Hobart Welding Products IRONMAN 275 User manual

Brand: Hobart Welding Products

Model: IRONMAN 275

Category: Welding System

Type: User manual

This manual is also suitable for

OM-198 683C

April 2000

Visit our website at

www.HobartWelders.com

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source

and Wire Feeder

IronMan 275

With Meters

And M-25 Gun

Hobart Welders 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. To locate your nearest

distributor or service agency call 1-877-Hobart1.

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 proper

maintenance. And if for some reason the unit

needs repair, there’s a Troubleshooting section

that will help you figure out what the problem

is. The parts list will then help you to decide

which exact part you may need to fix the

problem. Warranty and service information for

your particular model are also provided.

Hobart is registered to the

ISO 9001 Quality System

Standard.

Working as hard as you

do – every power source

from Hobart is backed by

the best warranty in the

business.

From Hobart to You

Hobart offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

The following terms are

used interchangeably

throughout this manual:

MIG = GMAW

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 3. . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Welding Power Source Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Welding Gun Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Installing Work Clamp 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Installing Welding Gun 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Connecting Olympic 30A Gun 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Setting Gun Polarity For Wire Type 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Installing Gas Supply 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Installing Wire Spool and Adjusting Hub Tension 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11. Positioning Jumper Links 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12. Electrical Service Guide 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-13. Selecting A Location And Connecting Input Power 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14. Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15. Weld Parameter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Voltmeter And Wire Feed Speed Meter Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE &TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Circuit Breaker CB1 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Unit Overload 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Replacing Gun Contact Tip 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Changing Drive Roll and Wire Inlet Guide 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Aligning Drive Rolls and Wire Guide 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Cleaning Or Replacing Gun Liner 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Replacing Switch And/Or Head Tube 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAM 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-198 683C

WARNING

This product, when used

for welding or cutting,

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.)

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OM-198 683 Page 1

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.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-4. Read and follow all

Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding 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 exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

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 RAYS 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 Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

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.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-198 683 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

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

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-198 683 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

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 Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci–dessus.

OM-198 683 Page 9

SECTION 2 – INSTALLATION

2-1. Specifications

Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase

Rated Output

Circuit

Voltage

200 (208) V 230 V 400 V 460 V 575 V KVA KW

250 A at 28 VDC,

40% Duty Cycle

200 A at 28 VDC,

60% Duty Cycle

38 48

2.3*

1.2*

0.8*

9.8

0.46*

7.5

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

.023 – .045 in

(0.6 – 1.2 mm)

.023 – .035 in

(0.6 – 0.9 mm)

.030 – .045 in

(0.8 – 1.2 mm)

(.65–17.8 m/min) W: 19 in (483 mm)

D: 30-1/4 in (768 mm)

(96 kg)

* While idling

Operating Temperature Range – –20C to +40C Storage Temperature Range – -30C to + 50C

2-2. Welding Power Source Duty Cycle And Overheating

4 Minutes Welding 6 Minutes Resting

6 Minutes Welding 4 Minutes Resting

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

Y Exceeding duty cycle can

damage unit and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 – 150 215-A

40% Duty Cycle At 250 Amperes

60% Duty Cycle At 200 Amperes

OM-198 683 Page 10

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

Duty Cycle is percentage of 10

minutes that gun can weld at

rated load without overheating.

Continuous Welding

SB1.1 8/93

Minutes

Definition .023 To .045 in (0.6 To 1.1 mm)

Hard Or Flux Cored Wires

100% Duty Cycle At 200 Amperes

Using CO

100% Duty Cycle At 150 Amperes

Using Mixed Gases

.023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires

60% Duty Cycle At 300 Amperes

Using CO

60% Duty Cycle At 200 Amperes

Using Mixed Gases

6 Minutes Welding 4 Minutes Resting

2-4. Volt-Ampere Curves

ssb1.1 10/91 – 196 844 / S-0700

1 Normal Volt-Ampere Curves

The volt-ampere curves show the

normal minimum and maximum

voltage and amperage output capa-

bilities of the welding power source.

Curves of other settings fall be-

tween the curves shown.

0 100 200 300 400

AMPERES

VOLTS

OM-198 683 Page 11

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 Hardware

5 Work Clamp

Route cable through clamp handle

and secure as shown.

Close door.

802 474-A

Tools Needed:

1/2, 3/4 in

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

against drive assembly (make sure

gun end does not touch drive rolls).

Tighten knob.

4 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

Close door.

Ref. 802 064-A

2-7. Connecting Olympic 30A Gun

The Olympic 30A welding gun connects directly to the 10-pin receptacle on the front of the welding power source – no

adapter required. NOTE: Two welding guns may be connected to the welding power source at the same time, but only

one welding gun may be in use at any one time. If the triggers of both welding guns are pulled at the same time, the weld

output and wirefeed motor are disabled.

OM-198 683 Page 12

2-8. Setting Gun Polarity For Wire Type

1 Polarity Changeover Label

Information

Always read and follow manufac-

ture’s recommended polarity.

3/4, 11/16 in

Ref. 190 821-A

Changing Polarity

Wire Drive

Assembly Lead

Work Clamp Lead

Positive Terminal

Shown as shipped – Electrode Positive (DCEP): For

solid steel, stainless steel, aluminum, or flux core with

gas wires (GMAW).

Negative Terminal

Electrode Negative (DCEN): Reverse lead connections

at terminals from that shown above for gasless flux core

wires (FCAW). Drive assembly becomes negative.

2-9. Installing Gas Supply

Ref. ST-148 265-B / ST-802 028

Tools Needed:

Obtain gas cylinder and chain to

running gear, wall, or other station-

ary support so cylinder cannot fall

and break off valve.

