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IronMan 230 And H200L4-15 Gun

1. 1 DUE AE NAKA sA M 604 538 WASHER flat 344 ID x 688 OD 1 A A RES ERA 146 524 HOSE sae 187 ID x 410 OD X 27 1 d E PN 242 524 GUIDE wire inlet 1o xe ea In CR C C Rn 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 OM 235 281 Page 48 Item Part No No 237 374 a AP 200258 169 724 169 725 169 726 169 727 087 299 000 067 000 068 RAT ITUR 000 069 ME t Leur e oe 169 728 T rr 169 729 Figure 8 6 H200L4 15 Gun Description Figure 8 6 H200L4 15 Gun NOZZLE slip type 500 orf flush NOZZLE slip type 500 orf 125 recess NOZZLE slip type 625 orf 125 recess NOZZLE slip type 625 orf flush NOZZLE slip type 625 orf 125 stich out TIP contact scr 023 wire x 1 125 TIP contact scr 030 wire x 1 125 TIP contact scr 035 wire x 1 125 TIP contact scr 045 wire x 1 125 ADAPTER contact tip ADAPTER nozzle w retaining ring 242 630 A Quantity 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 OPTIONAL OM 235 281 Page 49 Item Part No No Description Quantity 237 374 Figure 8 6
2. SECTION 8 PARTS LIST ICS Hardware is common and not available unless listed 10 Fig 8 3 17 Fig 8 4 21 242 214 A Figure 8 1 Main Assembly OM 235 281 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly s NC 234210 PANELE SITE maa Ba ada ah naan wt haaha ee ee ee desc ados 1 ouo 204 TAN s LATCH Side NUSH in tap tac e ERR Eo d SpA KA AG tr dedicado antra 2 ie utate ab es 134 464 LABEL warning general precautionary s s s ssa aasan a aaea 1 inu AO 234211 itt DOOR ASSY au admini ranis DL ascenso wet Made cauto c arb Su dns ide onde 1 Sens AM SUR a Pa 235 268 LABEL parameter consumables polarity 1 O rad 12234 209 c WRAPPER autos rta as 1 6 T1 236760 TRANSFORMER pwr main 200 230 1 T leal 2 202017 23 STABILIZER cinema dal Prin Rd eodd e DARNA DANGAN eil ede eg raf 1 B arsit 299529 o RECTIFIER aa pin nn Le O ital eae aed ess 1 OF ate MAG Fig 8 2 CENTER BAFFLE w components 1 MO ie ei kana Fig 8 3 PANEL rear w components 1 11 xx PEGI 199 192 xx CORD SET 6 500 129a 3 0 dra idas 1 AA 14610 se BASE magaan anak io Gea ur KANG DELIA NANG debeam Seow de a ene 1 1 Ee AAA IM A AA AAO AA AA 1 WA asus S ds 290 799 c WEE La ocn ua da Rd UR Se Stare nn Do Dd ini Ne E UP OA SEE 2 A 121614 2a RING rot
3. Check wire manufacturers recommended flow rate HAC Il JIN Rear Panel Tools Needed TZ 1 1 8 5 8 in 242 687 A OM 235 281 Page 17 3 12 Positioning Jumper Links A Turn off and disconnect input power Check input voltage available at site 1 Jumper Links Access Door Open door 200 VOLTS 2 Jumper Link Label Check label only one is on unit 3 Input Voltage Jumper Links Move jumper links to match input voltage Close and secure access door Tools Needed E Y CE 3 8 in 242 688 A OM 235 281 Page 18 3 13 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 60 Hz Single Phase Input Voltage 200 230 Input Amperes At Rated Output 37 0 32 5 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 45 40 Normal Operating 60 50 Min Input Conductor Size In AWG 4 10 10 Max Recommended Input Conductor Length In Feet Meters 23 Tara Min Grounding Conductor Size In AWG 4 10 10 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose
4. NEZ FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e 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 e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 C N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do SO e Do
5. e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection FRA WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Ac
6. Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 235 281 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Deplacer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les r
7. H200L4 15 Gun ler D A 170469 Melita ET 1 NO E E 169 730 WASHER shock sor iia 1 pos PA eee 242 585 s TUBE HEAD ASSY NAA ecrit ace AA edem iet 1 pru us ua T Se 242635 HANDLE front H 20 welding gun 1 TENG PE ire 229410 ae SWITCH Migger a ANAKAN ob n ACER Mc ced ec a eoe 1 e AA neice ao os 242 597 HANDLE rear H 20 welding gun 1 NU AP 242 597 COLLAR adapter feeder connector 1 an A PA s 242 604 CONNECTOR feeder H 20 welding gun 1 Pp CAN 079974 O RING 500 ID x 103cs rbr 2 o RM 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 o 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 ee M IEEE 194 012 LINER monocoil 035 045 wire x 15ft consisting of 1 A teas te te 079975 O RING 312 ID x 062 70 Dura BUNA N 1 log RT 227 800 CORD trigger assy y viii e ace e A x eo ce NAA 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 OPTIONAL Table 8 1 Accessories PART NO DESCRIPTION REMARKS 042 758 Dual Bottle Rack Kit Converts Single Cylinder Rack To Dual Rack 212
