Hobart Welders IronMan 250 Owner's Manual
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Hobart Welders IronMan 250 Owner's Manual

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IronMan 250
And M-25 Gun
OM-192 440Q
Specifications Covered by this Manual:
500 408, 500 444
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder
t
Includes Installation Instructions For
Optional Spoolmate Spoolgun Switch
April 2003

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Summary of Contents for Hobart Welders IronMan 250

  • Page 1 500 408, 500 444 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder IronMan 250 And M-25 Gun Includes Installation Instructions For Optional Spoolmate Spoolgun Switch Visit our website at www.HobartWelders.com...
  • Page 2 Hobart offers a Technical Manual which provides more detailed service and parts information for your Hobart Welders manufactures a full line unit. To obtain a Technical of welders and welding related equipment. Manual, contact your local distributor. Your distributor...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • 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 cause injury. 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: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Introduction

    SECTION 2 – INTRODUCTION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Max. Open Max. Open 200 V 230 V Rated Output Circuit Voltage 200 A at 24 VDC, 60% Duty Cycle 1.1* 1.3* 0.31* 0.18* No Load Wire Feed Wire Type and Diameter Dimensions...

  • Page 14: Welding Gun Duty Cycle And Overheating

    2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .045 in (0.6 To 1.1 mm)

  • Page 15: Installing Welding Gun

    2-5. 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. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. Ref. 802 285-B 2-6.

  • Page 16: Setting Gun Polarity For Wire Type

    2-7. Setting Gun Polarity For Wire Type Polarity Changeover Label Positive (+/Red) Output Terminal Negative (–/Black) Output Terminal Always read and follow wire manufacturer’s recommended polarity. Close door. Ref. ST-192 432 Tools Needed: 3/4 in Ref. 802 285-B 2-8. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools.

  • Page 17: Installing Gas Supply

    2-9. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or 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 18: Positioning Jumper Links

    2-10. Positioning Jumper Links Check input voltage available at site. Jumper Links Access Door Open door. 200 VOLTS Jumper Link Label Check label – only one is on unit. Input Voltage Jumper Links Move jumper links to match input 230 VOLTS voltage.

  • Page 19: Selecting A Location And Connecting Input Power

    2-12. Selecting A Location And Connecting Input Power Rating Label Supply correct input power. Plug Y Do not move Receptacle or operate unit Connect plug to receptacle. where it could tip. Input And Grounding 18 in (457 mm) of Conductors space for airflow Connect directly to line disconnect device if hard wiring is required.

  • Page 20: Threading Welding Wire

    2-13. 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: Ref. 802 285-B Hold wire tightly to keep it from unraveling. 6 in (150 mm) 4 in...

  • Page 21: Installing Optional Spoolmate Spoolgun Switch In Welding Power Source

    2-14. Installing Optional Spoolmate Spoolgun Switch In Welding Power Source Y Turn Off unit, and disconnect input power. Welding Power Source Center Baffle Switch Location Switch Mounting Plate Remove 2 screws securing switch mounting plate to center baffle. Pull switch mounting plate to pull wiring harness through center baffle hole.

  • Page 22: Connecting Spoolgun To Welding Power Source

    2-15. Connecting Spoolgun To Welding Power Source Tools Needed: Ref. 802 582 3/4 in Y Turn Off unit. negative (–) output terminal. put barbed end of diverter valve into hose. Secure with hose clamp. Disconnect and remove MIG (GMAW) Existing Gas Hose welding gun, if applicable.

  • Page 23: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Wire Speed Control The scale around the control is per- cent, not wire feed speed. Voltage Control The higher the selected number, the thicker the material that can be welded (see welding guide and Section 3-2).

  • Page 24: Weld Parameters

    3-2. Weld Parameters Selecting Wire, Gas and Control Settings* Suggested What Material Suggested Wire Sizes Shielding Gases are Y Wire T ou Welding? ypes (Diameter) and Flow Rate , 20 cfh .023” (0.6 mm) Steel Solid (or hard) 100% CO .030”...
  • Page 25 2/40 Example: read settings: Select Voltage and Wire Number on left of slash Speed Based on Thickness voltage, number right of slash wire– of Metal Being Welded speed. Means not “—” recommended. VO L T A WIRE SPEED 3/8” 1/4” 3/16”...

  • Page 26: Section 4 - Maintenance And Troubleshooting

    SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Remove drive roll and apply light coat of oil or grease to...

  • Page 27: Replacing Drive Roll And Wire Inlet Guide

    4-3. Replacing Drive Roll And Wire Inlet Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll Install correct drive roll for wire size and type.

  • Page 28: Replacing Gun Contact Tip

    4-5. Replacing Gun Contact Tip Y Turn power before replacing contact tip. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 800 797-C OM-192 440 Page 24...

  • Page 29: Cleaning Or Replacing Gun Liner

    4-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Blow out gun casing.

  • Page 30: Replacing Switch And/Or Head Tube

    4-7. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 31: Welding Troubleshooting Table

    4-8. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-12). Check and replace power switch if necessary. Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2). Replace building line fuse or reset circuit breaker if open (see Section 2-12).

  • Page 32: Notes

    Notes OM-192 440 Page 28...

  • Page 33: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM 206 590-A Figure 5-1. Circuit Diagram For Welding Power Source OM-192 440 Page 29...

  • Page 34: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. 802 281-E Figure 6-1. Main Assembly OM-192 440 Page 30...
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ... . . 203 481 PANEL, side ............
  • Page 36 Hardware is common and not available unless listed. 802 284-D Figure 6-2. Center Baffle w/Components OM-192 440 Page 32...
  • Page 37 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Center Baffle w/Components (Fig 6-1 Item 9) ....058 427 RING, retaining spool ..........
  • Page 38 Hardware is common and not available unless listed. 802 283 Figure 6-3. Rear Panel w/Components Item Dia. Part Mkgs. Description Quantity Figure 6-3. Rear Panel w/Components (Fig 6-1 Item 10) ....049 399 NUT, 312–18 push-on .
  • Page 39 Hardware is common and not available unless listed. 802 282-E Figure 6-4. Front Panel w/Components Item Dia. Part Mkgs. Description Quantity Figure 6-4. Front Panel w/Components (Fig 6-1 Item 17) ....143 974 HANDLE .
  • Page 40 5 6 7 Ref. 800 792-C Figure 6-5. M-25 Gun Item Part Description Quantity Figure 6-5. M-25 Gun (Fig 6-1 Item 20 ) ..200 258 NOZZLE, slip type .500 orf flush ......... . . ♦169 724 .
  • Page 41 Item Dia. Part Mkgs. Description Quantity Optional Spoolmate Spoolgun Switch ....186 420 SWITCH ASSY ..........
  • Page 42 Notes...
  • Page 43 Warranty Questions? and Champion 10,000 models.This warranty also applies to the Beta-Mig 1800, Champ 1435, 2060, Call 8500 models, Ironman 250, Stickmate models, Tigmate models, and HSW-15 and HSW-25 spot 1-877-HOBART1 welder models effective with Serial No. KK200262 and newer.
  • Page 44 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, Contact your Distributor for: retail or service location: Welding Supplies and Consumables...

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