®

Handler 210 232202

230 VAC, Single-Phase Wire Welding Package Feb. 2010

The Handler 210 is recommended for running the

Packed with Power in a
following wires: mild or stainless steel .023 –.035 in.
Portable Case! (0.6– 0.9 mm), flux cored .030 –.045 in. (0.8–
Optional Direct Plug-in Spool 1.2 mm), aluminum .030 –.035 in. (0.8 –0.9 mm).
Gun is easy to install and use! Comes complete with:
Rugged constant-voltage DC welding
Optional DP-3035
Spool Gun power source
PROCESSES Durable built-in wire feeder
MIG (GMAW) Integrated spool gun control circuitry with selector
Welding switch for MIG gun or spool gun operation
Built-in gas solenoid valve
Flux Cored (FCAW)
Welding Dual-gauge regulator and gas hose
he Handler 210 is the one portable MIG welder Comfortable 10 ft. (3 m) MIG gun
T that has 210 amps of welding power in a portable
case. Powerful output to handle 3/8 in. thick mild
10 ft. (3 m) work lead with clamp
Spare .030 in. (0.8 mm) contact tips
steel and enough control for 24 gauge material. Sample spool of .030 in. (0.8 mm) self-shielding
Purchase an optional direct plug-in spool gun to flux cored welding wire
eliminate wire feeding problems associated with soft Weld set-up and information chart
aluminum wire. The DP-3035 spool guns also run Power cord with plug
mild or stainless steel wires. Owner’s manual with parts lists, installation,
Seven output voltage settings and infinite wire feed operation, maintenance and MIG welding guidelines
speed control make the unit easy to set and adjust
for different materials, thicknesses and wires.

FEATURES
Max 210 amps in small portable case
7 voltage selections, enhanced magnetics
and infinite wire feed speed control
Accepts uncomplicated, simple-to-install
direct plug-in DP-3035 Spool Guns:
Integrated spool gun control circuitry is
standard
Proven built-in wire feeder with
quick-release tension lever
Replaceable, built-in contactor
Convenient polarity changeover with
tip holder
Quick-change, dual groove drive rolls
Short circuit protection
Self-resetting thermal overload
Solid-state motor protection
Hobart’s 5/3/1 Industrial Warranty
AND Technical Assistance
BENEFITS
Sized for transport of the unit to the job site and the power to weld 3/8 in. mild steel.
Permit easier fine control of the output parameters for improved arc performance with a smoother arc, less spatter, better
bead appearance, excellent penetration and minimal post-weld cleanup.
Spool guns enhance feedability and reduce “bird-nesting” associated with soft aluminum wires.
No additional control box or adapter is required to connect the DP-3035 spool guns.
Provides positive feed with adjustable tension. Easy access for threading wire.
Eases use and excellent safety feature. Makes the welding wire electrically “cold” when not pulling the trigger.
Access makes it quick and easy to change polarity when switching from solid wire to flux-cored wire. Includes convenient
storage holes for spare tips.
Easy to change from one wire diameter to another .023/.025 in. (0.6 mm) or .030 –.035 in. (0.8 – 0.9 mm).
Protects the unit against current overload.
Protects power transformer to ensure reliability.
Protects wire feed system from overload.
Five-year warranty on transformer and stabilizer; three years on electronics (drive motors, PC boards); and one year on
MIG torch. AND Worldwide Service Network and 1-800-332-3281 Tech Help Line for prompt service and assistance.

SPECIFICATIONS (SUBJECT TO CHANGE WITHOUT NOTICE.) INDUSTRIAL

Current Max. Open Wire Feed Amps Input at Rated Load, 60 Hz Net Shipping
Rated Output Range Circuit Voltage Speed Range 230 V KVA KW Dimensions Weight Weight
150 A, 23 VDC at 25 – 210 A 34 V 40 – 680 IPM, 24 5.33 4.6 H: 12-3/8 in. (315 mm) 76.5 lb. 87 lb.
30% Duty Cycle on 60 Hz 60 – 770 IPM W: 10-5/8 in. (270 mm) (34.8 kg) (39.6 kg)
at no load D: 19-1/2 in. (495 mm)

Certified by Canadian Standards Association to both Canadian and U.S. Standards.

