Hobart Welding Products IronMan 250 Owner's Manual
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Hobart Welding Products IronMan 250 Owner's Manual

Hobart Welding Products IronMan 250 Owner's Manual

Arc welding power source and wire feeder
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IronMan 250
And M-25 Gun
OM-192 440W
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder
Includes Installation Instructions For
Optional Spoolmate Spoolgun Switch
File: MIG (GMAW)
2006−10

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  • Page 1 OM-192 440W 2006−10 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 File: MIG (GMAW)
  • Page 2 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.

  • 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.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use 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: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

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

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Introduction

    SECTION 3 − INTRODUCTION 3-1. 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

    3-3. 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) .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires...

  • Page 15: Installing Welding Gun

    3-5. 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-D OM-192 440 Page 11...

  • Page 16: Connecting To Weld Output Terminals

    3-6. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in (19 mm) 803 778-A Correct Installation Incorrect Installation Y Turn off power before connecting to Weld Output Terminal minal. Slide weld cable terminal onto weld weld output terminals.

  • Page 17: Setting Gun Polarity For Wire Type

    3-8. 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-D 3-9. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools.

  • Page 18: Installing Gas Supply

    3-10. 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 19: Positioning Jumper Links

    3-11. 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 20: Electrical Service Guide

    3-12. Electrical Service Guide 60 Hz Single Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Circuit Breaker , Time-Delay Normal Operating Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) (33) (29) Min Grounding Conductor Size In AWG...

  • Page 21: Selecting A Location And Connecting Input Power

    3-13. Selecting A Location And Connecting Input Power Y Installation must meet all Na- Y Do not move or operate tional and Local Codes − unitwhere it could tip. have only qualified persons make this installation. Y Special installation may be required where gasoline or volatile liquids are present −...

  • Page 22: Threading Welding Wire

    3-14. 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-D Hold wire tightly to keep it from unraveling. 6 in (150 mm) 4 in...

  • Page 23: Installing Optional Spool Gun Switch In Welding Power Source

    3-15. Installing Optional Spool Gun 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 24: Connecting Spool Gun To Welding Power Source

    3-16. Connecting Spool Gun To Welding Power Source Tools Needed: Ref. 802 582-A 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 25: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. 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 4-2).

  • Page 26: Weld Parameters

    4-2. Weld Parameters Selecting Wire, Gas and Control Settings Suggested What Material Suggested Wire Sizes Shielding Gases are You Welding? Wire Types (Diameter) and Flow Rate .023”(0.6 mm) Steel Solid (or hard) 100% CO , 20 cfh .030”(0.8 mm) ER70S−6 .035”(0.9 mm) .045”(1.1 mm) .023”(0.6 mm)
  • Page 27 SETTINGS ON THIS CHART ARE STARTING Changing Polarity Example 2/40 = To read settings: VALUES ONLY AND ARE BASED ON A 230 INPUT LINE VOLTAGE. SEE OWNERS MANUAL FOR Number on left of slash MORE INFORMATION. is voltage,numberon Select Voltage and Wire Speed Based right of slash is wire−...

  • Page 28: Section 5 − Maintenance And Troubleshooting

    SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. 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 29: Replacing Drive Roll And Wire Inlet Guide

    5-3. 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 30: Replacing Gun Contact Tip

    5-5. 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 26...

  • Page 31: Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing

    5-6. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Y 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 7/16 in disconnect gun...

  • Page 32: Replacing Switch And/Or Head Tube

    5-7. Replacing Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure.

  • Page 33: Welding Troubleshooting Table

    5-8. Welding Troubleshooting Table Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-13). Check and replace power switch if necessary. Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 5-2). Replace building line fuse or reset circuit breaker if open (see Section 3-13).

  • Page 34: Section 6 − Mig Welding (Gmaw) Guidelines

    SECTION 6 − MIG WELDING (GMAW) GUIDELINES 6-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery Regulator/ cables before welding on a Flowmeter vehicle. Place work clamp as close to the weld as possible. Shielding Supply Wire Feeder/...

  • Page 35: Typical Mig Process Control Settings

    6-2. Typical MIG Process Control Settings NOTE 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 36: Holding And Positioning Welding Gun

    6-3. Holding And Positioning Welding Gun NOTE 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 37: Conditions That Affect Weld Bead Shape

    6-4. Conditions That Affect Weld Bead Shape NOTE 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 38: Gun Movement During Welding

    6-5. Gun Movement During Welding NOTE 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 39: 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 40: 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 41: 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 42: 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 43 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.
  • Page 44 Notes OM-192 440 Page 40...

  • Page 45: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 206 590-A Figure 7-1. Circuit Diagram For Welding Power Source OM-192 440 Page 41...

  • Page 46: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 281-F Figure 8-1. Main Assembly OM-192 440 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ... . . 203 481 PANEL, side ............
  • Page 48 Hardware is common and not available unless listed. 802 284-D Figure 8-2. Center Baffle w/Components OM-192 440 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9) ....058 427 RING, retaining spool ..........
  • Page 50 Hardware is common and not available unless listed. 802 283 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. 802 282-F 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) ....143 974 HANDLE .
  • Page 52 804 467-A Figure 8-5. M-25 Gun Item Dia. Part Mkgs. Description Quantity Figure 8-5. M-25 Gun (Fig 8-1 Item 22) ... . . 200 258 NOZZLE, slip type .500 orf flush .
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 8-5. M-25 Gun (Continued) ... . . 169 738 NUT, locking handle ..........
  • Page 54 Notes...
  • Page 55 Effective January 1, 2006 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface LG 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 Welding Process Handbooks Call 1-877-Hobart1 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. PRINTED IN USA 2005 Hobart Welding Products. 6/05...

This manual is also suitable for:

M-25

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