Hobart Welding Products IronMan 250, Owner'S Manual

Page 1: ...structions For Optional Spoolmate Spoolgun Switch IronMan 250 And M 25 Gun Processes OM 192 440W 2006 10 Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Description Arc Welding Power Source and Wire Feeder File MIG GMAW ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...lling Welding Gun 11 3 6 Connecting To Weld Output Terminals 12 3 7 Installing Work Clamp 12 3 8 Setting Gun Polarity For Wire Type 13 3 9 Installing Wire Spool And Adjusting Hub Tension 13 3 10 Installing Gas Supply 14 3 11 Positioning Jumper Links 15 3 12 Electrical Service Guide 16 3 13 Selecting A Location And Connecting Input Power 17 3 14 Threading Welding Wire 18 3 15 Installing Optional Sp...

Page 4: ... Weld Bead Characteristics 34 6 8 Troubleshooting Excessive Spatter 35 6 9 Troubleshooting Porosity 35 6 10 Troubleshooting Excessive Penetration 35 6 11 Troubleshooting Lack Of Penetration 36 6 12 Troubleshooting Incomplete Fusion 36 6 13 Troubleshooting Burn Through 36 6 14 Troubleshooting Waviness Of Bead 37 6 15 Troubleshooting Distortion 37 6 16 Common MIG Shielding Gases 38 6 17 Troubleshoot...

Page 5: ...10 147 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 prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 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 shield...

Page 7: ...es computers and communicationsequipment 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 equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...ion selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du section...

Page 10: ...ble de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules ...

Page 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Page 12: ... Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans le...

Page 13: ...7 mm 185 lb 84 kg 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm 030 045 in 0 8 1 2 mm m min D 36 1 2 in 927 mm While idling 6 Minutes Welding 4 Minutes Resting 3 2 Welding Power Source 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 u...

Page 14: ...uous Welding SB1 1 8 93 0 10 Minutes Definition 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 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 60 Duty Cycle At 300 Amperes Using CO2 60 Duty Cycle At 200 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting 3 4 Volt Ampere Curves Volt amperecu...

Page 15: ...ef 802 285 D 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door 3 4 2 1 ...

Page 16: ...ith nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean Tools Needed 3 4 in 19 mm 4 2 3 Do not place anything between Correct Installation Incorrect Installation 1 weld cable terminal and copper bar 3 7 Installing Work Clamp 1 Work Cable Route cab...

Page 17: ...minal 3 Negative Black Output Terminal Always read and follow wire manufacturer s recommended polarity Close door Ref 802 285 D Ref ST 192 432 3 2 3 9 Installing Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool tension is set 15 16 in Use compression spring with 8 in 200 mm spools Tools Needed 072573 B ...

Page 18: ...cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connecti...

Page 19: ...put voltage available at site 1 Jumper Links Access Door Open door 2 Jumper Link Label Check label only one is on unit 3 Input Voltage Jumper Links Move jumper links to match input voltage Close and secure access door 3 Tools Needed 2 3 8 in 200 VOLTS 230 VOLTS S 153 980 1 ...

Page 20: ... Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may...

Page 21: ... line ter minal 1 Rating Label Supply correct input power 2 Plug 3 Receptacle Connect plug to receptacle 4 Black And White Input Conductor L1 And L2 5 Green Or Green Yellow Grounding Conductor 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow groundingconductor to disconnec...

Page 22: ...d contact tip Turn On WOOD 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 Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Hold wire tightly to keep it from unraveling 1 2 3 4 Use pre...

Page 23: ... switch plug Retain jumper plug by placing looped lead over unit wiring harness 8 Switch Plug Connect switch plug to wiring har ness switch plug 9 Jam Nut Remove top jam nut from switch switch is equipped with two nuts a jam nut and a backing nut Insert switch shaft through switch mounting plate Switch should be positioned so lead with resistor is facing down Secure switch to plate with jam nut Ti...

Page 24: ... existing gas hose above barbed fitting at wire drive housing Install supplied hose clamp onto end of hose at wire drive housing and insert either of the two output barbed ends of diverter valve into hose Secure with hose clamp Install another supplied hose clamp onto end of hose from gas supply and insert in put barbed end of diverter valve into hose Secure with hose clamp Slide hose clamp down g...