8. Installing Optional DP 3545 Spool Gun To Welding Power Source 22 SEGTION 4 OPERATION 2 iver ose PIE YA IET IEEE BI ete EE eed ee a mre beta Gees ees 23 x a a 23 4 2 Weld Pararmelers xs ao oec ne ee AA Ra OR ac e cb GP hamak nG 24 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 25 BT ROWING Manntenati6e rimes die nn muta ce E x urea ees vele AED Sd EN E AS ABER Saved 25 9 2 5dpbplementan Protector 42s e x mares a CE Cup Rn Pa d Vea pde ee da 25 5 3 Replacing Drive Roll And Wire Inlet Guide II 26 5 4 Removing Knob From Front Panel hh hm hs 26 5 5 Aligning Drive Rolls and Wire Guide m n 27 5 6 Replacing Gun Contact TID a RO o 27 5 7 Installing Cable Hangers s ex S RIA RS RERQEREEGUe HE T R ee SCR DUO wx EE Ed 28 5 8 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing 29 5 9 Welding Troubleshooting Table 2 30 5 10 Wire Drive Gun Troubleshooting Table n 30 TABLE OF CONTENTS SECTION 6 MIG WELDING GMAW GUIDELINES 00c0oocooc nnn 31 6 1 Typical MIG Process Connections ms 31 6 2 Typical MIG Process Control Settings ene 32 6 3 Holding And Positioning Welding Gun ren 33 6 4 Conditions That Affect Weld Bead Shape 34 6 5
9. cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande m OM 235 281 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es a enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pi ces de rechange recom mand es par le constructeur e Effectuer r gulierement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et
10. 023 045 in 030 035 in 030 045 in 0 6 1 2 mn 0 8 0 9 mm 0 8 1 2 mn 3 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 unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty WELD AMPERES 50 60 e DUTY CYCLE 60 dutycycle 6 Minutes Welding 4 Minutes Resting Overheating l Na N Minutes duty1 4 95 227 953 A OM 235 281 Page 11 3 3 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves shown 150 Amperage OM 235 281 Page 12 va curve1 4 95 240 913 A 3 4 Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive
11. 9r 4 0v 9 07 5 ce e 87 92 2 Ce m wwg0 S 0 09 LANA nag 02 8 02 8 09 4 97 9 9 S 0 T v 0 92 1 OZ L wug 0 0 0 OO EXT xe 85 9 Or v Ob ge 2 L 0 L wug0 7Z0 DM ed d390 10 P311 G L pS 2 27 9 07 9 be JE 9c be le L wwu6 0 GE0 E NuUelod 195 n EU DTE S ob s ve v ve e 0e 92 1 02 1 Lugo 0 0 ME SUE _ o 2n _ vb v 0v 9 ce 0C L wug 0 7Z0 9JIM pilos 06 1 06 1 06 1 06 1 92 9 gL 9L unl SF0 ENS 9 9 9 9 9 9 96 9 ve S 82 7 vz y ed gt WG SEO ZOO 001 z9 6 z9 6 08 8 gr 4 97 9 0 5 9 t e wug 0 080 I vel 92 2 bala ww9 0 bZ0 ve 9 ve 9 ve 9 92 9 PZE 23 02 2 4 SYO 08 4 08 vb 9 07 5 ve S 0 92 0 2 Cuu6 0 GEO ot 92 6 02 8 09 4 97 9 96 9 0 v ve 0 9Z nan wug 0 0 0 COD 9097 IW 9567 06 6 b1 8 02 1 02 9 05 5 Ov v 0v ve 92 2 AN wug 0 peo O wwoz uug uuzi wwgo uugo bun uuzzL uugg uugg wwg7 uuzeg yougzo uouzgo uougro Uuouog0o You tzo pude ajey Mold uj og og 19S Aelod aun YOU 2 L YOU 8 YOU v L YOU 91 YOU 8 1 eDneD y ebnebor bnebg ebnebzz abneb pz jejeureiq saser Duipjeius pus CuSJeN m p m ma m xcd Ds Dunes paa 9JIM S 1y61y uo 1equinw Buas Heyo SI 97 uo JequinwN sassed ejdnjnui pue uonejedoad juiol anbiuyde 18do1d Buisn papjam aq ued sjeriojeu
12. Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com 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 phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committe
13. Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les cables ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les cables d un c t et a distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la piece aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 235 281 Page 9 OM 235 281 Page 10 SECTION 3 INTRODUCTION 3 1 Specifications Amps Input at Rated Output 60 Hz Single Phase Max Open Rated Output Circuit Voltage 200V 230 V KVA KW 175 A at 25 5 VDC 37 0 32 5 7 4 6 3 6096 Duty Cycle 38 2 4 2 3 0 54 0 30 While idling No Load Wire Feed Wire Type and Diameter Speed Dimensions Weight Solid Steel 0 700 IPM H 32 in 813 mm 185 Ib Stainless Steel Aluminum Flux Cored 0 17 8 W 18 7 8 in 479 mm 84 kg m min D 37 in 940 mm
14. DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures i e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P Q NI Pang LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprimes e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des
15. Gun Movement During Welding 00 c ccc eee hn 35 6 6 Poor Weld Bead Characteristics hn 35 6 7 Good Weld Bead Characteristics n 35 6 8 Troubleshooting Excessive Spatter na aana a nanana 36 6 9 Troubleshooting Porosi si iea tada o b gc P eia Snes acte tec estre D oem n E ie 36 6 10 Troubleshooting Excessive Penetration e enaena 36 6 11 Troubleshooting Lack Of Penetration n 37 6 12 Troubleshooting Incomplete Fusion n 37 6 13 Troubleshooting Burn Through n 37 6 14 Troubleshooting Waviness Of Bead 38 0 15 Io bleshooting DISIOFUOR c SES A ARA Que OO abe ALAN aie aha RD NG 38 6 16 Common MIG Shielding Gases a mia duree x rtr Ue quc Ri Gare ea data ANA aa ate MON 39 6 17 Troubleshooting Guide For Semiautomatic Welding Equipment 39 SECTION 7 ELECTRICAL DIAGRAM cri Re REIR IARE a 41 SECTIONS PARIS LIST acter eden A a ora tiui een maine tenus 42 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2009 07 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text A Indicates a hazardous situation which if not avoided A DANGER Indicates a hazardous situat
16. Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate V ele OM 235 281 Page 32 6 3 Holding And Positioning Welding Gun E 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 End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm Cradle Gun and Rest Hand on Workpiece OM 235 281 Page 33 6 4 Conditions That Affect Weld Bead Shape E 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 b 10 leeeeem 9 5 Push na ung aa ara ba o Ha lt Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT ke te LE Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT joi se Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 235 281 Page 34 6 5 Gun Movement During Welding 7 Normally a single stringer bead is satisfactory for most narrow gr
17. adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of O to 15 degrees 6 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 235 281 Page 37 6 14 Troubleshooting Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal D gt 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 Support hand on solid surface or use two hands 6 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces LIZ base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding op
18. are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW Cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on Pevite pas peut donner la mort ou des blessures graves Les
19. autres probl mes de procr ation 2 5 Principales normes de securite Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Considerations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques II y a eu et ily a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban
20. bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examinees En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O
21. 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagneticallycompatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 235 281 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and
22. not point gun toward any part of the body other people or any metal when threading welding wire 4 3 K MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place d D e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high
23. switch see Sections 3 4 and or Parts List Thermostat open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 3 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 5 6 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 3 14 Low high or erratic wire speed Readjust front panel settings see Section 4 1 Change to correct size drive roll see Section 5 3 Readjust drive roll pressure see Section 3 15 Replace inlet guide contact tip and or liner if necessary see Sections 5 3 5 6 and or 5 8 5 10 Wire Drive Gun Troubleshooting Table Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding or wire feeding intermittently Straighten gun cable and or replace damaged parts see Section 5 8 Adjust drive roll pressure see Section 3 15 Readjust hub tension see Section 3 8 Check supplementary protectors CB1 and or CB2 and reset if necessary see Section 5 2 Replace contact tip if blocked see Section 5 6 Clean or replace wire inlet guide or liner if dirty or plugged see Sections 5 3 and or 5 8 Replace drive roll if worn or slipping see Section 5 3 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Section
24. 3 4 and or see Parts List Check and clear any restrictions at drive assembly and liner see Section 5 8 Have nearest Factory Authorized Service Agent check drive motor OM 235 281 Page 30 SECTION 6 MIG WELDING GMAW GUIDELINES 6 1 Typical MIG Process Connections A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter E Wire Feeder Power Source Shielding Gas Workpiece STAR Work Clamp mig1_2007 05 Ref 801 909 A OM 235 281 Page 31 6 2 Typical MIG Process Control Settings 7 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 NS 1 8 or 0 125 in Convert Material Thickness to L Amperage A 4 0 001 in 1 ampere 0 125 in 125A y 0 023 in 30 90A 0 030 in 40 145A Select Wire Size 0 035 in 50 180A Wire Speed Select Wire Speed Se Recommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute Low voltage wire stubs into work High voltage arc is unstable spatter Select
25. 492 Regulator Flowmeter For Use With 10096 CO Shielding Gas 235 287 Dual Drive Roll 024 045 Allows Use Of 024 Solid Wire And 045 Solid And 0 6 1 2 mm Flux Cored Wire 132 958 Drive Roll 035 0 9 mm VK Groove V Knurl Drive Roll For Hard Shell Cored Wires 132 957 Drive Roll 045 1 2 mm VK Groove V Knurl Drive Roll For Hard Shell Cored Wires 300 349 DP 3545 20 Spool Gun Provides Excellent Feeding Of Aluminum Wire OM 235 281 Page 50 Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com WELDERS HOBART 331 WARRANTY Effective January 1 2009 5 311 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface of LK or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its orig
