Hobart IronMan 240 Owner'S Manual Download

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www.HobartWelders.com

Description

OM-284833B

2020

−

Processes

Arc Welding Power Source And

Wire Feeder

Hobart

IronMan 240

)

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Summary of Contents for IronMan 240

Page 1: ...www HobartWelders com Description OM 284833B 2020 08 Processes Arc Welding Power Source And Wire Feeder Hobart IronMan 240 MIG GMAW Welding Flux Cored FCAW Welding ...

Page 2: ...ation About Default Weld Parameters And Settings 11 4 4 Welding Power Source Specifications 11 4 5 Environmental Specifications 11 4 6 Welding Power Source Duty Cycle And Overheating 12 SECTION 5 INSTALLATION 13 5 1 Selecting A Location 13 5 2 Weld Output Terminals And Selecting Cable Sizes 14 5 3 Connecting Weld Output Cables 14 5 4 Installing Work Cable And Clamp 15 5 5 Connecting MIG Gun Spool ...

Page 3: ...ead Characteristics 32 9 8 Troubleshooting Excessive Spatter 33 9 9 Troubleshooting Porosity 33 9 10 Troubleshooting Excessive Penetration 33 9 11 Troubleshooting Lack Of Penetration 34 9 12 Troubleshooting Incomplete Fusion 34 9 13 Troubleshooting Burn Through 34 9 14 Troubleshooting Waviness Of Bead 35 9 15 Troubleshooting Distortion 35 9 16 Common GMAW MIG Shielding Gases 36 9 17 Troubleshootin...

Page 4: ......

Page 5: ...llow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomati...

Page 6: ...not possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling fl...

Page 7: ...to move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING D Allow cooling period follow r...

Page 8: ...cuments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association Website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Website www csagrou...

Page 9: ... de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliques telles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitab...

Page 10: ...udure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflamma...

Page 11: ...vant de mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire D Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil D En utilisant des fourches de levage pour déplacer l u...

Page 12: ...ards Institute Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents Website www global ...

Page 13: ...electric shock from wiring Safe94 2012 08 When power is applied failed parts can explode or cause other parts to explode Safe26 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V Hazardous voltage remains on input capacitors after power is turned off Do not touch fully charged capacitors Always wait 5 minutes after power is turned of...

Page 14: ...wer Or In put Voltage Gas Input IP Internal Protection Rating Single Phase Circuit Breaker Positive Negative X Duty Cycle Line Connection Increase Hz Hertz Single Phase Static Frequency Converter Transformer Rectifier A Amperage V Voltage Gas Metal Arc Welding GMAW Gas Metal Arc Welding GMAW MIG Gun Control Self Shielded Flux Cored Arc Welding FCAW Wire Feed Spool Gun Gas Postflow Notes ...

Page 15: ...ased upon application specific requirements The end user is solely responsible for selection and coordination of appropriate equipment adoption or adjustment of default weld parameters and settings and ultimate quality and durability of all resultant welds Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose 4 4 Weldi...

Page 16: ... of 10 minutes that unit can weld at rated load without overheating If unit overheats Thermistor RT1 opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 150 215 A 40 Duty Cycle At 250 Amperes ...

Page 17: ...n Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Line Disconnect Device Locate unit near correct input power supply 18 in 460 mm 18 in 460 mm Do not move or operate unit where it could tip Movement Location And Airflow loc_smallmig2 2018 05 161 122 1 ...

Page 18: ...0 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm2 for metric use For distances longer than those shown in this guide see AWS Fact Sheet No 39 Welding Cables availa...

Page 19: ...3 Page 15 5 4 Installing Work Cable And Clamp Tools Needed 1 Work Cable 2 Boot Route cable through front panel opening Slide boot onto work ca ble 3 Negative Output Terminal Connect cable to terminal and cov er connection with boot Close door 804909 B 3 4 in 1 2 3 Notes ...

Page 20: ...o IronMan 240 287587 A 1 MIG Gun 2 Spool Gun 3 Drive Assembly 4 Gun End 5 Gun Securing Knob Loosen gun securing knob Insert gun end through opening until it bottoms against the drive assembly Tighten the gun securing knob 6 Gun Trigger Plug Insert plug into receptacle and tight en threaded collar 3 4 1 3 5 2 6 4 5 ...

Page 21: ...eeded Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder 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 Con...

Page 22: ...a slight force is needed to turn spool tension is set 282945A Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the procedure as shown in the illustration Remove these components from spindle Spindle Spindle Install these components onto spindle Order additional spring Part No 186437 Order two additional 5 8 washers Part No 605941 ...

