Hobart Welding Products IronMan 275, Owner'S Manual

Page 1: ...198 683C April 2000 Visit our website at www HobartWelders com Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source and Wire Feeder IronMan 275 With Meters And M 25 Gun R ...

Page 2: ...e 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 parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particul...

Page 3: ...ting Olympic 30A Gun 11 2 8 Setting Gun Polarity For Wire Type 12 2 9 Installing Gas Supply 12 2 10 Installing Wire Spool and Adjusting Hub Tension 13 2 11 Positioning Jumper Links 13 2 12 Electrical Service Guide 14 2 13 Selecting A Location And Connecting Input Power 14 2 14 Threading Welding Wire 15 2 15 Weld Parameter 16 SECTION 3 OPERATION 18 3 1 Controls 18 3 2 Voltmeter And Wire Feed Speed ...

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Page 5: ...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 n...

Page 6: ... 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 sla...

Page 7: ... 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 i...

Page 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting 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 s...

Page 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement ...

Page 10: ...ct D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...nétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de p...

Page 13: ... 8 m min W 19 in 483 mm D 30 1 4 in 768 mm 96 kg While idling Operating Temperature Range 20C to 40C Storage Temperature Range 30C to 50C 2 2 Welding Power Source Duty Cycle And Overheating 4 Minutes Welding 6 Minutes Resting 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output s...

Page 14: ...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 2 4 Volt Ampere Curves ssb1 1 10 91 196 844 S 0700 1 Normal Volt Ampere Curves The volt ampere curve...

Page 15: ... Insert gun end through opening until it bottoms against drive assembly make sure gun end does not touch drive rolls Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door Ref 802 064 A 1 3 4 2 2 7 Connecting Olympic 30A Gun The Olympic 30A welding gun connects directly to the 10 pin receptacle on the front of the welding power source no adapter required...

Page 16: ...gas cylinder and chain to running gear wall or other station ary support so 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 Conn...

Page 17: ...0 mm spools Tools Needed 2 11 Positioning Jumper Links 802 476 A Check input 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 1 230 VOLTS 460 VOLTS 575 VOLTS S 144 916 A 3 8 in 200 VOLTS 230 VOLTS S 153 980 ...

Page 18: ...general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above Y Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard 2 13 Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power 2 Plug NEMA Type 6 50P 3 Receptacle NEMA Type 6 50R Connect plug t...

Page 19: ...ll 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 and latch door Ref 802 064 A S 0627 A Tighte...

Page 20: ...OM 198 683 Page 16 2 15 Weld Parameter ...

Page 21: ...OM 198 683 Page 17 196 843 VOL TAGE V V WIRE SPEED ...

Page 22: ... 3 OPERATION 3 1 Controls 1 Voltage Control Turn control clockwise to increase voltage 2 Wire Speed Control Turn control clockwise to increase wire feed speed 3 Power Switch 4 Voltmeter 5 Wire Feed Speed Meter 1 2 3 4 5 198 653 ...

Page 23: ...welding voltage will appear on the voltmeter The wire feed speed meter always displays preset wire feed speed IPM Gun Selection The wire feed speed meter will display preset wire feed speed IPM for the appropriate gun selection either MIG or spool gun To preset desired wire feed speed connect desired gun press gun trigger for one second and release trigger The meter preset will be retained by the ...

Page 24: ...grease to drive motor shaft 4 2 Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Circuit Breaker CB2 Overcurrent at pin D of receptacle RC7 will cause CB2 to open 3 Welding Gun Check gun liner for blockage or kinks 4 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow cooling period and reset breaker Close door 3 802 475 A Ref 800...

Page 25: ...zzle Tools Needed 1 2 4 5 Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching 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 1 3 2 4 5 Tools Needed 5 64 in 7 16 i...

Page 26: ...lls look ing down with pressure assembly open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Ref ST 800 412 A Correct Incorrect 4 3 2 1 5 Tools Needed ...

Page 27: ...ghten new liner Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Y Disconnect gun from unit first Tools Needed Lay gun cable out straight before installing new liner Head Tube 5 16 in Remove nozzle contact tip and adapter Blow out gun casing Remove liner 10 mm ...

Page 28: ...ecure with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch hous...

Page 29: ...ck for low line voltage see Section 2 13 Check input voltage jumper links and correct position if necessary see Section 2 11 Have Factory Authorized Service Agent check main control board Fan motor does not run 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...

