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Hobart Welding Products 230 manual

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  • Page 1

    IronMan 230 And H200L4-15 Gun Processes OM-235 281A 2009 − 07 Gas Metal Arc (MIG) W elding Flux Cored Arc (FCAW) W elding Description Arc Welding Power Source and Wire Feeder ™ File: MIG (GMA W)[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding 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. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 6 − MIG WELDING (GMA W) GUIDELINES 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. T ypical MIG Process Connections 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. T ypical MIG Process Control Settin[...]

  • Page 5

    OM-235 281 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009 − 07 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[...]

  • Page 6

    OM-235 281 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. 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 poo[...]

  • Page 7

    OM-235 281 Page 3 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.[...]

  • Page 8

    OM-235 281 Page 4 1-4. California Proposition 65 W arnings W elding 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 [...]

  • Page 9

    OM-235 281 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grav[...]

  • Page 10

    OM-235 281 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. 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. DES PIÈCES CH[...]

  • Page 11

    OM-235 281 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-235 281 Page 8 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 per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

  • Page 13

    OM-235 281 Page 9 2-5. P r inc ipa l es n or m es d e sé cur it é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , America[...]

  • Page 14

    OM-235 281 Page 10[...]

  • Page 15

    OM-235 281 Page 1 1 SECTION 3 − INTRODUCTION 3-1. Specifications Rated Output Max. Open Circuit V oltage Amps Input at Rated Output, 60 Hz, Single-Phase 200 V 230 V KV A 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 T ype and Diameter No Load Wire Feed Speed Dimensions W eight Solid Steel/ Sta[...]

  • Page 16

    OM-235 281 Page 12 3-3. V olt-Ampere Curves V olt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 − 240 913-A 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 0 50 100 150 200 250 300 Voltage Amperage[...]

  • Page 17

    OM-235 281 Page 13 SPOOL GUN MIG GUN CB2 CB1 3-4. Installing W elding Gun Ref. 242 143-A 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly . T ighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar . 5 MIG/Spool Gun Switch Switch is sh[...]

  • Page 18

    OM-235 281 Page 14 3-5. Connecting T o Weld Output T erminals 803 778-A ! T urn 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. 1 W eld Output T erminal 2 Supplied Weld Output T erminal Nut 3 Weld Cable T erminal 4 Copper Bar Remove su[...]

  • Page 19

    OM-235 281 Page 15 3-7. Setting Gun Polarity For Wire T ype T ools Needed: 3/4 in Ref. 242 145-A 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). Driv[...]

  • Page 20

    OM-235 281 Page 16 3-9. Installing 10 lb Wire Spool And Adjusting Hub T ension 242 147-A 1 Spool Hub 2 Spool Hub Adapter 3 Spool Hub Nut 4 Keyed Washer (2) 5 Compression Spring 6 W asher 7 Nut Assemble components in numer- ical order as shown. Slide spool hub adapter up on hu b for the smaller spool making sure it is positioned in the anti-rotation[...]

  • Page 21

    OM-235 281 Page 17 3-1 1. Installing Gas Supply 242 687-A T ools Needed: 1-1/8, 5/8 in Rear Panel . DO NOT use Argon/Mixed gas regulator/flowmeter with CO 2 shielding gas. See Parts List for optional CO 2 gas regulator/flowmeter. Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break off [...]

  • Page 22

    OM-235 281 Page 18 3-12. Positioning Jumper Links 242 688-A ! T urn off and disconnect input power . Check input voltage available at site. 1 Jumper Links Access Door Open door . 2 Jumper Link Label Check label − only one is on unit. 3 Input V oltage Jumper Links Move jumper links to match input voltage. Close and secure access door . 3 T ools Ne[...]

  • Page 23

    OM-235 281 Page 19 3-13. Electrical Service Guide 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 V oltage 200 230 Input Amperes At[...]

  • Page 24

    OM-235 281 Page 20 3-14. Selecting A Location And Connecting Input Power Ref. 242 691-A / 802 286-E ! Do not move or operate unit where it could tip. 18 in (457 mm) of space for airflow ! Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. ! Special installation may be required where gasoli[...]

  • Page 25

    OM-235 281 Page 21 3-15. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight before threading wire. 7 T ools Needed: 6 in (150 mm) . Hold wire tightly to keep it from unraveling. WOOD Open pressure assembly . Pull and hold wi[...]

  • Page 26

    OM-235 281 Page 22 SPOOL GUN MIG GUN 3-16. Installing Optional DP 3545 Spool Gun T o W elding Power Source 242 143-A / 242 154-A ! T ur n Off unit, and disconnect input power . 1 Drive Assembly 2 Spool Gun 3 Gun Securing Thumbscrew 4 Gun End Loosen thumbscrew . Insert gun en d through opening until it bottoms against drive assembly . T ighten thumb[...]

  • Page 27

    OM-235 281 Page 23 SECTION 4 − OPERA TION 4-1. Controls 1 Wire Speed Control Control varies the rate of wire being fed through the welding gun. 2 V oltage 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 i[...]

  • Page 28

    OM-235 281 Page 24 4-2. W eld Parameters Selecting Wire, Gas and Control Settings Settings are approximate and are based on a 230 Input line voltage. Adjust as required. Thicker materials can be welded using proper technique, joint preparation and multiple passes. .024” ( 0.6mm ) .030” ( 0.8mm ) .035” ( 0.9mm ) .045” ( 1.1mm ) .024” ( 0.6[...]