Page 23: ...ated Maximum Supply Current I1max A 62 6 55 7 Maximum Effective Supply Current I1eff A 46 3 40 Maximum Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 70 60 Normal Operating Fuses 3 80 70 Maximum Recommended Supply Conductor Length In Feet Meters 4 79 24 105 32 Raceway Installation Minimum Supply Conductor Size In AWG mm2 5 8 10 8 10 Minimum Grounding Conductor Size In AWG mm2 5 8...

Page 24: ...Cord Connect directly to line disconnect device if hard wiring is required 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals 7 Green Or Green Yellow Grounding Conductor 8 Black and White Input Conductor L1 and L2 Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input ...

Page 25: ... pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On 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 and latch door Ref 8049...

Page 26: ... A complete Parts List is available at www HobartWelders com OM 284833 Page 22 5 13 Weld Parameters ...

Page 27: ... A complete Parts List is available at www HobartWelders com OM 284833 Page 23 284702 B ...

Page 28: ...d speed 3 Diagnostic Light Refer to section 7 6 if light is illumi nated or flashing 4 Power On Light Power should be on when S1 is turned on 4 2 1 3 This unit has three automatic timers included in its operation to help save contact tips gas and wire Tip Saver Weld output shuts off if tip is shorted to work surface Safety shut off Weld output will shut off if no arc is detected within 3 seconds a...

Page 29: ...er Temp light illuminates output and wire feed will shut down Wait for unit to cool down allowing fan motor to run until Over Temp light turns off If unit is cool and no weld output continues contact Factory Authorized Service Agent 7 3 Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten sc...

Page 30: ...s released 7 6 Diagnostic Light The Diagnostic light provides diagnostic modes to help troubleshoot various malfunctions with the unit Status Condition Error Remedy Off Normal Unit working properly None On Over Temperature Unit overheated and output stopped Release trigger and allow cooling fan to run until diagnostic light turns off Flashing 1 Time Trigger Error Gun trigger is closed or shorted w...

Page 31: ...speed Readjust front panel settings see Section 6 1 Change to correct size drive roll see Section 7 3 Readjust drive roll pressure see Section 5 12 Replace inlet guide contact tip and or liner if necessary see welding gun Owner s Manual Wire Drive Gun Trouble Remedy Wire feeding stops during welding Straighten gun cable and or replace damaged parts see welding gun Owner s Manual Adjust drive roll ...

Page 32: ...OM 284833 Page 28 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Welding Power Source Circuit Diagram ...

Page 33: ...OM 284833 Page 29 284828 A ...

Page 34: ...kness to amperage A 0 001 in 0 025 mm 1 ampere 0 0625 in 1 59 mm 0 001 62 5 A 2 Select Wire Size See table below 3 Select Wire Feed Speed Amperage Wire feed speed amperage controls weld pene tration See table below 4 Select Voltage Voltage controls height and width of weld bead Low Voltage wire stubs into work High Voltage arc is unstable spatter Set voltage midway between high and low voltage 1 1...

Page 35: ...90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle Groove Welds End View of Work Angle Side View of Gun Angle Fillet Welds 9 3 Holding And Positioning Welding Gun Slow Fillet Weld Electode Extensions Stickout Electrode Extensions Stickout Gun Angles And Weld Bead Profiles 10 10 S 0634 Push Perpendicular Drag Short Normal Long Short Normal Long Normal Fast Weld bead shape d...

Page 36: ...se weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 5 Gun Movement During Welding 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 9 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer...

Page 37: ...ockets in weld metal S 0635 Possible Causes Remedy Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas c...

Page 38: ...ty at welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Remedy Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper...

Page 39: ...port hand on solid surface or use two hands 9 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Remedy Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range...

Page 40: ...1 Heavy Thicknesses 2 90 HE 7 1 2 AR 2 1 2 CO2 9 17 Troubleshooting Guide For GMAW MIG Welding Process Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure on wire feed rolls Increase pressure setting on wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake press...

Page 41: ...ating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact ti...

Page 42: ... flux cored 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Ref S 0026 B 7 91 Wire Diameter Fraction Decimal Metric 030 035 in 030 in 035 in 045 in 030 035 in 030 in 035 in 045 in 0 8 0 9 mm 0 8 mm 0 9 mm 1 2 mm Kit No 204 579 079 594 079 595 079 596 Drive Roll Part No Type 203 526 053 695 053 700 053 697 V Grooved V Grooved V Gr...

Page 43: ...mum of one year whichever is greater HF Units MIG Flowgauge Regulators No Labor MIG Guns TIG Torches Motor Driven Guns Plasma Cutting Torches Relays Remote Controls Replacement Parts No labor 90 days Running Gear Trailers Spoolguns 4 6 Months Parts Batteries 5 Engines and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components s...

Page 44: ...LC 2020 01 Miller Electric Mfg LLC An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA For Assistance Call 1 800 332 3281 Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Please complete and retain with your personal records Owner s Record Thank you for purchasing Hobart Our trained tec...

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