Hobart Welders An Illinois Tool Works Company Web Site HobartWelders.com

Hobart Retail Sales Phone 800-626-9420 FAX 800-424-1544
U.S. Distributor Sales Phone 920-735-4576 FAX 800-637-2315
Canadian Sales Phone 888-489-9353 FAX 519-421-0480
International Sales Phone 920-735-4509 FAX 920-735-4125
 HANDLER 210 WELDING GUIDE (CONVENIENTLY LOCATED ON FEEDER COMPARTMENT DOOR)
/

CONTROL PANEL
1
ON

OFF

WIRE FEED POWER 1. Wire Speed Control

4 2. Voltage Switch
Handler 210 ®

3 5
3. Trigger Lead Connection
230V WIRE FEED WELDER 2 6
25-210 AMP OUTPUT 4. Power Switch
MADE IN 1 7 5 5. Over Temp Light
2 OVER TEMP

DO NOT SWITCH

3 WHILE WELDING

23 23
150 150
30 30

V
34 34

TRIGGER VOLTAGE

PERFORMANCE DATA
DUTY CYCLE VOLT/AMP CURVE
35
200
175 30
OUTPUT AMPERES

130
25
100
VOLTAGE

80
20
60 7
5 6
40 15 4
3
1 2
10
20
5
10
10 20 30 40 50 60 70 80 100 0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
DUTY CYCLE % AMPERAGE

2
 OPTIONS/ACCESSORIES
SPOOL GUN AND ACCESSORIES

Small Running Gear/Cylinder Rack #194776
Durable construction. For gas cylinders no
larger than 7 in. (178 mm) diameter, maximum
weight 75 lb. (34 kg).
Running Gear/Cylinder Rack #770187
Heavy-duty construction. For gas cylinders no
larger than 7 in. (178 mm) diameter, maximum
weight 100 lb. (45 kg).
Protective Cover #195186
Weather-resistant nylon resists stains and
mildew, and protects the finish of your welder.
Drive Rolls
Dual-Groove, V-Smooth #237338
For .023/.025 in. (0.6 mm) and .030 –.035 in.
(0.8 – 0.9 mm) wire.
DP-3035 Spool Guns
Dual-Groove, V-Knurled #202926 Weld 16 gauge (1.6 mm) up to 1/4 in.
For .030 –.035 in. (0.8 – 0.9 mm) and .045 in. (6.3 mm) thick aluminum with the Handler 210.
(1.2 mm) flux cored wire. Rated 150 amps, 60% duty cycle.
MIG GUN AND ACCESSORIES For .023 –.035 in. (0.6 – 0.9 mm)
aluminum, steel and stainless steel wire
H100S4-10 Replacement MIG Torch #245926 on 4 in. (102 mm) diameter spools.
For .030 –.035 in. (0.8 – 0.9 mm) wire. Shipped with (3) .030 in. (0.8 mm) and
Includes 10 ft. (3 m) cable. (3) .035 in. (0.9 mm) contact tips.
#300199 DP-3035-10 with 10 ft. (3 m) cable.
Contact Tips
Includes rugged plastic carrying case.
(See chart on below)
#300173 DP-3025-20 with 20 ft. (6 m) cable.
MIG Nozzle Shipped in cardboard storage carton.
(See chart below)
Protects tip adapter and
focuses gas coverage.
Contact Tips (5 per package)
Gasless Flux Cored Nozzle #199730 For .023/.025 in. (0.6 mm) wire.
(See chart below) #186419 For .030 in. (0.8 mm) wire.
For use with self-shielding #186406 For .035 in. (0.9 mm) wire.
flux cored wires. Improves
visibility, eases access in Nozzle #186405
tight corners, protects tip adapter/gas diffuser
from spatter and from shorting to the work piece. Drive Roll (1) #199731
Usable with H9, H10, H14, M10, and M15 torches. For .023 in. (0.6 mm) wire.
#186413 For .030/.035 in.
Tip Adapter (0.8/0.9 mm) wire.
(See chart below)
Push Roll (1)
#199732 For .023 in.
(0.6 mm) wire.
Replacement Liners #186414 For .030/.035 in.
(See chart below) (0.8/0.9 mm) wire.

