Related Manuals for Hobart Welders IronMan 230
Summary of Contents for Hobart Welders IronMan 230
- Page 1 OM-235 281B 2010−04 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)
- Page 2 Protect Your Investment! Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1. - Page 4 TABLE OF CONTENTS SECTION 6 − MIG WELDING (GMAW) GUIDELINES ..........6-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 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. - Page 6 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.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
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. -
Page 8: California Proposition 65 Warnings
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 &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 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. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. 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.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,... - Page 14 OM-235 281 Page 10...
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Page 15: Section 3 − Introduction
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... -
Page 16: Volt-Ampere Curves
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... -
Page 17: Installing Welding Gun
3-4. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. SPOOL GUN Gun Trigger Plug SPOOL GUN Insert plug into receptacle, and tighten threaded collar. MIG GUN MIG/Spool Gun Switch MIG GUN... -
Page 18: Connecting To Weld Output Terminals
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... -
Page 19: Setting Gun Polarity For Wire Type
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). -
Page 20: Installing 10 Lb Wire Spool And Adjusting Hub Tension
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. -
Page 21: Installing Gas Supply
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. -
Page 22: Positioning Jumper Links
3-12. Positioning Jumper Links Turn off and disconnect input power. Check input voltage available at site. Jumper Links Access Door Open door. Jumper Link Label 200 VOLTS Check label − only one is on unit. Input Voltage Jumper Links Move jumper links to match input voltage. -
Page 23: Electrical Service Guide
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 (V) -
Page 24: Serial Number And Rating Label Location
3-14. 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. 3-15. -
Page 25: Threading Welding Wire
3-16. 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 before threading wire. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in. -
Page 26: Installing Optional Dp 3545 Spool Gun To Welding Power Source
3-17. 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. -
Page 27: Section 4 − Operation
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... -
Page 28: Weld Parameters
4-2. Weld Parameters OM-235 281 Page 24... -
Page 29: Section 5 − Maintenance And Troubleshooting
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable... -
Page 30: Replacing Drive Roll And Wire Inlet Guide
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. -
Page 31: Aligning Drive Rolls And Wire Guide
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. -
Page 32: Installing Cable Hangers
5-7. Installing Cable Hangers Turn power before installing cable hangers. Cable Hanger Screws Tools Needed: Ref. 242 165-A OM-235 281 Page 28... -
Page 33: Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing
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. -
Page 34: Welding Troubleshooting Table
5-9. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-15). 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). -
Page 35: Section 6 − Mig Welding (Gmaw) Guidelines
SECTION 6 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 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/... -
Page 36: Typical Mig Process Control Settings
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) -
Page 37: Holding And Positioning Welding Gun
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... -
Page 38: Conditions That Affect Weld Bead Shape
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... -
Page 39: Gun Movement During Welding
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 −... -
Page 40: Troubleshooting − Excessive Spatter
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. -
Page 41: Troubleshooting − Lack Of Penetration
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. -
Page 42: Troubleshooting − Waviness Of Bead
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. -
Page 43: Common Mig Shielding Gases
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. - Page 44 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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Page 45: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 240 907-A Figure 7-1. Circuit Diagram For Welding Power Source OM-235 281 Page 41... -
Page 46: Section 8 − Parts List
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 242 214-A Figure 8-1. Main Assembly OM-235 281 Page 42... - Page 47 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... . . 234 210 PANEL, side ............
- Page 48 Hardware is common and not available unless listed. 242 215-A Figure 8-2. Center Baffle w/Components OM-235 281 Page 44...
- Page 49 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9) ....211 877 NUT, retaining spool ..........
- Page 50 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 .
- Page 51 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 .
- Page 52 242 526-A Figure 8-5. Wire Drive Assembly Item Part Description Quantity 234 206 8-5. Wire Drive Assembly ..... 235 282 .
- Page 53 242 630-A Figure 8-6. H200L4−15 Gun Item Part Description Quantity 237 374 Figure 8-6. H200L4−15 Gun ....200 258 NOZZLE, slip type .500 orf flush .
- Page 54 Item Part Description Quantity 237 374 Figure 8-6. H200L4−15 Gun ....170 468 O−RING ............
- Page 55 Effective January 1, 2010 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MA 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.
- Page 56 Owner’s Record Please complete and retain with your personal records. Protect Your Investment! Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, Contact your Distributor for: retail or service location:...
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