  • Page 29

    OM-235 281 Page 25 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3 Months l Damaged Or Unreadable Labels l Cracked Parts n l Cabl[...]

  • Page 30

    OM-235 281 Page 26 5-3. Replacing Drive Roll And Wire Inlet Guide 242 533-A 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stamped markings on the outer surface of the foll refers to the gr[...]

  • Page 31

    OM-235 281 Page 27 5-5. Aligning Drive Rolls and Wire Guide Y T urn Off power . View is from top of drive rolls look- ing down with pressure assembly open. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver , and turn screw in or out until drive roll groove lines up with wire guide. Close pressure rol[...]

  • Page 32

    OM-235 281 Page 28 5-7. Installing Cable Hangers Ref. 242 165-A ! T urn Off power before installing cable hangers. 1 Cable Hanger 2 Screws T ools Needed: 1 2[...]

  • Page 33

    OM-235 281 Page 29 5-8. Removing Nozzle, Contact T ip, And Adapter , Changing Liner , And Cleaning Gun Casing 242 207-A ! T urn off welding power source/wire feeder . 1 Nozzle 2 Contact Tip 3 Tip Adapter 4 Nozzle Adapter . Wire size stamped on tip − check and match wire size. Head T ube T ools Needed: 5/8, 7/16 in Lay gun cable out straight befor[...]

  • Page 34

    OM-235 281 Page 30 5-9. W elding T roubleshooting T able W elding T rouble 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[...]

  • Page 35

    OM-235 281 Page 31 SECTION 6 − MIG WELDING (GMA W) GUIDELINES Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shielding Gas W ork Clamp 6-1. T ypical MIG Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce w or k cl am p as close to the w[...]

  • Page 36

    OM-235 281 Page 32 6-2. T ypical MIG Process Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A C[...]

  • Page 37

    OM-235 281 Page 33 6-3. Holding And Positioning Welding Gun . W elding 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 e nd o f noz zle, and t ip of wire is p osit ione d cor rect ly on sea m. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4[...]

  • Page 38

    OM-235 281 Page 34 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. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROF[...]

  • Page 39

    OM-235 281 Page 35 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 acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Alon[...]

  • Page 40

    OM-235 281 Page 36 6-8. T roubleshooting − 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Us[...]

  • Page 41

    OM-235 281 Page 37 6-1 1. T roubleshooting − 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 maintai[...]

  • Page 42

    OM-235 281 Page 38 6-14. T roubleshooting − W aviness Of Bead W aviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding 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 ha[...]

  • Page 43

    OM-235 281 Page 39 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 Short Cir[...]

  • Page 44

    OM-235 281 Page 40 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed o n welding power [...]

  • Page 45

    OM-235 281 Page 41 SECTION 7 − ELECTRICAL DIAGRAM 240 907-A Figure 7-1. Circuit Diagram For Welding Power Source[...]

  • Page 46

    OM-235 281 Page 42 SECTION 8 − P ARTS LIST 242 214-A . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 11 12 13 14 15 16 18 19 21 21 22 23 24 20 9 − Fig. 8-2 10 − Fig. 8-3 17 − Fig. 8-4 Figure 8-1. Main Assembly[...]

  • Page 47

    OM-235 281 Page 43 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-1. Main Assembly 1 234 210 P ANEL, side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 204 71 1 LA TCH, side flush 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 48

    OM-235 281 Page 44 242 215-A . Hardware is common and not available unless listed. 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 Figure 8-2. Center Baffle w/Components[...]

  • Page 49

    OM-235 281 Page 45 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9) 1 21 1 877 NUT , retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 270 195 NUT , tension 1 . . . . . . . . . . . . . . . . . . [...]

  • Page 50

    OM-235 281 Page 46 242 510-A . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 Figure 8-3. Rear Panel w/Components Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-3. Rear Panel w/Components (Fig 8-1 Item 10) 1 049 399 NUT , 312 − 18 push-on 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 51

    OM-235 281 Page 47 242 216-A . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 12 11 Figure 8-4. Front Panel w/Components Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-4. Front Panel w/Components (Fig 8-1 Item 17) 1 235 261 HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 52

    OM-235 281 Page 48 242 526-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Figure 8-5. Wire Drive Assembly Quantity Description Part No. 234 206 Item No. 8-5. Wire Drive Assembly 1 235 282 HEAD FEED ASSY 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 M[...]

  • Page 53

    OM-235 281 Page 49 242 630-A 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 11 Figure 8-6. H200L4 − 15 Gun Quantity Description Part No. 237 374 Item No. Figure 8-6. H200L4 − 15 Gun 1 200 258 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦ 169 724 NOZZLE, slip[...]

  • Page 54

    OM-235 281 Page 50 Quantity Description Part No. 237 374 Item No. Figure 8-6. H200L4 − 15 Gun 5 170 468 O − RING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 169 730 WASHER, shock 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 55

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2009 − 01 Service Y o u 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 Hoba[...]

  • Page 56

    ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Hobart Welding Products. 2009 − 01 Hoba rt We lding Pr oduct s An Illinois T ool W or ks Comp any 600 W est Main Stree t Tr oy , OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Liter atur e Or Nea re st Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date[...]