CONSUMABLES FOR H14 MIG GUN

Item Hobart Package Part #* Miller Package Part #**
Contact Tips
.023/.025 in. (0.6 mm) #770174 (5 per package) #087 299 (10 per package)
.030 in. (0.8 mm) #770177 (5 per package) #000 067 (10 per package)
.035 in. (0.9 mm) #770180 (5 per package) #000 068 (10 per package)
.045 in. (1.2 mm) #770183 (5 per package) #000 069 (10 per package)

MIG Nozzle (Standard) #770404 #169 715

Gasless Flux Cored Nozzle #770487 #226 190
Tip Adapter #770402 #169 716

Replacement Liners
.023/.025 in. (0.6 mm) #196139 #194 010
.030/.035 in. (0.8/0.9 mm) #196139 #194 011
.035/.045 in. (0.9/1.2 mm) #196140 #194 012
*Available at farm and tool supply retailers.
**Available at Hobart/Miller welding distributors.
3
 TYPICAL INSTALLATION FOR OPTIONAL DP-3035 SPOOL GUN TO HANDLER 210

Quick and easy to install the DP-3035 Spool Gun to the Handler® 210. Just plug the lead into the
feedhead, attach the trigger lead and flip the switch on the inside panel for spool gun operation.
Install the correct wire and gas for the job and its ready to go.

Spool Gun
Gas Hose to Gas Regulator Trigger Lead
Handler 210
230 VAC Power Cord Spool Gun Weld Cable

Work Cable Workpiece

ORDERING INFORMATION AND SYSTEM CHECKLIST

Equipment and Options Stock No. Description Qty. Price

Handler® 210 #500526 230/240 VAC, 60 Hz with gas valve, regulator and hose
UPC: #715959358859; Shipping Weight: 87 lb. (39.6 kg); Carton Dimensions: 24 x 13-3/8 x 19 in. (610 x 340 x 483 mm);
Pallet Qty: 12; Pallet Dimensions: 48 x 40 x 43 in. (1219 x 1016 x 1080 mm); Pallet Weight: 1074 lb. (488 kg)

Accessories
Small Running Gear/Cylinder Rack #194776
Running Gear/Cylinder Rack #770187
Protective Cover #195186
Dual-Groove Drive Rolls #237338* V-Smooth .023/.025 in. (0.6 mm) and .030–.035 in. (0.8–0.9 mm)
#202926 V-Knurled .030 –.035 in. (0.8 – 0.9 mm) and .045 in. (1.2 mm)

MIG Gun and Accessories

H100S4-10 MIG Torch #245926* 10 ft. (3 m), .030 –.035 in. (0.8 – 0.9 mm)
Contact Tips See chart on page 3
Nozzles See chart on page 3
Tip Adapter See chart on page 3
Replacement Liners See chart on page 3
Other

Spool Gun and Accessories

DP-3035-10 Spool Gun #300199 Includes 10 ft. (3 m) cable, in rugged plastic carrying case
DP-3035-20 Spool Gun #300173 Includes 20 ft. (6 m) cable, in cardboard storage carton
Contact Tips #199730 For .023/.025 in. (0.6 mm) wire
#186419 For .030 in. (0.8 mm) wire
#186406 For .035 in. (0.8 mm) wire
Nozzle #186405
Drive Roll #199731 For .023 in. (0.6 mm) wire
#186413 For .030/.035 in. (0.8/0.9 mm) wire
Push Roll #199732 For .023 in. (0.6 mm) wire
#186414 For .030/.035 in. (0.8/0.9 mm) wire
Other

Date: Total Quoted Price:

*Standard with Unit

DISTRIBUTED BY:

Litho in USA