26. 6 E 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to dis connect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 3 13 fused dis connect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 3 15 Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 4 5 Drive Roll 6 Outlet Wire Guide l 7 Gun Conduit Cable B 7 Lay gun cable out straight before threading wire Mura Tools Needed C7 Hold wire tightly to keep it from unraveling Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire CS Hold wire in groove before closing pressure assembly OFF POWER Lay gun cable out straight and Turn power ON remove gun nozzle and contact tip Close and tighten pressure assembly and let go of wire Tighten Y WOOD ES Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire approximately 5 16 in 8 mm comes out of gun Reinstall Tighten knob enough to prevent slipping from contact tip Close door contact tip and nozzle 242 692 A OM 235 281 Page 21 3 16 Installing Optional DP 3545 Spool Gun To We
27. 8 4 Front Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 8 4 Front Panel w Components Fig 8 1 Item 17 bide AE 2939261 sx HANDLE 5 32 21 nt Madu osa bA oed ew ates taies irre 1 TE UM and sasha 294 208 PANEL TONE sos rb em Rr b eoe no o met ooo beate 1 DER 207 074 HANDLE switch RR RR run 1 TIC MMC 207 077 KNOB potentiometer II I 1 EC EM R2 208207 POTENTIOMETER CP flat 1 T 2W 1K linear wire feed speed 1 ne c S2 237378 SWITCH rotary 63A 12 position 1 su ae ee Ol magka 124511 SWITCH tgl DPST 40A 600 VAC 1 DE A eee na 210 389 BUSHING snap in nyl 0 0 0 teen eee 1 T err PL1 238764 LIGHT ind wht lens 28V power on 1 ka NO a ROD 048282 RECEPTACLE W SOCKETS 325p vio dc eC en n wc c ee 1 A a duse igs a LABEL nameplate order by model and serial no 1 12 C2 C3 C4 C5 136735 CAPACITOR cer disc 1uf 500 VDC 4 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 OM 235 281 Page 47 242 526 A Figure 8 5 Wire Drive Assembly Item Part No No Description Quantity 234 206 8 5 Wire Drive Assembly a SP AA 235282 Jw HE
28. AD FEED ASSY an des e a nt a dee de e p n 1 MAE MORS MIT sus 235 283 MOTOR gear 24VDC 190 RPM 1 T ATA AT 235 284 CARRIER drive roll assy p00 ka dba K RID Re xx ERE 1 UE A eG meee 602 209 SCREW 250 20x 1 25 sochd 1 a Wado us nears hee 166 072 sx SPACER Galuros A HUAG Miwa oad bow 2k 1 bose de due Dia 235 285 CARRIER drive roll 10mm shaft 1 1 LS die Sol eves 174 609 i SOREW MSS 012 eite de Sept eot nA WAN be 1 AA rene Se 173 620 BUSHING motor mtg 3 mg TT eau t els a 174 610 SCREW M6 1 0 x 20 soc hd button cap 3 AA en day aes 192029 WASHER flat 250 ID x 437 OD 3 AA A 235 208 GOVER MOIO GIVE sisi aio ancien Land 1 A AR ie EE 196 654 SCREW thumb 1 4 20 res 1 Tu PEDIS 235 286 ROLL drive v groove 030 035 wire 2 LC O O eee 079 240 SCREW 375 16x 1 75 hexhd 1 T L ao 602 243 WASHER flat 438 ID x 1 00 OD 1 Ss en re 602 213 WASHER lock 380 ID x 691 OD 1 bur d dra ica cb testis dosis 199 632 NUT 375 16 50 hex 94 h oio ERR ER 1 E 238 304 WASHER flat 170 ID x 375 OD 1 Na PAA 222035 KNOB T 1 562 bar w 312 18
29. HILE WELDING VOLTAGE POWER 3 o POWER TRIGGER 5 Ref 242 155 A OM 235 281 Page 23 Weld Parameters 4 2 ev cl 8 LL EC 0l ve 6 82 1 _ _ E wwz vol 4390 08 31 83 01 v5 6 97 8 vv 2 9 7 ge e ww6 0 seo U0B1Y 96001 IV 9989 86 31 28 01 9 6 09 8 08 9 ge 96 2 gt wwugo 080 WNUN unfoods Gre da pe ZL 0 LL 9c 0L 2 6 ANO RE a ONES wuz L Zv0 so 09 6 Ss Sm s jeuondo uiuM 09 LL 26 01 07 8 ve 1 ve lv 0 vola WW6 0 S 0 OB 95001 TV Eror xxWUNUIWN Y WNUIWN Y 99 01 09 6 97 8 av 1 1 07 9 ge e 9 8 Z po PES OEO 08 6 vv 8c 9 02 unup L Svo suoneojddy joopino N300 40 05 8 05 8 trL 07 9 86 9 92 02 2 PEE wwug 9 Seo 40 pUIM 40J pooc Aelod 198 9918 P511 15 1 PB Bala vv G ve 92 Z bali wug o oso P2Imbay seo Duipieius ON naa e118 B3 9 9 99 9 oG Y 0v 96 2 c 2c 0 1 wwg 9 080 209 Ka IY 86 Laal 101 EX PIE er 08 9 vv 8 c ve c 8c wwg9 0 vzo AYejo4 188 anG 09 9 09 9 09 9 gg Z 05 9 vv G 9 y ce e 92 2 WW6 0 GEO 209 8 2 DS sso ureis c9 8 c9 8 c9 8 c9 8 09 2 96 9 9 ce tp oc Z wug 0 0 0 3Y ko blak 9606 ssojureis 09 9 8v G 97 7 UE 7 UC 2 ug 7Z0 us ve 9 ve 9 ve 9 ze 9 0 S ec 02 2 NEM EN mad uu SYO 9v 4 9v 4
30. IS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province KY P P hobart_warr 2009 01 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 Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor retail or service location Contact your Distributor for Welding Supplies and Consumables Call 1 877 Hob
31. OM 235 281A 2009 07 Processes Gas Metal Arc MIG Welding Flux Cored Arc FCAW Welding HOBART WELDERS Description wd El EN Arc Welding Power Source and Wire Feeder IronMan 230 And H200L4 15 Gun Online Forum www HobartWelders com OWNER S MANUAL File MIG GMAW PN 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 Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve 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 WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered to the you may need to fix the problem Warranty and from Hobart is backed by ISO 9001 2000 Quality Service information for your particular model the best warranty in the System Standard business are also provided 150 9001 2000 QUALITY SYSTEM Protect Your Investment Hobart Welders manufactures a full line of welders and wel
