Hobart Welding Products 250 manual

Includes Installation Instructions For Optional Spoolmate Spoolgun Switch IronMan 250 And M-25 Gun Processes OM-192 440W 2006 − 10 Gas Metal Arc (MIG) W elding Flux Cored Arc (FCAW) W elding Description Arc Welding Power Source and Wire Feeder ™ File: MIG (GMA W)[...]

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[...]

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

T ABLE OF CONTENTS SECTION 6 − MIG WELDING (GMA W) GUIDELINES 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. T ypical MIG Process Connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. T ypical MIG Process Control Settin[...]

OM-192 440 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 me[...]

OM-192 440 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watchin[...]

OM-192 440 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.[...]

OM-192 440 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W[...]

OM-192 440 Pag e 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les utili sés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss[...]

OM-192 440 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

OM-192 440 Pag e 7 2-3 . Dange rs suppléme ntaire s en r elation avec l’install ation, le f onctionnem ent et l a mai ntenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger [...]

OM-192 440 Page 8 2-5. Princi pales nor mes de sécurit é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W e[...]

OM-192 440 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications Max Open Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. Open Circuit V oltage 200 V 230 V KV A KW 200 A at 24 VDC, 60% Duty Cycle 35 40 1.1* 35 1.3* 8 0.31* 6.8 0.18* Wire T ype and Diameter No Load Wire Feed Speed Dimensions W eight Solid Steel/ Stainless Steel Alu[...]

OM-192 440 Page 10 3-3. 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[...]

OM-192 440 Page 1 1 3-5. Installing W elding Gun Ref. 802 285-D 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 . Close door . 3 4 2 1[...]

OM-192 440 Page 12 3-6. Connecting T o Weld Output T erminals 803 778-A Y T urn off power before connecting to weld output terminals. Y 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[...]

OM-192 440 Page 13 3-8. Setting Gun Polarity For Wire T ype T ools Needed: 3/4 in 1 1 Polarity Changeover Label 2 Positive (+/Red) Output T erminal 3 Negative ( − /Black) Output T erminal Always read and follow wire manufacturer ’s recommended polarity . Close door . Ref. 802 285-D Ref. ST-192 432 3 2 3-9. Installing Wire Spool And Adjusting Hu[...]

OM-192 440 Page 14 3-10. Installing Gas Supply Ref. 220 747-A / 802 028-A / Ref. 802 286-E T ools Needed: 1-1/8, 5/8 in 1 2 3 Argon Gas Or Mixed Gas Rear Panel 6 . 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[...]

OM-192 440 Page 15 3-1 1. Positioning Jumper Links Ref. 802 285-D 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 Needed: 2 3/8 in 200 VOL TS 230 VOL T[...]

OM-192 440 Page 16 3-12. Electrical Service Guide 60 Hz Single Phase Input V oltage 200 230 Input Amperes At Rated Output 40 35 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 50 40 Normal Operating 3 60 50 Min Input Conductor Size In A WG 4 8 10 Max Recommended Input Conductor Length In Feet (Meters) 108 (33) 94 (2[...]

OM-192 440 Page 17 3-13. Selecting A Location And Connecting Input Power 803 766-B / 802 286-E 4 2 Y Do not move or operate unitwhere it could tip. 18 in (457 mm) of space for airflow 1 Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Special installation may be required where gasolin[...]

OM-192 440 Page 18 3-14. Threading Welding Wire Ref. 802 285-D 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. T ools Needed: 6 in (150 mm) Pull and hold wire; cut off end. 4 in (102 mm) T ighten Remove gun nozzle and contact tip. Turn On. WOO[...]

OM-192 440 Page 19 3-15. Installing Optional Spool Gun Switch In W elding Power Source 802 936-A T ools Needed: 1/4 in 9/16 in Y T ur n Off unit, and disconnect input power . 1 Welding Power Source Center Baf fle 2 Switch Location 3 Switch Mounting Plate Remove 2 screws securing switch mounting plate to center baf fle. Pull switch mounting plate to[...]

OM-192 440 Page 20 3-16. Connecting Spool Gun T o W elding Power Source Ref. 802 582-A T ools Needed: Y T urn Off unit. Disconnect and remove MIG (GMA W) welding gun, if applicable. 1 Front Panel Opening 2 Spool Gun Weld Cable Route weld cable through front panel open- ing. 3 Positive (+) Output T erminal Connect spool gun weld cable to positive (+[...]

OM-192 440 Page 21 SECTION 4 − OPERA TION 4-1. Controls 1 Wire Speed Control Th e scale around the control is per- cent, not wire feed speed. 2 V oltage Control The higher the selected number , the thicker the material that can be welded (see welding guide and Section 4-2). 3 Power Switch 1 Ref. 195 721 2 3[...]

