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OM-235 281A 2009−07 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder IronMan 230 And H200L4-15 Gun File: MIG (GMAW)
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From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−07 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
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D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
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Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.
LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...
SECTION 3 − INTRODUCTION 3-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Max. Open 200 V 230 V Rated Output Circuit Voltage 175 A at 25.5 VDC, 37.0 32.5 60% Duty Cycle 2.4* 2.3* 0.54* 0.30* * While idling No Load Wire Feed Wire Type and Diameter...
3-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. 40.0 35.0 30.0 25.0 20.0 15.0 10.0 Amperage va_curve1 4/95 − 240 913-A OM-235 281 Page 12...
3-5. Connecting To Weld Output Terminals Do not place anything between Tools Needed: weld cable terminal and copper bar. 3/4 in (19 mm) 803 778-A Correct Installation Incorrect Installation Weld Output Terminal output terminal and secure with nut so that Turn off power before connecting to weld cable terminal is tight against copper Supplied Weld Output Terminal Nut...
3-7. Setting Gun Polarity For Wire Type Changing Polarity Wire Drive Assembly Lead Positive Terminal Work Clamp Lead − Negative Terminal Shown as shipped - Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW). Electrode Negative (DCEN): Reverse lead connections at terminals from that shown above for gasless flux core wires (FCAW).
3-9. Installing 10 lb Wire Spool And Adjusting Hub Tension Spool Hub Spool Hub Adapter Spool Hub Nut Keyed Washer (2) Compression Spring Washer Assemble components in numer- ical order as shown. Slide spool hub adapter up on hub for the smaller spool making sure it is positioned in the anti-rotation notches.
3-11. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. See Parts List for optional Cylinder Valve gas regulator/flowmeter.
3-12. Positioning Jumper Links Turn off and disconnect input power. Check input voltage available at site. Jumper Links Access Door 200 VOLTS Open door. Jumper Link Label Check label − only one is on unit. Input Voltage Jumper Links 230 VOLTS Move jumper links to match input voltage.
3-13. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase Input Voltage...
3-14. Selecting A Location And Connecting Input Power Do not move or operate unit where it could tip. 18 in (457 mm) of space for airflow =GND/PE Earth Ground 230 VAC, 1 Ref. 242 691-A / 802 286-E Rating Label Disconnect Device Line Terminals Installation must meet all National and Local Codes −...
3-16. Installing Optional DP 3545 Spool Gun To Welding Power Source Turn Off unit, and disconnect input power. Drive Assembly Spool Gun Gun Securing Thumbscrew SPOOL GUN Gun End SPOOL GUN Loosen thumbscrew. Insert gun MIG GUN end through opening until it bottoms against drive assembly.
SECTION 4 − OPERATION 4-1. Controls Wire Speed Control Control varies the rate of wire being fed through the welding gun. Voltage Control Control varies the voltage level of the welding arc. The voltage range is 1 (minimum) to 12 (maximum). Power Switch thermostatically controlled and only runs when...
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Maintain more often Disconnect power during severe conditions. before maintaining. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable...
5-3. Replacing Drive Roll And Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves. The stamped markings on the outer surface of the foll refers to the groove on the opposite side of the drive roll.
5-5. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look- ing down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.
5-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Turn off welding power source/wire feeder. Nozzle Contact Tip Tip Adapter Head Nozzle Adapter Tube Wire size stamped on tip − check and match wire size. Cut off wire and disconnect gun 7/16 in from feeder.
5-9. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-14). Place Power switch in the ON position. Place MIG/Spool Gun switch in the proper position. Check and replace Power switch if necessary. Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 5-2).
SECTION 6 − MIG WELDING (GMAW) GUIDELINES 6-1. Typical 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/ Power Source...
6-2. Typical MIG Process Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in Convert Material Thickness to Amperage (A)
6-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece...
6-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Push Drag Perpendicular GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...
6-5. 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 −...
6-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
6-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions 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.
6-14. 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 Corrective Actions 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.
6-16. Common 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.
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Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if 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 Readjust welding parameters.
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Hardware is common and not available unless listed. 242 510-A Figure 8-3. Rear Panel w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-3. Rear Panel w/Components (Fig 8-1 Item 10) ....049 399 NUT, 312−18 push-on .
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Hardware is common and not available unless listed. 242 216-A Figure 8-4. Front Panel w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-4. Front Panel w/Components (Fig 8-1 Item 17) ....235 261 HANDLE .
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Effective January 1, 2009 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of LK or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
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Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2009 Hobart Welding Products. 2009−01...