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OM-198 683C
April 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
IronMan 275
With Meters
And M-25 Gun
Visit our website at
www.HobartWelders.com
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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
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. 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 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Circuit 200 (208) V 230 V 400 V 460 V 575 V KVA KW Voltage 250 A at 28 VDC, 200 A at 28 VDC, 38 48 42 24 21 17 9.8 7.5 40% Duty Cycle 60% Duty Cycle 2.3* 2* 1.2* 1* 0.8* 0.46* 0.13* Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Solid Steel Stainless Steel Flux Cored 25–700 IPM H: 37 in (940 mm) 212 lb (.65–17.8 m/min) W: 19 in (483 mm) (96 kg) .023 – .045 in .
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2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .045 in (0.6 To 1.1 mm) .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires Hard Or Flux Cored Wires 0 60% Duty Cycle At 300 Amperes 100% Duty Cycle At 200 Amperes Using CO 2 10 Using CO 2 60% Duty Cycle At 200 Amperes Minutes 100%
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2-5. Installing Work Clamp 1 Work Cable 2 Boot Slide boot onto work cable. Route cable out front panel opening from inside. 3 Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. 4 4 Hardware 5 Work Clamp Route cable through clamp handle and secure as shown. 5 Close door. 1 2 3 Tools Needed: 1/2, 3/4 in 802 474-A 2-6. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun end through opening until it bottoms agains
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2-8. Setting Gun Polarity For Wire Type 1 Polarity Changeover Label Information Changing Polarity Always read and follow manufac- ture’s recommended polarity. Wire Drive Work Clamp Lead Assembly Lead 1 Positive Terminal Negative Terminal 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
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2-10. Installing Wire Spool and Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in ST-072573-B 2-11. Positioning Jumper Links Check input voltage available at site. 230 VOLTS 1 Jumper Links Access Door Open door. 3 200 VOLTS 2 Jumper Link Label 460 VOLTS Check label – only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input 230 VOLTS 575 VOLTS voltage. Close and secu
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2-12. Electrical Service Guide Input Voltage 200 230 400 460 575 Input Amperes At Rated Output 48 42 24 21 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 1 2 Circuit Breaker , Time-Delay 60 50 30 25 20 3 Normal Operating 70 60 35 30 25 Min Input Conductor Size In AWG/Kcmil 8 8 12 12 14 96 127 156 206 209 Max Recommended Input Conductor Length In Feet (Meters) (29) (39) (47) (63) (64) Min Grounding Conductor Size In AWG/Kcmil 8 10 12 12 14 Reference: 1999 National Electri
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2-14. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 4 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 7 Tools Needed: 1 2 35 6 Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Use pressure indicator Tighten scale to set a desired drive roll pressure. 1 Pressure 2 Indicator 3 Scale 4 Close
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2-15. Weld Parameter OM-198 683 Page 16