Page 25: ...trols 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide and Section 4 2 3 Power Switch 1 Ref 195 721 2 3 ...

Page 26: ... 045 1 1 mm 045 1 1 mm 023 0 6 mm 030 0 8 mm 035 0 9 mm 035 0 9 mm 030 0 8 mm 047 1 2 mm 030 0 8 mm 035 0 9 mm 047 1 2 mm Selecting Wire Gas and Control Settings 10 20 30 40 50 60 70 80 90 WIRE SPEED Wire Speed listed is a starting value only Wire Speed setting can be fine tuned while welding Wire Speed also depends on other variables such as stick out travel speed weld angle cleaniness of metal e...

Page 27: ...4 80 3 60 3 52 2 22 5 100 4 64 5 38 4 28 4 12 4 50 4 54 3 52 4 54 VOLTA GE 1 2 3 4 5 6 10 20 30 40 50 60 70 80 90 WIRE SPEED Wire Size Stock No V Grooved 024 030 035 202925 024 045 407230 004 V Knurled 030 035 193330 039 045 052 1 16 193331 A Nozzle 625 orf flush 169 726 500 orf recess 169 724 625 orf recess 169 725 500 orf flush 200 258 B Tips 625 orf stickout 169 727 023 0 6 mm 030 0 8 mm 035 0 ...

Page 28: ... coat of oil or grease to drive motor shaft 5 2 Supplementary Protectors Ref 802 285 D Y Turn Off unit 1 Supplementary Protector CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 SupplementaryProtector CB2 CB2 protects the trigger circuit from overload If CB...

Page 29: ...ize and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 5 4 Removing Knob From Front Panel Y Turn Off power 1 Front Panel 2 Knob 3 Spring Clip 4 Control Shaft 5 Slot Rotate knob to allow access to slot Insert Allen wrench or stiff piece of wire into slot and while depressing spring clip slide knob off control shaft To reinstall push knob fully onto contr...

Page 30: ...ng Gun Contact Tip Ref 800 797 C Y Turn Off power before replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed 1 2 ...

Page 31: ...n tip check and match wire size Head Tube Tools Needed 5 8 7 16 in Lay gun cable out straight before installing new liner Remove nozzle contact tip and adapter Unscrew and remove liner Blow out gun casing Cut off wire and disconnect gun from feeder 7 16 in 3 4 in 20 mm Liner Stickout Install Liner Thread wire according to welding power source wire feeder manual Reassemble gun in reverse order from...

Page 32: ...nto new head tube Hand tightenhead tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle locking nut Y Turn Off welding power source wire feeder and disconnect gun Remove switch housing Install new switch and connect leads polarity is not important Reassemble in reverse order If replacing ...

Page 33: ...e speed Readjust front panel settings see Section 4 1 Change to correct size drive roll see Section 5 3 Readjust drive roll pressure see Section 3 14 Replace inlet guide contact tip and or liner if necessary see Sections 5 3 5 5 and or 5 6 5 9 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straightengun cable and or replace damaged pa...

Page 34: ... Y 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 Wire Feeder Power Source Workpiece Gun Regulator Flowmeter Gas Hose Shielding Gas Supply Work Clamp light mig 5 967 Ref 802 285 D ...

Page 35: ...ameters 035 in Recommendation Wire Speed Approx 802 280 F 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in 3 5 in per ampere 2 in per ampere 1 6 in per ampere Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Low voltage wire stubs into work High voltage...

Page 36: ... 13 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS ...

Page 37: ...lectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WELD BEAD PROFILES 10 10 GUN TRAVEL SPEED S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast ...

Page 38: ...ement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 6 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 6 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or la...

Page 39: ... Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clea...

Page 40: ...ion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper l...

Page 41: ...Support hand on solid surface or use two hands 6 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lowe...

Page 42: ...maged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls wire feed rolls bird nesting Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted int...

Page 43: ...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 welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary ...

Page 44: ...OM 192 440 Page 40 Notes ...

