Hobart Welders IronMan 250 Owner'S Manual Download

Page: 1 / 44

Includes Installation Instructions For

Optional Spoolmate Spoolgun Switch

IronMan 250

And M-25 Gun

Processes

OM-192 440Q

April 2003

Specifications Covered by this Manual:
500 408, 500 444

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)
Welding

Description

Arc Welding Power Source and Wire
Feeder

Visit our website at

www.HobartWelders.com

Summary of Contents for IronMan 250

Page 1: ...witch IronMan 250 And M 25 Gun Processes OM 192 440Q April 2003 Specifications Covered by this Manual 500 408 500 444 Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding Description Arc Welding Power Source and Wire Feeder t Visit our website at www HobartWelders com ...

Page 2: ... made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular ...

Page 3: ...on 13 2 9 Installing Gas Supply 13 2 10 Positioning Jumper Links 14 2 11 Electrical Service Guide 14 2 12 Selecting A Location And Connecting Input Power 15 2 13 Threading Welding Wire 16 2 14 Installing Optional Spoolmate Spoolgun Switch In Welding Power Source 17 2 15 Connecting Spoolgun To Welding Power Source 18 SECTION 3 OPERATION 19 3 1 Controls 19 3 2 Weld Parameters 20 SECTION 4 MAINTENANC...

Page 4: ......

Page 5: ...or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do n...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ... maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area i...

Page 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one s...

Page 9: ...tion est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement ...

Page 10: ...ct D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...nétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir ex aminé plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du National Re search Council a conclu L accumulation de p...

Page 13: ...7 mm 185 lb 84 kg 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm 030 045 in 0 8 1 2 mm m min D 36 1 2 in 927 mm While idling 6 Minutes Welding 4 Minutes Resting 2 2 Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for u...

Page 14: ...uous Welding SB1 1 8 93 0 10 Minutes Definition 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 100 Duty Cycle At 200 Amperes Using CO2 100 Duty Cycle At 150 Amperes Using Mixed Gases 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 60 Duty Cycle At 300 Amperes Using CO2 60 Duty Cycle At 200 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting 2 4 Volt Ampere Curves Volt amperecu...

Page 15: ...hten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door 3 4 2 1 2 6 Installing Work Clamp 1 Work Cable Route cable out front panel opening from inside 2 Negative Black Output Terminal Connect cable to terminal 3 Hardware 4 Work Clamp Route cable through clamp handle and secure as shown Close door Ref 802 285 B Ref 801 566 Tools Needed 1 2 3 4 in 2 1 3 4 ...

Page 16: ...minal 3 Negative Black Output Terminal Always read and follow wire manufacturer s recommended polarity Close door 3 2 Ref 802 285 B Ref ST 192 432 2 8 Installing Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool tension is set 15 16 in Use compression spring with 8 in 200 mm spools Tools Needed 072573 B ...

Page 17: ...linder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection...

Page 18: ...uit Breaker Rating In Amperes Circuit Breaker 1 Time Delay 2 50 40 Normal Operating 3 60 50 Min Input Conductor Size In AWG Kcmil 8 10 Max Recommended Input Conductor Length In Feet Meters 108 33 94 29 Min Grounding Conductor Size In AWG Kcmil 10 10 Reference 1999 National Electrical Code NEC 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are...

Page 19: ...rs Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 2 11 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 2 L1 L2 230 VAC 1 3 L1 L2 Y Always connect grounding conductor first GND PE 5 Y Do not move or operate unit where it could tip 18 in 457 mm of space for airflo...

Page 20: ...d contact tip Turn On WOOD Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire 7 6 1 2 3 5 Hold wire tightly to keep it from unraveling 4 1...

Page 21: ...g harness switch plug Retain jumper plug by placing looped lead over unit wiring harness 8 Switch Plug Connect switch plug to wiring har ness switch plug 9 Jam Nut Remove top jam nut from switch switch is equipped with two nuts a jam nut and a backing nut Insert switch shaft through switch mounting plate Switch should be positioned so lead with resistor is facing down Secure switch to plate with j...

Page 22: ...isting gas hose above barbed fitting at wire drive housing Install supplied hose clamp onto end of hose at wire drive housing and insert either of the two output barbed ends of diverter valve into hose Secure with hose clamp Install another supplied hose clamp onto end of hose from gas supply and insert in put barbed end of diverter valve into hose Secure with hose clamp Slide hose clamp down gas ...

Page 23: ...trols 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide and Section 3 2 3 Power Switch 1 Ref 195 721 2 3 ...

Page 24: ...8 mm 035 0 9 mm 045 1 1 mm 023 0 6 mm 030 0 8 mm 035 0 9 mm 045 1 1 mm 030 0 8 mm 035 0 9 mm 045 1 1 mm 023 0 6 mm 030 0 8 mm 035 0 9 mm 030 0 8 mm 035 0 9 mm 047 1 2 mm 030 0 8 mm 035 0 9 mm 047 1 2 mm Do not change Voltage switch position while welding Wire Speed is a starting value only and can be adjusted while welding Weld conditions also depend on other variables such as stickout travel spee...

Page 25: ...5 1 0 1 8 1 0 Select Voltage and Wire Speed Based on Thickness of Metal Being Welded 3 16 4 8 mm 5 85 4 50 4 36 4 70 4 55 4 45 4 50 3 20 5 100 4 64 5 38 4 12 4 50 VO L T A G E 1 2 3 4 5 6 7 10 20 30 40 50 60 70 80 90 WIRE SPEED Example 2 40 To read settings Number on left of slash is voltage number on right of slash is wire recommended 3 8 9 5 mm 5 66 7 60 7 100 7 82 7 60 5 46 7 75 6 50 6 18 6 60 ...

