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Hobart Welding Products OM-198 683C manual

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  • Page 1

    OM-198 683C April 2000 Visit our website at www.HobartWelders.com Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Arc Welding Power Source and Wire Feeder IronMan 275 W ith Mete rs And M-25 Gun R[...]

  • 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 catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-198 683 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Wat[...]

  • Page 6

    OM-198 683 Page 2 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. ARC RA YS can burn eyes and skin. D 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[...]

  • Page 7

    OM-198 683 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-198 683 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 yea[...]

  • Page 9

    OM-198 683 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-198 683 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-198 683 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-198 683 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for[...]

  • Page 13

    OM-198 683 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Circuit V oltage 200 (208) V 230 V 400 V 460 V 575 V KV A KW 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle 38 48 2.3* 42 2* 24 1.2* 21 1* 17 0.8* 9.8 0.46* 7.5 0.13* Wire T ype and Diamet[...]

  • Page 14

    OM-198 683 Page 10 2-3. W elding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RA TED 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 Duty Cycle is percentage of 10 minutes that gun can weld at rated load without[...]

  • Page 15

    OM-198 683 Page 1 1 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 T erminal Connect cable to terminal and cover connection with boot. 4 Hardware 5 W ork Clamp Route cable through clamp handle and secure as shown. Close door . 802 474-A T ools Nee[...]

  • Page 16

    OM-198 683 Page 12 2-8. Setting Gun Polarity For Wire T ype 1 Polarity Changeover Label Information Always read and follow manufac- ture ’ s recommended polarity . 1 3/4, 1 1/16 in Ref. 190 821-A Changing Polarity D D Wire Drive Assembly Lead Work Clamp Lead + Positive T erminal Shown as shipped – Electrode Positive (DCEP): For solid steel, sta[...]

  • Page 17

    OM-198 683 Page 13 2-10. Installing Wire Spool and Adjusting Hub T ension ST-072573-B When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. T ools Needed: 2-1 1. Positioning Jumper Links 802 476-A Check input voltage available at site. 1 Jumper Links Access Door Open door . 2 Jumper [...]

  • Page 18

    OM-198 683 Page 14 2-12. Electrical Service Guide Input V oltage 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 Circuit Breaker 1 , Time-Delay 2 60 50 30 25 20 Normal Operating 3 70 60 35 30 25 Min Input Conductor Size In A WG/Kcmil 8 8 12 12 14 Max Recommended Inp[...]

  • Page 19

    OM-198 683 Page 15 2-14. Threading W elding 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. 4 7 35 6 2 1 T ools Needed: 6 in (150 mm) . Hold wire tightly to keep it from unraveling. WOOD Open pressure assembly . Pull and hold wire; cut of[...]

  • Page 20

    OM-198 683 Page 16 2-15. W eld Parameter[...]

  • Page 21

    OM-198 683 Page 17 196 843 VOL TAGE V V WIRE SPEED[...]

  • Page 22

    OM-198 683 Page 18 SECTION 3 – OPERA TION 3-1. Controls 1 V oltage Control T urn control clockwise to increase voltage. 2 Wire Speed Control T urn control clockwise to increase wire feed speed. 3 Power Switch 4 V oltmeter 5 Wire Feed Speed Meter 1 2 3 4 5 198 653[...]

  • Page 23

    OM-198 683 Page 19 3-2. V oltmeter And Wire Feed Speed Meter Operation 1 V oltmeter 2 Wire Feed Speed Meter Power Up Status Both meters display zeros at unit power up. After one second, preset values appear on both meters. The MIG gun settings (not spool gun) are always the default at initial power up of the unit. W elding Status When either a MIG [...]

  • Page 24

    OM-198 683 Page 20 SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Blow out or vacuum inside. OR Remove drive roll and carrie[...]

  • Page 25

    OM-198 683 Page 21 4-4. Replacing Gun Contact Tip Ref. 800 797-C Y T urn Off power . 1 Nozzle 2 Contact Tip Cut of f welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. T ools Needed: 1 2 4-5. Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw . Slide t[...]

  • Page 26

    OM-198 683 Page 22 4-6. 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 27

    OM-198 683 Page 23 4-7. Cleaning Or Replacing Gun Liner Ref. ST-800 797-C 5/16 in, 10 mm T o Reassemble Gun: Install and tighten new liner . Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter , contact tip, and nozzle. Y Disconnect gun fro m u n i t f i r s t . T ools Needed: Lay gun cable out straight befor[...]

  • Page 28

    OM-198 683 Page 24 4-8. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 1 Remove handle locking nut. 2 Remove switch housing. Note : If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue[...]

  • Page 29

    OM-198 683 Page 25 4-9. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-13). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connections (see Section 2-6). Have Factory Authorized S[...]

  • Page 30

    OM-198 683 Page 26 Notes[...]

  • Page 31

    OM-198 683 Page 27 SECTION 5 – ELECTRICAL DIAGRAM 197 699-D Figure 5-1. Circuit Diagram[...]

  • Page 32

    OM – 198 683 Page 28 SECTION 6 – P ARTS LIST 802 059-B . Hardware is common and not available unless listed. Figure 6-1. Main Assembly[...]

  • Page 33

    OM-198 683 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Main Assembly Quantity 1 Fig 6-2 BAFFLE, center w/components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Z1 199 159 ST ABILIZER, dual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 34

    OM – 198 683 Page 30 802 060-C . Hardware is common and not available unless listed. Figure 6-2. Baffle, Center w/Components[...]

  • Page 35

    OM-198 683 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 1) Quantity 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085 980 NUT , stl hex full .625-1 1 1 . . . . . . . . . . . [...]

  • Page 36

    OM – 198 683 Page 32 Ref. 800 792-B 1 234 56 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6-3. M-25 Gun[...]

  • Page 37

    OM-198 683 Page 33 Quantity Description Part No. Item No. Figure 6-3. M-25 Gun (Fig 6-1 Item 16 ) 1 200 258 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 169 724 NOZZLE, slip type .500 orf .125 recess . . . . . . . . 1 ♦ 169 725 NOZZLE, slip type [...]

  • Page 38

    OM – 198 683 Page 34 Quantity Description Part No. Dia. Mkgs. Item No. Figure 6-4. Panel, Front w/Components (Fig 6-1 Item 15) 1 +196 798 P ANEL, front control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 653 LABEL, nameplate 1 . . . . . . . . . . . . . . . . . .[...]

  • Page 39

    OM-198 683 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 6-5. Wire Drive And Gears (Fig 6-2 Item 26) Quantity 1 602 009 SCREW , .250-20 x 1.25 soc hd gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/components 1 . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    OM – 198 683 Page 36 T able 6-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 V -Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V -Knurled rolls for hard shelled c[...]

  • Page 41

    Notes[...]

  • Page 42

    Notes[...]

  • Page 43

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 4/00 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 distribut[...]

  • Page 44

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding Pr oducts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , OH 4 5373 USA For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t D ealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]