OM-235 281B 2010 04 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder IronMan 230 And H200L4-15 Gun File: MIG (GMAW)
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.
TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 6 MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . .
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING som _2010 03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
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 & 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.
SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION fre_som_2010 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
OM-235 281 Page 10
SECTION 3 INTRODUCTION 3-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. Open Circuit Voltage 200 V 230 V KVA KW 175 A at 25.5 VDC, 60% Duty Cycle 38 37.0 2.4* 32.5 2.3* 7.4 0.54* 6.3 0.30* * While idling Wire Type and Diameter Solid Steel/ Stainless Steel Aluminum Flux Cored .023 .045 in. (0.6 1.2 mm) .030 .035 in. (0.8 0.9 mm) .030 .045 in. (0.8 1.2 mm) No Load Wire Feed Speed Dimensions Weight 0 700 IPM (0 17.8 m/min) H: 32 in.
3-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. 40.0 35.0 30.0 Voltage 25.0 20.0 15.0 10.0 5.0 0.
3-4. Installing Welding Gun 1 2 3 Drive Assembly Gun Securing Knob Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. SPOOL GUN 5 SPOOL GUN MIG GUN 4 CB2 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. CB1 5 MIG GUN 1 MIG/Spool Gun Switch Switch is shown in MIG position. Close door. 3 2 4 Ref.
3-5. Connecting To Weld Output Terminals 1 2 3 4 Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) 803 778-A Correct Installation ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.
3-7. Setting Gun Polarity For Wire Type Changing Polarity Wire Drive Assembly Lead + Positive Terminal Work Clamp Lead 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 assembly becomes negative. Tools Needed: 3/4 in. Ref. 242 145-A 3-8.
3-9. Installing 10 lb Wire Spool And Adjusting Hub Tension 1 2 3 4 5 6 7 Spool Hub Spool Hub Adapter Spool Hub Nut Keyed Washer (2) Compression Spring Washer Nut Assemble components in numerical order as shown. 2 1 Slide spool hub adapter up on hub for the smaller spool making sure it is positioned in the anti-rotation notches. 3 4 Secure hub nut on spool hub adaptor. 5 Position remaining components. 6 Hand tighten nut to create a slight drag while rotating wire spool. 7 .
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. . DO NOT use Argon/Mixed gas regulator/flowmeter 1 with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. 4a 2 3a 7 5 Argon Gas Or Mixed Gas 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.
3-12. Positioning Jumper Links ! Turn off and disconnect input power. Check input voltage available at site. 1 Jumper Links Access Door Open door. 2 200 VOLTS Check label 3 3 230 VOLTS Jumper Link Label only one is on unit. Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure access door. S-153 980 2 1 Tools Needed: 3/8 in.
3-13. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations 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 (V) 200 230 Input Amperes (A) At Rated Output 37.0 32.
3-14. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-15. Selecting A Location And Connecting Input Power ! Do not move or operate unit where it could tip. 18 in.
3-16. Threading Welding Wire 1 2 3 4 5 6 7 4 7 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight before threading wire. Tools Needed: 1 2 3 5 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. . Hold wire in groove before closing pressure assembly.
3-17. Installing Optional DP 3545 Spool Gun To Welding Power Source SPOOL GUN 6 SPOOL GUN CB2 MIG GUN CB1 ! Turn Off unit, and disconnect input power. 1 2 3 4 Drive Assembly Spool Gun Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 MIG GUN . Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar.
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.
OM-235 281 Page 24 Flux Core E71T–GS “Set Polarity” for (DCEN)” “Set Polarity” for (DCEP)” Stainless Steel “Set Polarity” for (DCEP)” Solid Wire ER70S–6 Wire Type, and Polarity Setting DP 3545 Spoolgun Aluminum** 5356 AL (DCEP) Aluminum** Aluminum 4043 AL With Optional (DCEP) Steel Stainless Steel Steel Material Being Welded —— —— 2 / 26 —— —— —— 1 / 32 —— —— 2 / 24 —— —— —— 1 / 30 .045” ( 1.1mm ) .024” ( 0.6mm ) .030” ( 0.8mm ) .035” ( 0.9mm ) .045” ( 1.1mm ) .024” ( 0.6mm ) —— .035” ( 0.
SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent l = Replace Reference Every 3 Months l Damaged Or Unreadable Labels l Cracked Parts n l Cables n ~ Tighten Weld Terminal OR Every 6 Months ~ Inside Unit n Remove drive roll and apply light coat of oil or grease to drive motor shaft 5-2.
5-3. Replacing Drive Roll And Wire Inlet Guide 1 2 Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 2 3 4 1 Securing Screw Inlet Wire Guide Drive Roll The drive roll consists of two different 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 3-16).
5-5. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls looking down with pressure assembly open. 3 1 Correct Incorrect 4 2 5 1 2 3 4 5 Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear 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.
5-7. Installing Cable Hangers ! Turn Off power before installing cable hangers. 1 2 Cable Hanger Screws 2 1 Tools Needed: Ref.
5-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 2 3 4 Head Tube 1 7/16 in ! Turn off welding source/wire feeder. 1 Nozzle 2 Contact Tip 3 Tip Adapter 4 Nozzle Adapter power . Wire size stamped on tip check and match wire size. Cut off wire and disconnect gun from feeder. 5/8 in Remove nozzle, contact tip, and adapter. Unscrew and remove liner. Blow out gun casing. Lay gun cable out straight before installing new liner.
