Related Manuals for Hobart IronMan 240
Summary of Contents for Hobart IronMan 240
- Page 1 OM-284833B 2020−08 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Hobart IronMan 240 www.HobartWelders.com...
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Page 2: Table Of Contents
5-5. Connecting MIG Gun/Spool Gun to IronMan 240 ........ - Page 3 ..............WARRANTY Hobart is registered to the ISO 9001 Quality...
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. - Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.
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Page 7: Additional Hazards For Installation, Operation, And Maintenance
D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition. -
Page 8: California Proposition 65 Warnings
H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...
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Page 11: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à... -
Page 12: Proposition Californienne 65 Avertissements
D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles. -
Page 13: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. -
Page 14: Miscellaneous Symbols And Definitions
3-2. Miscellaneous Symbols And Definitions Rated No Load Circuit Breaker Amperage Voltage (OCV) Positive Voltage Direct Current (DC) Gas Metal Arc Negative Welding (GMAW) Primary Voltage Gas Metal Arc Conventional Welding (GMAW) Duty Cycle Load Voltage MIG / Gun Control Self-Shielded Flux Rated Welding Cored Arc... -
Page 15: Section 4 − Specifications
A complete Parts List is available at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. -
Page 16: Welding Power Source Duty Cycle And Overheating
A complete Parts List is available at www.HobartWelders.com 4-6. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, Thermistor (RT1) opens, output stops, and cooling fan runs. -
Page 17: Section 5 − Installation
A complete Parts List is available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. -
Page 18: Weld Output Terminals And Selecting Cable Sizes
A complete Parts List is available at www.HobartWelders.com 5-2. Weld Output Terminals And Selecting Cable Sizes NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). -
Page 19: Installing Work Cable And Clamp
A complete Parts List is available at www.HobartWelders.com 5-4. Installing Work Cable And Clamp Work Cable Tools Needed: Boot 3/4 in. Route cable through front panel opening. Slide boot onto work ca- ble. Negative (-) Output Terminal Connect cable to terminal and cov- er connection with boot. -
Page 20: Connecting Mig Gun/Spool Gun To Ironman 240
A complete Parts List is available at www.HobartWelders.com 5-5. Connecting MIG Gun/Spool Gun to IronMan 240 MIG Gun Spool Gun Drive Assembly Gun End Gun Securing Knob Loosen gun securing knob. Insert gun end through opening until it bottoms against the drive assembly. Tighten the gun securing knob. -
Page 21: Setting Gun Polarity For Wire Type
A complete Parts List is available at www.HobartWelders.com 5-6. Setting Gun Polarity For Wire Type Changing Polarity Polarity Changeover Label Information Always read and follow manufacture’s recommended polarity. Wire Drive Work Clamp Lead Assembly Lead Positive Terminal Negative Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). -
Page 22: Installing Wire Spool And Adjusting Hub Tension
A complete Parts List is available at www.HobartWelders.com 5-8. Installing Wire Spool And Adjusting Hub Tension Hand tighten knob clockwise. When a slight force is needed to turn spool, tension is set. To install either a 1 lb or 2 lb wire Installing 1 Or 2 lb Wire Spool spool, follow the procedure as shown in the illustration. -
Page 23: Positioning Jumper Links
A complete Parts List is available at www.HobartWelders.com 5-9. Positioning Jumper Links Check input voltage available at Tools Needed: site. Philips Screw Driver #1 Jumper Links Access Door Open door. 3/8 in. Jumper Link Label Check label − only one is on unit. Input Voltage Jumper Links 208 VOLTS 240 VOLTS... -
Page 24: Connecting Input Power
A complete Parts List is available at www.HobartWelders.com 5-11. Connecting Input Power =GND/PE Earth Ground 240 VAC, 1 804912-A Receptacle Connect green or green/yellow grounding Installation must meet all National [NEMA Type 6-50R (Customer conductor to disconnect device grounding and Local Codes − have only qualified Supplied)] terminal first. -
Page 25: Threading Welding Wire
A complete Parts List is available at www.HobartWelders.com 5-12. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. -
Page 26: Weld Parameters
A complete Parts List is available at www.HobartWelders.com 5-13. Weld Parameters OM-284833 Page 22... - Page 27 A complete Parts List is available at www.HobartWelders.com 284702-B OM-284833 Page 23...
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Page 28: Section 6 − Operation
A complete Parts List is available at www.HobartWelders.com SECTION 6 − OPERATION 6-1. Controls Voltage Control Turn control clockwise to increase voltage. Wire Feed Control Turn control clockwise to increase wire feed speed. Diagnostic Light Refer to section 7-6 if light is illumi- nated or flashing. -
Page 29: Section 7 − Maintenance &Troubleshooting
A complete Parts List is available at www.HobartWelders.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels... -
Page 30: Aligning Drive Rolls And Wire Guide
A complete Parts List is available at www.HobartWelders.com 7-4. Aligning Drive Rolls and Wire Guide Turn Off power. View is from top of drive rolls looking down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw... -
Page 31: Troubleshooting
A complete Parts List is available at www.HobartWelders.com 7-7. Troubleshooting Trouble Remedy Secure power cord plug in receptacle (see Section 5-11). No weld output; wire does not feed. Check and replace power switch if necessary. Replace building line fuse or reset circuit breaker if open (see Section 5-11). Secure gun plug in receptacle or repair leads, or replace trigger switch (see welding gun Owner’s Manual). -
Page 32: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Welding Power Source Circuit Diagram OM-284833 Page 28... - Page 33 284828-A OM-284833 Page 29...
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Page 34: Section 9 − Guidelines For Mig Welding (Gmaw)
SECTION 9 − GUIDELINES FOR MIG WELDING (GMAW) 9-1. Typical GMAW (MIG) Process Connections 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. Regulator/ Flowmeter Wire Feeder/... -
Page 35: Holding And Positioning Welding Gun
9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam. -
Page 36: Gun Movement During Welding
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. Stringer Bead − Steady Movement Along Seam Weave Bead −... -
Page 37: Troubleshooting − Excessive Spatter
9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Remedy Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 38: Troubleshooting − Lack Of Penetration
9-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Remedy Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 39: Troubleshooting − Waviness Of Bead
9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Remedy Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. -
Page 40: Common Gmaw (Mig) Shielding Gases
9-16. Common GMAW (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Short Short... - Page 41 Problem Probable Cause Remedy Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder. Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line.
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Page 42: Section 10 − Parts List
SECTION 10 − PARTS LIST 10-1. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire (solid steel and metal cored). U-Grooved rolls for soft and soft shelled cored wires (aluminum). U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). - Page 43 Effective January 1, 2020 Warranty Questions? 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Call serial number preface of NA or newer. 1-800-332-3281 8 AM − 5 PM EST This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.
- Page 44 (Date which equipment was delivered to original customer.) Distributor Address City State Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number.