Hobart Welding Products 250 installation instructions

Includes Installation Instructions For

Optional Spoolmate Spoolgun Switch

IronMan 250And M-25 Gun

Processes

OM-192 440W 2006−10

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)

Welding

Description

Arc Welding Power Source and Wire

Feeder

™

File: MIG (GMAW)

Contents

Main Includes Installation Instructions For Optional Spoolmate Spoolgun Switch IronMan 250 And M-25 Gun From Hobart to You Page TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. FLYING METAL can injure eyes. BUILDUP OF GAS can injure or kill. HOT PARTS can cause severe burns. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING STATIC (ESD) can damage PC boards. 1-5. Principal Safety Standards 1-6. EMF Information SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Symboles utiliss . 2-2. Dangers relatifs au soudage la rc UNE DCHARGE LECTRIQUE peut entraner la mort. LES RAYONS DARC peuvent entra- ner des brlures aux yeux et la peau. LE SOUDAGE peut provoquer un incendie ou une explosion. DES PARTICULES VOLANTES peuvent blesser les yeux. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort. DES PICES CHAUDES peuvent provoquer des brlures graves. 2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance Risque DINCENDIE OU DEXPLO- SION. LA CHUTE DE LAPPAREIL peut blesser. LEMPLOI EXCESSIF peut SUR- CHAUFFER LQUIPEMENT. LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims. 2-5. Principales normes de scurit 2-6. Information EMF SECTION 3 INTRODUCTION 3-1. Specifications 3-2. Welding Power Source Duty Cycle And Overheating A or V 3-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. 3-4. Volt-Ampere Curves 3-5. Installing Welding Gun 3-6. Connecting To Weld Output Terminals 3-7. Installing Work Clamp 3-8. Setting Gun Polarity For Wire Type 3-9. Installing Wire Spool And Adjusting Hub Tension 3-10. Installing Gas Supply . 3-11. Positioning Jumper Links 3-12. Electrical Service Guide 3-13. Selecting A Location And Connecting Input Power 1 3-14. Threading Welding Wire . 3-15. Installing Optional Spool Gun Switch In Welding Power Source 3-16. Connecting Spool Gun To Welding Power Source SECTION 4 OPERATION 4-1. Controls 4-2. Weld Parameters Selecting Wire, Gas and Control Settings What Material are You Welding? Suggested Wire Types Suggested Shielding Gases and Flow Rate Wire Sizes (Diameter) Changing Polarity M25Consumables DriveRolls Example 2/40 = A B C D E F G H SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance 3 Months 6 Months 5-2. Supplementary Protectors 5-3. Replacing Drive Roll And Wire Inlet Guide 5-4. Removing Knob From Front Panel 5-5. Replacing Gun Contact Tip 5-6. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing . 5-7. Replacing Switch And/Or Head Tube 5-8. Welding Troubleshooting Table 5-9. Wire Drive/Gun Troubleshooting Table 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 6-4. Conditions That Affect Weld Bead Shape 6-5. Gun Movement During Welding 6-6. Poor Weld Bead Characteristics 6-7. Good Weld Bead Characteristics 6-8. Troubleshooting Excessive Spatter 6-9. Troubleshooting Porosity 6-10. Troubleshooting Excessive Penetration 6-11. Troubleshooting Lack Of Penetration 6-12. Troubleshooting Incomplete Fusion 6-13. Troubleshooting Burn-Through 6-14. Troubleshooting Waviness Of Bead 6-15. Troubleshooting Distortion 6-16. Common MIG Shielding Gases 6-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Page Page Page SECTION 8 PARTS LIST Figure 8-1. Main Assembly Page Figure 8-2. Center Baffle w/Components Page Page Page Page Page Page Warranty Questions? Call 1-800-332-3281 7 AM 6 PM EST Effective January 1, 2006 * Original Main Power Rectifiers * Transformers * Stabilizers * Reactors Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record Protect Your Investment! Register your product at: HobartWelders.com