32. Type Changing Polarity Wire Drive Assembly Lead Positive Terminal HA Work CI Lead Negative Terminal a ork Clamp Lea Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with gas wires GMAW Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux core wires FCAW Drive assembly becomes negative Tools Needed IZ 3 4 in Ref 242 145 A 3 8 Installing 2 Ib Wire Spool And Adjusting Hub Tension Keyed Washer Wire Spool 2 LB Keyed Washer Compression Spring Washer Nut Assemble components in numer ical order as shown Hand tighten nut to create a slight drag while rotating wire spool Over tightening nut may cause wire slippage 242 146 A OM 235 281 Page 15 3 9 Installing 10 Ib Wire Spool And Adjusting Hub Tension Spool Hub Spool Hub Adapter Spool Hub Nut Keyed Washer 2 Compression Spring Washer Nut Assemble components in numer ical order as shown Slide spool hub adapter up on hub for the smaller spool making sure it is positioned in the anti rotation notches Secure hub nut on spool hub ad aptor Position remaining components Hand tighten nut to create a slight drag while rotating wire spool 7 Over tightening nut may cause wire slippage 242 147 A 3 10 Installing 33 Ib Wire Spool And Adjusting Hub Tension Spool Hub Spool Hub Adapter Spool Hu
33. Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HE Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately 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 Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the sp
34. an 9 3 deed uba AG Aa KG a D ee Re 2 be PA 235 875 CASTER swvl 4 00 in X 1 250 in 2 M UC ee Fig 8 4 PANEL front w components 1 MO EN 233 473 CABLE work 10 no 3 w clamp amp boot including 1 E EP 196 310 2 OOVERCabIG 5 aaa apa tes ahs Nae mata Ene esae I Eno do Enis Aa 1 20 Leu eg 146 149 2000 CABLE 53s 2 ae Aa uen re catego id d 1 24 ye dette A 233452 sena CLAMP WOLK acaricia i ANN sae ares die oh nieto baw du atn dodi ated 1 Det ers 235 263 BRACKET CADACIlON 2 52m ET ei a be ies ate cx etin ora eb aet ean 1 aida 234212 S CAPACITOR 100 000 Uranio ie is vidos 1 Ps PEE 233 420 44 CHOKE ZOU 2 o TS KA aar met ka a ERR a 1 a Ser 091 685 RESISTOR 25 ohm SU W 1 TD 238 759 REGULATOR FLOWGAUGE 0 50 CFH ARGON CO2 kit 1 TR RUN NOR 144 108 HOSE AS rita dy eos WORSE a Ie a ana a idos 1 ere ian dria 238 910 va HANGER Cable aiii pi Nena Sr epos ina NADA iia 2 ax aede eue e bran 239 173 H200L4 15 GUN replacement 1 When ordering a component originally displaying a precautionary label the label should also be ordered 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 OM 235 281 Page 43 3 Hardw
35. are is common and not available unless listed CN 11 13 22 242 215 A Figure 8 2 Center Baffle w Components OM 235 281 Page 44 Item Dia No Mkgs OPTIONAL 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 Part No 234 206 146 524 Description NUT retaining spool NUT tension aa iuba ete trs say WASHER 1 1 oh e ERR SPRING cprsn 2 430 OD x 90 wire x 2 50 WASHER flat 632 ID x 1 50 OD x 12 keyed HUB spool ADAPTOR spool hub WASHER brake ss BAFFLE center i2 ec oe ii REEL SUPPORT usted io TRANSFORMER control BLOCK terminal 5 pole CONTACTOR def 40A 3P TERMINAL ASSY pri 1 PH 200 230 voltage LINK jumper term bd pri DOOR access changeover SWITCH tgl SPST 15A 125VAC on none off spd term SUPPLEMENTARY PROTECTOR man reset 1P 5A 250V SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V CIRCUIT CARD ASSY control TERMINAL pwr output black TERMINAL pwr output red STAND OFF SUPPORT PC card LABEL warning electric shock LABEL warning electric shock 4 moving parts DRIVE ASSY wir
36. art1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks 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 ORIGINAL INSTRUCTIONS PRINTED IN USA C 2009 Hobart Welding Products 2009 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call 1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 HOBART ZG WELDERS
37. assembly Tighten knob SPOOL GUN s 4 Gun Trigger Plug 5 1 A Insert plug into receptacle and id i tighten threaded collar MIG GUN E 5 MIG Spool Gun Switch Switch is shown in MIG position IU EE K L Ref 242 143 A OM 235 281 Page 13 3 5 Connecting To Weld Output Terminals 1 Nin Pa Do not place anything between weld cable terminal and copper bar Tools Needed J 3 4 in 19 mm Correct Installation Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Hemove supplied nut from weld output ter minal Slide weld cable terminal onto weld A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine 3 6 Installing Work Clamp Tools Needed YT 1 2 3 4 in OM 235 281 Page 14 803 778 A Incorrect Installation output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean 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 242 145 A 3 7 Setting Gun Polarity For Wire
38. auses Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 235 281 Page 36 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 Improper weld technique Maintain normal gun angle of O to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 6 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 Corrective Actions 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