Page 30: ...OM 198 683 Page 26 Notes ...

Page 31: ...OM 198 683 Page 27 SECTION 5 ELECTRICAL DIAGRAM 197 699 D Figure 5 1 Circuit Diagram ...

Page 32: ...OM 198 683 Page 28 SECTION 6 PARTS LIST 802 059 B Hardware is common and not available unless listed Figure 6 1 Main Assembly ...

Page 33: ...9 CAPACITOR rectifier 4 TP1 154 243 THERMOSTAT NC 1 TP2 154 244 THERMOSTAT NO 1 143 852 FOOT mtg rectifier 1 198 232 FOOT mtg rectifier 1 PLG3 115 094 HOUSING PLUG SKTS 4 position 1 PLG7 115 091 HOUSING PLUG SKTS 10 position 1 14 008 999 CASTER plstc swvl 4 in dia 2 15 Fig 6 4 PANEL front w components 1 16 169 596 GUN 12ft 030 035 wire Fig 6 3 1 17 150 387 BAFFLE air 1 18 T1 196 795 TRANSFORMER pw...

Page 34: ...OM 198 683 Page 30 802 060 C Hardware is common and not available unless listed Figure 6 2 Baffle Center w Components ...

Page 35: ...ING RECEPTACLE SOCKETS 1 PLG6 115 092 HOUSING PLUG SOCKETS 1 PLG7 130 203 HOUSING PLUG SOCKETS 1 17 R5 119 998 RESISTOR WW fxd 300W 5 ohm 1 18 TE1 188 910 TERMINAL ASSEMBLY pri 1ph double voltage 200 230 or 230 400 1 18 TE1 192 907 TERMINAL ASSEMBLY pri 1ph triple voltage 230 460 575 1 19 038 618 LINK jumper term bd pri as req 20 CR2 000 174 RELAY 24VAC 3PDT 10A 120VAC 1 189 364 RESISTOR w termina...

Page 36: ...OM 198 683 Page 32 Ref 800 792 B 1 2 3 4 5 6 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6 3 M 25 Gun ...

Page 37: ... nozzle 1 5 170 467 RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 194 523 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 180 433 CORD trigger assembly 1 14 079 974 O RING 500 ID x 103CS rbr 2 15 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 194 011 LINER monocoil 030 035 wire x 15ft consisting...

Page 38: ...052 HOUSING RECEPTACLE SOCKETS 1 7 186 473 PANEL front 1 8 S1 128 755 SWITCH tgl 1 9 RC1 048 282 RECEPTACLE w SOCKETS 1 10 RC7 190 363 RECEPTACLE w SOCKETS 1 11 189 810 PANEL logo 1 12 038 502 Cable Tie 1 13 186 472 PANEL louver Order Item 9 Cable Tie when ordering louver panel 1 14 193 632 NUT 375 16 56 hex 34H stl 2 15 097 924 KNOB pointer 1 625dia x 250 ID 2 Hardware is common and not available...

Page 39: ...405 ID x 740 OD 2 193 635 RING rtng ext 394 shaft x 1 15 079 633 FITTING hose brs barbed M 3 16tbg 1 16 601 966 SCREW 375 16 x 1 25hexhd 2 18 604 538 WASHER flat stl SAE 312 1 19 124 778 KNOB plstc T 1 000 lg x 312 18 x 2 000 bar 1 20 173 619 CARRIER drive roll w components 1 21 174 609 SCREW M 4 7 x 12 1 22 174 610 SCREW M 6 1 0 x 20 soc hd 3 23 192 029 WASHER flat 250 ID x 437 OD 3 24 173 620 BU...

Page 40: ...062 1 6 mm 079 598 053 699 V Grooved 056 195 052 in 052 1 3 mm 079 597 053 698 V Grooved 056 193 Description Part No Dia Mkgs Item No Figure 6 6 Panel Rear w Components Fig 6 1 Item 3 Quantity 1 148 809 BLADE fan 9 in 5wg 34deg 309 bore CCW 1 2 FM1 188 706 MOTOR fan 230V 50 60 Hz 1550RPM 312dia shaft 1 3 188 709 WINDTUNNEL 9 in 1 4 GS1 125 785 VALVE 24VAC 2 way custom port 1 8 orf 1 5 143 810 PANE...

Page 41: ...Notes ...

Page 42: ...Notes ...

Page 43: ...obart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact 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 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warra...

Page 44: ...r To locate a Distributor retail 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 th...