5-9. Welding Troubleshooting Table Welding Trouble No weld output; wire does not feed. Remedy Secure power cord plug in receptacle (see Section 3-15). 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 3-15).
SECTION 6 MIG WELDING (GMAW) GUIDELINES mig1 2009 12 6-1. Typical MIG Process Connections ! 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 Wire Feeder/ Power Source Gun Shielding Gas Gas Workpiece Work Clamp Ref.
6-2. Typical MIG Process Control Settings . 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. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) (0.001 in. = 1 ampere) 0.125 in. = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in. 30 90 A 0.030 in. 40 145 A 0.035 in.
6-3. Holding And Positioning Welding Gun . 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. 1 1 3 2 2 3 4 5 5 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) 1/4 to 1/2 in.
6-4. Conditions That Affect Weld Bead Shape . 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.
6-5. Gun Movement During Welding . Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 1 2 2 3 Stringer Bead Steady Movement Along Seam Weave Bead Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 3 S-0054-A 6-6.
6-8. Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead. 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.
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 0 to 15 degrees to achieve maximum penetration.
6-14. Troubleshooting Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal. 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 base metal to move.
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.
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 and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters. welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.
SECTION 7 ELECTRICAL DIAGRAM 240 907-A Figure 7-1.
SECTION 8 PARTS LIST . Hardware is common and 24 2 1 3 21 4 20 18 19 17 Fig. 8-4 5 22 23 21 16 9 10 Fig. 8-2 6 Fig. 8-3 7 8 13 12 14 15 11 not available unless listed. 242 214-A Figure 8-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Main Assembly . . . 1 . . . . . . . . . . 234 210 . . . 2 . . . . . . . . . . 204 711 . . . 3 . . . . . . . . . . 134 464 . . . 4 . . . . . . . . . . 234 211 . . . . . . . . . . . . . . . . 235 268 . . . 5 . . . . . . . . . +234 209 . . . 6 . . . . T1 . . 236 760 . . . 7 . . . . Z1 . . 232 877 . . . 8 . . . SR1 . . 239 529 . . . 9 . . . . . . . . . . . Fig 8-2 . . . 10 . . . . . . . . . . . Fig 8-3 . . . 11 . . PLG1 . 199 192 . . . 12 . . .
. Hardware is common and not available unless listed. 1 9 2 3 4 10 5 17 6 7 18 8 23 24 19 12 11 13 16 20 25 15 26 14 27 21 22 242 215-A Figure 8-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 . . . . . . . . . . . . . . 211 877 . . . . . . . . . . . . . 270 195 . . . . . . . . . . . . . 605 941 . . . . . . . . . . . . . 186 437 . . . . . . . . . . . . . 057 971 . . . . . . . . . . . . . 238 652 . . . . . . .
. Hardware is common and not available unless listed. 7 6 8 5 9 4 3 10 2 1 242 510-A Figure 8-3. Rear Panel w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-3. Rear Panel w/Components (Fig 8-1 Item 10) ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 . . . . . . . . . . . . . 049 399 . . . . . . . . . . . . . 148 809 . . . . . FM . . . . 188 706 . . . . . . . . . . . . . . 203 711 . . . . . . . . . . . . . 216 395 . . . . . . . . . . . . . 203 478 . . . . .
. Hardware is common and 1 not available unless listed. 2 4 5 11 6 3 7 8 12 10 9 242 216-A Figure 8-4. Front Panel w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-4. Front Panel w/Components (Fig 8-1 Item 17) ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 . . . . . . . . . . . . . 235 261 . . . . . . . . . . . . . . . 234 208 . . . . . . . . . . . . . . . 207 074 . . . . . . . . . . . . . . . 207 077 . . . . . . . R2 . . . . 208 207 . . .
2 11 22 12 5 3 10 14 8 9 4 21 1 15 16 20 19 18 7 13 17 6 242 526-A Figure 8-5. Wire Drive Assembly Item No. Part No. 234 206 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 .................. . . . . . . M1 . . . . . . . . .................. .................. .................. .................. .................. .................. .................. .................. .................. ...
1 2 3 4 5 6 7 8 9 16 15 14 13 12 11 10 242 630-A Figure 8-6. H200L4 15 Gun Item No. Part No. 237 374 . . . 1 . . . . . . . . . . . . . . . 200 258 . . . . . . . . . . . . . . . . . . . ♦169 724 . . . . . . . . . . . . . . . . . . . ♦169 725 . . . . . . . . . . . . . . . . . . . ♦169 726 . . . . . . . . . . . . . . . . . . . ♦169 727 . . . 2 . . . . . . . . . . . . . ♦087 299 . . . . . . . . . . . . . . . . . . . ♦000 067 . . . . . . . . . . . . . . . . . . . ♦000 068 . . . . . . . . . . . . . . .
Item No. Part No. 237 374 ... 5 ............... ... 6 ............... ... 7 ............... ... 8 ............... ... 9 ............... . . . 10 . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . ..................... ..................... . . . 15 . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . .
Effective January 1, 2010 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MA or newer. Warranty Questions? Call 1-800-332-3281 7 AM 5 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.
Owner’s Record Please complete and retain with your personal records. Model Name Protect Your Investment! Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number.