39. b Nut Keyed Washer 2 Compression Spring Washer Nut Assemble components in numer ical order as shown Slide spool hub adapter up on hub for the smaller spool making sure itis positioned in the anti rotation notches Secure hub nut on spool hub ad aptor Position remaining components Hand tighten nut to create a slight drag while rotating wire spool Over tightening nut may cause wire slippage 242 148 A OM 235 281 Page 16 3 11 Installing Gas Supply Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve EF DO NOT use Argon Mixed gas regulator flowmeter 1 Cap with CO shielding gas See Parts List for optional CO gas regulator flowmeter 2 Cylinder Valve 4a Remove cap stand to side of valve and open valve slightly Gas flow T O 2 blows dust and dirt from valve 3 Close valve er lb s 3 Oylinder QA a Argon Or Mixed Gas Cylinder 5 7 b CO Cylinder Argon Gas Or Tae Gas 4 Regulator Flowmeter a Argon Or Mixed Gas Regulator Flowmeter b CO Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For MIG Gun Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Gas Flow Adjustment Control Typical flow rate is 20 cfh cubic feet per hour
40. ch as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding pr
41. cidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen pipes OM 235 281 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles su
42. d contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 235 281 Page 40 SECTION 7 ELECTRICAL DIAGRAM SPOOL GUN MOTOR MIG GUN MOTOR p 16 14 a WFS ly 3 SPOOL GUN MIG GUN S3 6 X ES RCE 8K Ree te u w oO o L Z c x N J a 2 o N g srl O di Ta aika cp Qu uj u e O olo a ZA ZA C E 4 N MN VN v y In O Pa S K S Oo Hr 9 8 a a oj w r ol o S ia M O 3 36 3E SE e E Se SE 3 a AHIHIHIHI SIGA ra l Ga l a l Ka T a amp ae a a ka ba paba 3 A s gt O A Y DO C TO O D FO e 14 Rm uz EL o ie e e e E ae the orn E Bi 8 R O O RV E O O JS p o ESSE Wu ai o zs DOO o o o Li ls a N pe rS A WARNING e Do not touch live electrical parts ld o e Disconnect input power or stop AA a engine before servicing DAA J e Do not operate with covers removed 2 un E ELECTRIC e Have only qualified persons install si g SHOCK HAZARD use or service this unit mI 240 907 A Figure 7 1 Circuit Diagram For Welding Power Source OM 235 281 Page 41
43. dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil rm UNE D CHARGE LECTRIQUE peut gt entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la piece est sous tension lorsque le courant est d livr la sortie Le circuit d a
44. differ ent sized grooves The stamped markings on the outer surface of the foll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread wire see Section 3 15 4 Drive Roll Securing Nut Turn nut one click to secure drive roll 242 533 A Front Panel Knob Spring Clip Control Shaft Slot Rotate knob to allow access to slot Insert Allen wrench or stiff piece of wire into slot and while depressing spring clip slide knob off control shaft To reinstall push knob fully onto control shaft A Turn Off power 1 2 3 4 5 242 693 A OM 235 281 Page 26 5 5 Aligning Drive Rolls and Wire Guide A Turn Off power View is from top of drive rolls look ing down with pressure assembly open Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Incorrect Insert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Tools Needed Ref 800 412 A 5 6 Replacing Gun Contact Tip Turn Off power before replacing contact tip Nozzle Contact Tip Cut off welding wire at contact tip Hemove nozzle Hemove contact tip and install new contact tip Reinstall nozzle Tools Needed Ref 242 164 A OM 235 281 Page 27 5 7 Installing Cable Hangers A Turn Off power before installing cable hangers Cable Hanger Screws Too
45. ding related equipment For information on other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 Hobart1 or HobartWelders com visit our website at www Hobart Welders com For Technical Help call 1 800 332 3281 ORARI AS Hob Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 tl O MPSS kee ae Rae wee Ke iad ed tute abad een AA 1 152 Arc Welding Hazard 3 orsus ae e RIDERE REED ne ane uim deu a dio ees 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings aeaaaee 4 1 5 Principal Safety Standards a de pieced enon c RD c o S oo Dodo te ND A 4 156 EMP Tee x nene su auci ai d n Dar ti Kada c acr Sak rt Do otn a a bd ndo a d Ric 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS USES e daan rd ace Baka free a re etse dnce o ee Dalee aah RERUM een en 5 2 2 Dangers relatifs au soudage l arc cee e 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes d
46. e HOSE DAS sorna dace Quantity Figure 8 2 Center Baffle w Components Fig 8 1 Item 9 OM 235 281 Page 45 ICS Hardware is common and not available unless listed 9 10 242 510 A Figure 8 3 Rear Panel w Components Item Dia Part No Mkgs No Description Quantity Figure 8 3 Rear Panel w Components Fig 8 1 Item 10 TE Sion gs Bk eh acai 049 399 2 NUT 3T12218 PUSN ON a asd E mds dr a pene nei e e o on e 1 iu 3 btt tayan Kag DACH ds 148 909 lt EAN S9In5Wg Re C e i xe doces Durs idt oca due sn ce e d 1 e FM 188706 MOTOR fan 230V 50 60 HZ 1 Nag TTT 209 1 WINDTUNNEL lt T rueda raso rent do dra ti 1 D NAAA 216395 VALVE 2 way 35 VDC custom port 1 8 orf w frict 1 KAO PA 2094798 PANEL TOA cR EE ERI als E aaa al ah eed 1 iu add id 169654 BRACKET support tank cs ri a e Ee e NGA 1 Nu MODERN 100441 x2 CHAIN Safely aaa ts e CEU a RE Rp qos om lie hbase te 1 TE UPPER 197 TOT a NUT 750 NPT 1 91 hex 27 FH nyl DIK suelas riera 1 Mom 604 102 CONN clamp cable 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 OM 235 281 Page 46 3 Hardware is common and not available unless listed 5 11 6 NG 7 8 12 9 242 216 A Figure