Page 45: ...OM 192 440 Page 41 SECTION 7 ELECTRICAL DIAGRAM 206 590 A Figure 7 1 Circuit Diagram For Welding Power Source ...

Page 46: ... 440 Page 42 SECTION 8 PARTS LIST 802 281 F Hardware is common and not available unless listed 18 19 21 20 16 15 14 13 12 11 8 7 6 5 4 3 2 1 9 Fig 8 2 10 Fig 8 3 17 Fig 8 4 22 Fig 8 5 Figure 8 1 Main Assembly ...

Page 47: ...911 CORD SET 250V 6 50p 8 10ga 3 c for 200 230 1 12 146 161 BASE 1 13 135 390 AXLE 1 14 186 758 WHEEL 2 15 121 614 RING retaining 2 16 209 870 CASTER swvl 4 00 in X 1 250 in poly olefin 2 17 Fig 8 4 PANEL front w components 1 18 196 328 CABLE work 10 no 3 w clamp boot including 1 19 196 318 COVER cable 1 20 146 149 CABLE 1 21 130 750 CLAMP work 1 22 227 715 M 25 GUN 12 ft 030 035 WIRE Fig 8 5 1 22...

Page 48: ... Page 44 802 284 D Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 20 23 25 27 28 29 33 34 35 37 26 17 18 19 25 24 30 31 32 36 21 22 Figure 8 2 Center Baffle w Components ...

Page 49: ...492 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 20 PC1 171 986 CIRCUIT CARD ASSEMBLY control 1 21 038 618 LINK jumper term bd pri as req 22 TE1 188 910 TERMINAL ASSEMBLY pri 1ph double voltage 200 230 1 23 039 046 TERMINAL pwr output black w nut 1 24 039 047 TERMINAL pwr output red w nut 1 25 C7 10 136 735 CAPACITOR 1 uf 500 v 4 26 196 625 DRIVE ASSEMBLY wire including 1 27 196 601 MOTOR gear ...

Page 50: ... 34 deg 1 3 M 188 706 MOTOR fan 230V 50 60 Hz 1 4 203 711 WINDTUNNEL 9in 1 5 216 396 VALVE 24 VAC 2 way custom port 1 8 orf w frict 1 6 203 478 PANEL rear 1 7 169 654 BRACKET support tank 1 8 188 441 CHAIN safety 1 9 137 761 NUT 750 NPT 1 31 hex 27 H nyl blk 1 10 604 102 CONN clamp cable 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement ...

Page 51: ...207 077 KNOB 1 5 208 207 POTENTIOMETER CP flat 1 T 2W 1K linear wire feed speed 1 6 S2 226 602 SWITCH selector 7 position 1 228 166 SCREW 010 24X2 00 pan hd phl stl pld trilob thdfmg 3 7 S1 124 511 SWITCH tgl DPST 40A 600 VAC 1 8 170 647 BUSHING snap in nyl 1 9 204 413 BUSHING snap in nyl 1 10 048 282 RECEPTACLE W SOCKETS 1 11 LABEL nameplate order by model and serial no 1 To maintain the factory ...

Page 52: ...s 1 1 169 725 NOZZLE slip type 625 orf 125 recess 1 1 169 726 NOZZLE slip type 625 orf flush 1 1 169 727 NOZZLE slip type 625 orf 125 stickout 1 2 087 299 TIP contact scr 023 wire x 1 125 2 000 067 TIP contact scr 030 wire x 1 125 2 000 068 TIP contact scr 035 wire x 1 125 2 000 069 TIP contact scr 045 wire x 1 125 3 169 728 ADAPTER contact tip 1 4 169 729 ADAPTER nozzle w retaining ring 1 5 170 4...

Page 53: ...nal performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Description Part No Dia Mkgs Item No Quantity Optional Spool Gun Switch 186 420 SWITCH ASSY 1 202 449 PLATE switch 1 202 910 LABEL spoolgun mig gun 1 To maintain the factory original performance of your equipment use only Manufacture...

Page 54: ...Notes ...

Page 55: ...ntact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warran...

Page 56: ...or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to Resources...