OM-192 440 Page 22 4-2. W eld Parameters Input Line Voltage Parameter Chart Settings Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC Weld Will Be Hotter Lower Settings Use Parameter Chart Inside Door Weld Will Be Colder Raise Settings Steel Steel − for outdoor , windy applications or when weld appearance is not critical. Stainless s[...]

OM-192 440 Page 23 200 785-C 3/8” (9.5 mm) — — — 5/66 7/70 7/60 7/100 7/82 7/60 7/75 6/50 5/46 —— — — — — 1/4” (6.4 mm) 4/58 5/56 5/40 5/100 5/76 4/60 4/50 5/58 4/38 4/30 6/90 5/70 6/50 6/45 6/18 6/64 6/60 5/36 5/42 5/16 5/56 5/54 1/8” (3.2 mm) 4/75 3/45 4/44 3/75 3/60 3/48 2/30 2/20 2/0 2/0 4/60 4/62 4/34 4/28 4/12 4/50 14 [...]

OM-192 440 Page 24 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . OR Remove drive roll and apply light co[...]

OM-192 440 Page 25 5-3. Replacing Drive Roll And Wire Inlet Guide Ref. 802 285-C 1 Inlet Wire Guide 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 Install correct drive roll for wire size and type. 4 Drive Roll Securing Screw Secure drive roll with screw[...]

OM-192 440 Page 26 5-5. Replacing Gun Contact Tip Ref. 800 797-C Y T urn Off power before replacing contact tip. 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[...]

OM-192 440 Page 27 5-6. Removing Nozzle, Contact T ip, And Adapter , Changing Liner , And Cleaning Gun Casing 804 466-A Y 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[...]

OM-192 440 Page 28 5-7. Replacing Switch And/Or Head T ube Ref. 800 795-D T ools Needed: 3/4 in Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Install existing shock washer onto new head tube. Hand-tighten head tube into cable connector . Place head tube in vice a[...]

OM-192 440 Page 29 5-8. 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 3-13 ). 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 cir[...]

OM-192 440 Page 30 SECTION 6 − MIG WELDING (GMA W) GUIDELINES 6-1. T ypical MIG Process Connections Y 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 weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Shie[...]

OM-192 440 Page 31 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. NOTE 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 [...]

OM-192 440 Page 32 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 Electro[...]

OM-192 440 Page 33 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. NOTE Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PR[...]

OM-192 440 Page 34 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Al[...]

OM-192 440 Page 35 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[...]

OM-192 440 Page 36 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[...]

OM-192 440 Page 37 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[...]

OM-192 440 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 Short Cir[...]

OM-192 440 Page 39 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 [...]

OM-192 440 Page 40 Notes[...]

OM-192 440 Page 41 SECTION 7 − ELECTRICAL DIAGRAM 206 590-A Figure 7-1. Circuit Diagram For Welding Power Source[...]

OM-192 440 Page 42 SECTION 8 − P ARTS LIST 802 281-F . Hardware is common and not available unless listed. 18 19 21 20 16 15 14 13 12 11 8 7 6 5 4 3 2 1 9 − Fig 8-2 10 − Fig 8-3 17 − Fig 8-4 22 − Fig 8-5 Figure 8-1. Main Assembly[...]

OM-192 440 Page 43 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-1. Main Assembly 1 203 481 P ANEL, side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 151 187 LA TCH, side flush 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-192 440 Page 44 802 284-D . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 20 23 25 27 28 29 33 34 35 37 26 17 18 19 25 24 30 31 32 36 21 22 Figure 8-2. Center Baffle w/Components[...]

OM-192 440 Page 45 Description Part No. Dia. Mkgs. Item No. Quantity Figure 8-2. Center Baffle w/Components (Fig 8-1 Item 9) 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085 980 NUT , 625-1 1 .94 hex 1 . . . . . . . . . . . . . . . . .[...]

OM-192 440 Page 46 802 283 . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-192 440 Page 47 802 282-F . Hardware is common and not available unless listed. 9 11 10 8 7 6 5 4 3 2 1 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) 1 143 974 HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-192 440 Page 48 804 467-A 1 2 345 6 7 8 9 13 16 10 11 14 15 12 Figure 8-5. M-25 Gun Description Part No. Dia. Mkgs. Item No. Figure 8-5. M-25 Gun (Fig 8-1 Item 22) Quantity 1 200 258 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 +169 724 NOZZLE, slip[...]

OM-192 440 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-5. M-25 Gun (Continued) Quantity 8 169 738 NUT , locking handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 169 732 NUT , jam 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Notes[...]

Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2006 − 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[...]

PRINTED IN USA © 2005 Hobart Welding Products. 6/05 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 which equipment was delivered to[...]