47. e S curit s naa sae doe aus ede mes a anie oigo as 9 2 6 Information EMP vs s Gas sum doe le ER a REN eoe o KUDA NE eno ge ue de 9 SECTION 3 INTRODUCTION vi Circa si DA NAAT VE REESE ISIN AE TAREA AURIUM KU GR 11 c MEE e cliezile E PE STET TT TT I ET TTD 11 3 2 Welding Power Source Duty Cycle And Overheating sassa saas anaana 11 Sox VOIDATHDOFO OHEUBS ica tese f ED Cafe e A inse dale Da IGBO A KA e e a 12 3 4 Installing Welding GUN AAN Oed parare du esee aiutato DAS 13 3 5 Connecting To Weld Output Terminals 0 cc nr 14 3 6 Installing Wolk Glampi cu AR AAA as AAA AAA AS ee 14 3 7 Setting Gun Polarity For Wire Type mr 15 3 8 Installing 2 lb Wire Spool And Adjusting Hub Tension 1 15 3 9 Installing 10 Ib Wire Spool And Adjusting Hub Tension 16 3 10 Installing 33 Ib Wire Spool And Adjusting Hub Tension 16 3 17 Installing GaS SUODIY xu d ia See ede ee bat aie ee wees sea NA m ae a o wr dia Paes we d Ded 17 3 12 Positioning Jumper LINKS aaa ewe ede nG NG sun LA wee AREE RET RE NE Ed 18 3 19 Electrical Semice GUIDE 2 fel Aa a dened va waka dk nda rw EY da eR Gaetan eves Sen 19 3 14 Selecting A Location And Connecting Input Power ssasas saaan n anana 20 3 15 Threading Welding WING wis susce eet ann eee t ce eee c Re s eee eee ee ed ee ee 21 3 16
48. e of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields 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 OM 235 281 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there
49. ece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns Pini OM 235 281 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe
50. ecifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR TH
51. ecouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pou
52. eration Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 235 281 Page 38 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 Application Gas Spray Arc Steel Short Circuiting Steel Py eat Aluminum Argon X Argon 25 CO X 80 or greater Argon X x1 balance CO or Oxygen 100 CO X Tri Mix X 1 Limited short circuiting use 2 9096 HE 7 1 2 AR 2 1 2 CO 6 17 Troubleshooting Guide For Semiautomatic Welding Equipment 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 pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pr
53. essure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas oylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas solenoid valve not operating 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 OM 235 281 Page 39 Problem Probable Cause Remedy 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 an
54. i e En cas dinterferences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 235 281 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou
55. il 19x2IlU pap a Mm bulag 2191 JO Ssouxoiu 104 sPBumes peeds alim pue eBejoA pepueuiuio29H p nb se 3sn py e6e3joA eui indu pez e uo peseq ale pue ejeuirxojdde aie sbunjes shuas 041002 pue sep al Bunos OM 235 281 Page 24 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5 1 Routine Maintenance A Disconnect power Maintain more often before maintaining during severe conditions y Check Change Clean x Replace Reference To be done by Factory Authorized Service Agent NA x Every 3 Months x Damaged Or Unreadable L x Cables L Tighten Weld Labels Terminal Every 6 Months Inside Unit L Remove drive roll and apply light coat of oil or grease to drive motor shaft 5 2 Supplementary Protectors Tum Off unit 1 Supplementary Protector CB1 CB1 protects main circuit board PC1 2 Supplementary Protector CB2 CB2 protects the drive motor circuit from overload If drive motor shorts or fails check gun liner blockage or kinks check for jammed wire or bind ing drive rolls Correct problem Press button to reset supplementary protector SPOOL GUN CB2 MIG GUN CBI Ref 242 160 A OM 235 281 Page 25 5 3 Replacing 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 screw 3 Drive Roll The drive roll consists of two
56. inal retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers only to include SCRs diodes and discrete rectifier modules Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes dle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1
57. ion which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any
