Instruction/ maintenance manual of the product OM-198 683C Hobart Welding Products
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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.
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.
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 . . . . . . . . . . .
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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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 Cir.
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.
OM-198 683 Page 16 2-15. W eld Parameter.
OM-198 683 Page 17 196 843 VOL TAGE V V WIRE SPEED.
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.
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.
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.
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 .
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.
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.
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.
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).
OM-198 683 Page 26 Notes.
OM-198 683 Page 27 SECTION 5 – ELECTRICAL DIAGRAM 197 699-D Figure 5-1. Circuit Diagram.
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.
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 .
OM – 198 683 Page 30 802 060-C . Hardware is common and not available unless listed. Figure 6-2. Baffle, Center w/Components.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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).
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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.
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: Call1-800-3.
An important point after buying a device Hobart Welding Products OM-198 683C (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products OM-198 683C yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-198 683C - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-198 683C you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-198 683C will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-198 683C, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-198 683C.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-198 683C. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-198 683C along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
