioning Jumper Links
Ref. ST-801 789
Check input voltage available at
site.
1 Jumper Links Access Door
Open door.
2 Jumper Link Label
3 Input Voltage Jumper Links
Move jumper links to match input
voltage.
Close and secure access door.
Close door.
Tools Needed:
1
3/8 in
3
2
200 VOLTS
230 VOLTS
460 VOLTS
S-144 918-C
230 VOLTS
460 VOLTS
575 VOLTS
S-144 916-A
14 OM-185 158
2.11 Electrical Service Guide
S-0092J
Input Voltage 200 230 460 575
Input Amperes At Rated Output 50 44 22 17
Max Recommended Standard Fuse Or Circuit Breaker Rating In Am-
peres
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)
2.12 Selecting a Location and Connecting Input Power
Have only qualified persons make
this installation.
1 Rating Label
Supply correct input power.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
ST-801 788
18 in (457 mm)
for airflow
Size and ratings must comply with ap-
plicable codes. Install conductors in
conduit or equivalent into a deener-
gized line disconnect device (see
Section 2.11).
GND/PE
Connect First
L1
L2
GND/PE
1
15OM-185 158
2.13 Threading Welding Wire
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
7 Gun Conduit Cable
Lay gun cable out straight.
7
6
Tools Needed:
Ref. ST-801 789 / S-0627-A
6 in
(150 mm)
. Hold wire tightly to keep it
from unraveling.
4 in
(102 mm)
Tighten
WOOD
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip. Turn On.
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire.
Close door.
1
2 3
4
5
16 OM-185 158
3. Operation
3.1 Controls
1 Wire Speed Control
The scale around the control is per-
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 param-
eters chart.
3 Pilot Light
4 Power Switch
1
2
4 3
17OM-185 158
3.2 Weld Parameters
S-185 221
Wire Type, Wire
Operator
Material Thickness
Shielding Gas,
And Flow Rate
Diameter
(inch)
Operator
Control Settings
3/8 in 5/16 in 1/4 in 3/16 in 10 ga 12 ga 14 ga 16 ga 18 ga 20 ga 22 ga 24 ga
Volts – – – 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
Mild Steel
ER70S-6
.030
Feed Speed% – – 45 36 27 26 19 15 13 11 10 9
ER70S-6
CO
2
20 cfh
Volts 22.5 22.0 20.5 20.0 20.0 19.5 19.0 19.0 18.5 18.5 – –
20 cfh
.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
Mild Steel
ER70S-6
.030
Feed Speed% – – 58 43 41 33 28 22 21 15 13 10
ER70S-6
75% Ar
25% CO
2
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% O
2
20 cfh
.035
Feed Speed% 65 64 64 60 54 – – – – – – –
Volts – 24.0 23.5 23.5 22.5 22.5 22.5 22.0 20.5 – – –
Stainless Steel
308L
.030
Feed Speed% – 63 56 47 42 38 34 28 23 – – –
308L
HeArCO
2
20 cfh
Volts 26.0 25.0 24.0 24.0 22.5 21.5 21.5 21.5 20.0 19.5 – –
20 cfh
.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% O
2
20 cfh
.035
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
(No Gas)
.035
Feed Speed% – – – – 20 12 10 7 5 2 0 –
Volts – 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
E71T-1
CO
2
Volts 26.0 25.5 25.5 25.0 24.5 24.0 – – – – – –
CO
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 – – – – –
Flux Cored
E71T-1
.035
Feed Speed% – 73 65 46 36 33 30 – – – – –
E71T-1
75% Ar
25% CO
2
Volts 25.5 25.5 24.5 24.0 23.5 23.5 – – – – – –
20 cfh
.045
Feed Speed% 33 28 26 21 20 19 – – – – – –
Aluminum 5356
Volts 26.0 25.0 24.0 22.5 21.0 16.0 15.5 – – – – –
Aluminum 5356
Argon
3/64
Feed Speed% 70 64 58 50 36 34 31 – – – – –
18 OM-185 158
3.3 Installing Receptacle Module for use with a Spool Gun (Optional)
ST-801 869
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
2
3
4
19OM-185 158
4. Maintenance and Troubleshooting
4.1 Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace unreadable labels.
Repair or replace
cracked weld cable.
Clean and tighten weld terminals.
6 Months
Blow out or vacuum inside. During
heavy service, clean monthly.
OR
4.2 Circuit Breaker CB1
Ref. ST-801 789
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.
1
2
3
20 OM-185 158
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 Aligning Drive Rolls and Wire Guide
Y Turn Off power.
View is from top of drive rolls look-
ing down with pressure assembly
open.
1 Allen Wrench (Supplied)
2 Drive Roll Securing Nut
3 Drive Roll
4 Wire Guide
5 Welding Wire
6 Drive Gear
Insert wrench, and turn screw in or
out until drive roll groove lines up
with wire guide.
Close pressure roll assembly.
Close door.
Ref. ST-800 412-A
Correct Incorrect
5
4
3
2
1
6
Tools Needed:
3/16 in
4.5 Troubleshooting
Trouble Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2.12).
Replace building line fuse or reset circuit breaker if open (see Section 2.12).
Reset circuit breaker CB1 (see Section 4.2).
Secure gun trigger connections (see Section 2.5).
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 Gun Owner’s Manual).
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 2.12).
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 2.8).
21OM-185 158
Trouble Remedy
Readjust drive roll pressure (see Section 2.13).
Replace inlet guide, contact tip, and/or liner if necessary (see Gun Owner’s Manual).
Check 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 Gun Owner’s Manual).
Readjust drive roll pressure (see Section 2.13).
Change to correct size drive rolls (see Section 2.8).
Rethread welding wire (see Section 2.13).
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 2.6).
22 OM-1308
5. Electrical Diagram
5.1 Circuit Diagram for Welding Power Source
SC-184 944
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Hobart Welding Products 2510 User manual
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