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 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect customer supplied gas

hose between regulator/flowmeter

gas hose connection, and fitting on

rear of welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic

feet per hour). Check wire man-

ufacturer’s recommended flow

rate.

8CO

Adapter (Customer Sup-

plied)

9 O-Ring (Customer Supplied)

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

1-1/8, 5/8 in

Gas

8 9

Argon Gas

OM-198 683 Page 13

2-10. Installing Wire Spool and Adjusting Hub Tension

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.

Tools Needed:

2-11. Positioning Jumper Links

802 476-A

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 Voltage Jumper Links

Move jumper links to match input

voltage.

Close and secure access door.

Tools Needed:

230 VOLTS

460 VOLTS

575 VOLTS

S-144 916-A

3/8 in

200 VOLTS

230 VOLTS

S-153 980

OM-198 683 Page 14

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

Circuit Breaker

, Time-Delay

60 50 30 25 20

Normal Operating

70 60 35 30 25

Min Input Conductor Size In AWG/Kcmil 8 8 12 12 14

Max Recommended Input Conductor Length In Feet (Meters)

(29)

127

(39)

156

(47)

206

(63)

209

(64)

Min Grounding Conductor Size In AWG/Kcmil 8 10 12 12 14

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

2-13. Selecting A Location And Connecting Input Power

1 Rating Label

Supply correct input power.

2 Plug (NEMA Type 6-50P)

3 Receptacle

(NEMA Type 6-50R)

Connect plug to receptacle.

4 Input And Grounding

Conductors

Connect directly to line disconnect

device if hard wiring is required.

5 Line Disconnect Device

See Section 2-12.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

802 477

L1L2

230 VAC, 1

18 in (457 mm) of

space for airflow

Y Do not move or operate unit

where it could tip.

Y Always connect

grounding conductor first.

= GND/PE

OM-198 683 Page 15

2-14. 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.

621

Tools Needed:

6 in

(150 mm)

. Hold wire tightly to keep it

from unraveling.

WOOD

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

Remove gun nozzle and contact tip. Turn On.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Ref. 802 064-A / S-0627-A

Tighten

. Use pressure indicator

scale to set a desired

drive roll pressure.

Pressure

Indicator

Scale

Tighten

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OM-198 683 Page 18

SECTION 3 – OPERATION

3-1. Controls

1 Voltage Control

Turn control clockwise to increase

voltage.

2 Wire Speed Control

Turn control clockwise to increase

wire feed speed.

3 Power Switch

4 Voltmeter

5 Wire Feed Speed Meter

198 653

OM-198 683 Page 19

3-2. Voltmeter And Wire Feed Speed Meter Operation

1 Voltmeter

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.

Welding Status

When either a MIG gun or spool gun

trigger is pressed and a welding arc

is established, the voltmeter

displays actual weld voltage. When

the gun trigger is released and

welding arc extinguished, the

voltmeter displays the last actual

voltage for 5 seconds and then

returns to preset voltage. If welding

resumes before unit displays

preset voltage, actual welding

voltage will appear on the voltmeter.

The wire feed speed meter always

displays preset wire feed speed

(IPM).

Gun Selection

The wire feed speed meter will

display preset wire feed speed

(IPM) for the appropriate gun

selection either MIG or spool gun.

To preset desired wire feed speed,

connect desired gun, press gun

trigger for one second, and release

trigger. The meter preset will be

retained by the meter board until a

different gun is connected and

preset is performed or the unit is

turned off and back on. The MIG

gun settings (not spool gun) are

always the default at initial power up

of the unit.

Error Message

If the rectifier thermostat opens, the

voltmeter will display (H – –) and the

wire feed speed meter will display

(– – –). During this overheated

condition, the unit is inoperative and

the meters retain their display until

the rectifier returns to normal

operating temperature.

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.

Remove drive roll and

carrier. Apply light coat

of oil or grease to drive

motor shaft.

4-2. Circuit Breaker CB1

1 Circuit Breaker CB1

If CB1 opens, wire feeding stops.

2 Circuit Breaker CB2

Overcurrent at pin D of receptacle

RC7 will cause CB2 to open.

3 Welding Gun

Check gun liner for blockage or

kinks.

4 Wire Drive Assembly

Check for jammed wire, binding

drive gear or misaligned drive rolls.

Allow cooling period and reset

breaker. Close door.

802 475-A / Ref. 800 797-C

4-3. Unit Overload

Thermostat TP1 in rectifier Z1 protects the unit from damage due to overheating. If TP1 opens, wait several minutes

before trying to weld.

OM-198 683 Page 21

4-4. Replacing Gun Contact Tip

Ref. 800 797-C

Y Turn Off power.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.

Remove nozzle.

Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

4-5. Changing Drive Roll and Wire Inlet Guide

1 Securing Screw

2 Inlet Wire Guide

Loosen screw. Slide tip as close to

drive rolls as possible without

touching. Tighten screw.

3 Anti-Wear Guide

Install guide as shown.

4 Drive Roll

Install correct drive roll for wire size

and type.

5 Drive Roll Securing Nut

Turn nut one click to secure drive

roll.

Tools Needed:

5/64 in

7/16 in

ST-150 227-D

OM-198 683 Page 22

4-6. Aligning Drive Rolls and Wire Guide

Y Turn 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 roll assembly.

Ref. ST-800 412-A

Correct Incorrect

Tools Needed:

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Hobart Welding Products IRONMAN 275 User manual

Brand: Hobart Welding Products

Model: IRONMAN 275

Category: Welding System

Type: User manual

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