58. lding Power Source SPOOL GUN 6 MIG GUN DA L OM 235 281 Page 22 A Turn Off unit and disconnect input power Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew Insert gun end through opening until it bottoms against drive assembly Tighten thumbscrew B cnm IF Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position 7 Polarity Change Over Terminal Block To make proper polarity connection see Section 3 7 Close door 8 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Feed Speed control see Section 4 1 9 Voltage Control Arc voltage is controlled by welding power source Voltage control see Section 4 1 10 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed 242 143 A 242 154 A SECTION 4 OPERATION 4 1 Controls 1 Wire Speed Control Control varies the rate of wire being fed through the welding gun 2 Voltage Control Control varies the voltage level of the welding arc The voltage range is 1 minimum to 12 maximum 3 Power Switch The fan is thermostatically controlled and only runs when cooling is needed 4 Power Light 5 Gun Trigger Receptacle DO NOT SWITCH W
59. lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante EF Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordeme
60. limentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la piece couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures metalliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque
61. ls Needed Ref 242 165 A OM 235 281 Page 28 5 8 Removing Nozzle Contact Tip And Adapter Changing Liner And Cleaning Gun Casing PIAN A Turn off welding power EA source wire feeder 1 Nozzle 2 Contact Tip 3 Tip Adapter 4 Nozzle Adapter 7 Wire size stamped on tip check and match wire size Cut off wire and disconnect gun 7 16 in from feeder 5 8 in Remove nozzle contact tip and adapter Unscrew and remove liner Blow out Lay gun cable out gun casing E straight before installing new liner Reassemble gun in reverse order from taking it apart Install Liner Liner o Stickout CS Thread wire according to welding power source wire feeder manual Tools Needed COPI X Q C BIB 7 16 in 242 207 A OM 235 281 Page 29 5 9 Welding Troubleshooting Table Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 3 14 Place Power switch in the ON position Place MIG Spool Gun switch in the proper position 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 14 Secure gun trigger plug in receptacle or repair leads or replace trigger
62. n dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 6 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions 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 change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 6 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld LALO Excessive Penetration Good Penetration S 0639 Possible C
63. no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 235 281 Page 19 3 14 Selecting A Location And Connecting Input Power A A A A 18 in 457 mm of space for airflow Installation must meet all National and Local Codes have only quali fied persons make this installation Special installation may be required where gasoline or volatile liquids are present see NEC Ar ticle 511 or CEC Section 20 Disconnect and lockout tagout in put power before connecting input conductors from unit Always connect green or green yel low conductor to supply grounding terminal first and never to a line terminal OM 235 281 Page 20 1 Rating Label Supply correct input power 2 Plug NEMA Type 6 50P 3 Receptacle NEMA Type 6 50R Connect plug to receptacle 4 Input Power Cord 5 Black And White Input Conductor L1 And L2 6 Green Or Green Yellow Grounding Conductor 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal A Do not move or operate unit where it could tip 230 VAC 1 e Ref 242 691 A 802 28
64. nts d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr
65. o its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpi
66. ocess be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit
67. on utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer
68. oove 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 Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 6 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 6 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 235 281 Page 35 6 8 Troubleshooting Excessive Spatter necs Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead LALA ld 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 Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clea
69. physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow 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 semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards 7 Indicates special instructions e a A This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Properly install and ground this equipment according t
70. rvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES ru SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de n
71. s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 235 281 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pieces chaudes utiliser les outils recomman des et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage genere des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat ria
72. une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE
73. utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emplo
74. ux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau

IronMan 230 And H200L4-15 Gun

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