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OM-284833 Page 8

LIRE LES INSTRUCTIONS.

D

Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal-

lation, l’utilisation ou l’entretien de l’appareil.

Lire les informations de sécurité au début du

manuel et dans chaque section.

D

N’utiliser que les pièces de rechange recommandées par le

constructeur.

D

Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de

l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

D

Le rayonnement haute fréquence (H.F.) peut 

provoquer des interférences avec les équi-

pements de radio

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’installation.

D

L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

D

Effectuer régulièrement le contrôle et l’entretien de l’installation.

D

Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan-

ce correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

D

L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement

électronique sensible tel que les ordinateurs et

l’équipement commandé par ordinateur tel que

les robots.

D

Veiller à ce que tout l’équipement de la zone de soudage soit com-

patible électromagnétiquement.

D

Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi

bas que possible (ex. par terre).

D

Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D

Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à  ce mode d’emploi.

D

En cas d’interférences après avoir pris les mesures précédentes,

il incombe à l’utilisateur de prendre des mesures supplémentaires

telles que le déplacement du poste, l’utilisation de câbles blindés,

l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone

de travail.

2-4. Proposition californienne 65 Avertissements

AVERTISSEMENT : ce produit peut vous exposer à des pro-

duits chimiques tels que le plomb, reconnus par l’État de

Californie comme cancérigènes et sources de malformations

ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes,

 American Welding

Society standard ANSI Standard Z49.1. Website: www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protec-

tion,

 ANSI Standard Z87.1 from American National Standards 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.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.csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work,

 NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.
OSHA

 Occupational Safety and Health Standards for General Industry

,

Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part

1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
OSHA 

Important Note Regarding the ACGIH TLV, Policy Statement on

the Uses of TLVs and BEIs.

 Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation

 from

 

the

National Institute for Occupational Safety and Health (NIOSH).

Website: www.cdc.gov/NIOSH.

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant issu d’un

soudage à l’arc (et de procédés connexes, y compris le soudage par

points, le gougeage, le découpage plasma et les opérations de

chauffage par induction) crée un champ électromagnétique (CEM)

autour du circuit de soudage. Les champs électromagnétiques produits

peuvent causer interférence à certains implants médicaux, p. ex. les

stimulateurs cardiaques. Des mesures de protection pour les porteurs

d’implants médicaux doivent être prises: Limiter par exemple tout accès

aux passants ou procéder à une évaluation des risques individuels pour

les soudeurs. Tous les soudeurs doivent appliquer les procédures

suivantes pour minimiser l’exposition aux CEM provenant du circuit de

soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni

s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le

dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par points,

de gougeage, du coupage plasma ou de chauffage par induction. Si le

médecin approuve, il est recommandé de suivre les procédures précé-

dentes.

Содержание IronMan 240

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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