Page 26: ...and apply light coat of oil or grease to drive motor shaft 4 2 Circuit Breakers Ref 802 285 B 2 Y Turn Off unit 1 Circuit Breaker CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails If CB1 opens wire feeding stops Check for gun liner blockage or kinks and check for jammed wire or binding drive rolls 2 Circuit Breaker CB2 CB2 protects the trigger circuit from overload If CB2 open...

Page 27: ...tall correct drive roll for wire size and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 4 4 Removing Knob From Front Panel Y Turn Off power 1 Front Panel 2 Knob 3 Slot 4 Control Shaft Rotate knob to allow access to slot Insert tip of screwdriver into slot and while pushing on spring clip pull knob off control shaft To reinstall push knob fully onto con...

Page 28: ...ng Gun Contact Tip Ref 800 797 C Y Turn Off power before replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed 1 2 ...

Page 29: ...hten new liner Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Y Disconnect gun from unit first Tools Needed Lay gun cable out straight before installing new liner Head Tube 5 16 in Remove nozzle contact tip and adapter Blow out gun casing Remove liner 10 mm ...

Page 30: ...ure with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch housin...

Page 31: ...e speed Readjust front panel settings see Section 3 1 Change to correct size drive roll see Section 4 3 Readjust drive roll pressure see Section 2 13 Replace inlet guide contact tip and or liner if necessary see Sections 4 3 4 5 and or 4 6 4 9 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straightengun cable and or replace damaged pa...

Page 32: ...OM 192 440 Page 28 Notes ...

Page 33: ...OM 192 440 Page 29 SECTION 5 ELECTRICAL DIAGRAM 206 590 A Figure 5 1 Circuit Diagram For Welding Power Source ...

Page 34: ... 440 Page 30 SECTION 6 PARTS LIST 802 281 E Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 Fig 6 2 10 Fig 6 3 11 12 13 14 15 16 17 Fig 6 4 20 21 20 Fig 6 5 19 18 Figure 6 1 Main Assembly ...

Page 35: ... 390 AXLE 1 14 186 758 WHEEL 2 15 121 614 RING retaining 2 16 008 999 CASTER 2 17 Fig 6 4 PANEL front w components 1 18 196 328 CABLE work 10 no 3 w clamp boot consisting of 1 19 196 318 COVER cable 1 20 146 149 CABLE 1 21 130 750 CLAMP work 1 22 169 596 GUN M 25 Fig 6 5 1 209 123 REGULATOR FLOWMETER 10 50 CFH 1 144 108 HOSE gas 5 ft 1 212 492 REGULATOR FLOWMETER 10 50 CFH CO2 1 When ordering a co...

Page 36: ... Page 32 802 284 D Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 20 23 25 27 28 29 33 34 35 37 26 17 18 19 25 24 30 31 32 36 21 22 Figure 6 2 Center Baffle w Components ...

Page 37: ...ER man reset 1P 10A 250V 1 20 PC1 171 986 CIRCUIT CARD ASSEMBLY control 1 21 038 618 LINK jumper term bd pri as req 22 TE1 188 910 TERMINAL ASSEMBLY pri 1ph double voltage 200 230 1 23 039 046 TERMINAL pwr output black w nut 1 24 039 047 TERMINAL pwr output red w nut 1 25 C7 10 136 735 CAPACITOR 1 uf 500 v 4 26 196 625 DRIVE ASSEMBLY wire consisting of 1 27 196 601 MOTOR gear 1 28 203 081 SCREW fe...

Page 38: ...809 FAN 9 in 5wg 34 deg 1 3 M 188 706 MOTOR fan 230V 50 60 Hz 1 4 203 711 WINDTUNNEL 9in 1 5 125 785 VALVE 24VAC 2way custom port 1 6 203 478 PANEL rear 1 7 169 654 BRACKET support tank 1 8 188 441 CHAIN safety 1 9 605 227 NUT 750 14 knurled 1 10 604 102 CONN clamp cable 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and s...

Page 39: ...switch 1 4 207 077 KNOB 1 5 208 207 POTENTIOMETER CP flat 1 T 2W 1K linear wire feed speed 1 6 S2 192 373 SWITCH selector 7 position 1 7 S1 124 511 SWITCH tgl DPST 40A 600 VAC 1 8 170 647 BUSHING snap in nyl 1 9 204 413 BUSHING snap in nyl 1 10 048 282 RECEPTACLE W SOCKETS 1 11 195 721 LABEL nameplate 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggeste...

Page 40: ...tact tip 1 4 169 729 ADAPTER nozzle 1 5 170 467 RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 194 523 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 180 433 CORD trigger assembly 1 14 209 486 CONNECTOR feeder 1 15 079 974 O RING 500 ID x 103CS rbr 2 16 194 011 LINER monocoil 030 035 wire x 15ft consisting of ...

Page 41: ...ASSY 1 202 449 PLATE switch 1 605 510 CABLE TIE 1 604 804 SCREW 008 15x 37 hexwhd pln 2 202 910 LABEL spoolgun mig gun 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor ...

Page 42: ...Notes ...

Page 43: ...parately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are cover...

Page 44: ...r To locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact th...

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