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Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
IronMan 230
And H200L4-15 Gun
Hob_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read and follow these precautions.
WELDING can cause fire or explosion. D Wear approved ear protection if noise level is
high.
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 CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause Shielding gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is pressure. If damaged, a cylinder can explode. Since
safe before doing any welding. gas cylinders are normally part of the welding
process, be sure to treat them carefully.
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 Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Never weld on a pressurized cylinder − explosion will result.
cause fire on the hidden side. D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Do not weld on closed containers such as tanks, drums, or pipes, tings designed for the specific application; maintain them and
unless they are properly prepared according to AWS F4.1 (see associated parts in good condition.
Safety Standards). D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-235 281 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
LES RAYONS DE L’ARC peuvent D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des brûlures dans les
yeux et sur la peau. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
génère des rayons visibles et invisibles intense
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité). DES PIECES DE METAL ou DES
D Porter des lunettes de sécurité avec écrans latéraux même sous
SALETES peuvent provoquer des
votre casque. blessures dans les yeux.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
protéger les autres contre les rayonnements les éblouissements
fil de fer, et le meulage génèrent des étincelles et des particules
et les étincelles ; prévenir toute personne sur les lieux de ne pas métalliques volantes. Pendant la période de refroidissement des
regarder l’arc.
soudures, elles risquent de projeter du laitier.
D Porter des vêtements confectionnés avec des matières résistan- D Porter des lunettes de sécurité avec écrans latéraux ou un écran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
OM-235 281 Page 6
LES ACCUMULATIONS DE GAZ LES BOUTEILLES peuvent exploser
risquent de provoquer des blessures si elles sont endommagées.
ou même la mort.
Des bouteilles de gaz protecteur contiennent du gaz
D Fermer l’alimentation du gaz protecteur en cas sous haute pression. Si une bouteille est endom-
de non-utilisation. magée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
D Veiller toujours à bien aérer les espaces confi- soudage, les manipuler avec précaution.
nés ou se servir d’un respirateur d’adduction
d’air homologué. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) de se renverser.
peuvent affecter les implants médicaux.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester D Ne jamais placer une torche de soudage sur une bouteille à gaz.
à distance. D Une électrode de soudage ne doit jamais entrer en contact avec
D Les porteurs d’implants médicaux doivent consulter une bouteille.
leur médecin et le fabricant du dispositif avant de s’approcher D Ne jamais souder une bouteille pressurisée − risque d’explosion.
de la zone où se déroule du soudage à l’arc, du soudage
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
par points, du gougeage, de la découpe plasma
tuyaux et raccords convenables pour cette application spécifique ;
ou une opération de chauffage par induction.
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
LE BRUIT peut endommager l’ouïe. la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffi-
Le bruit des processus et des équipements peut samment de personnes pour soulever et déplacer les bouteilles.
affecter l’ouïe.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
D Porter des protections approuvées pour les l’équipement connexe et le dépliant P-1 de la CGA (Compressed
oreilles si le niveau sonore est trop élevé. Gas Association) mentionné dans les principales normes de sécu-
rité.
3-1. Specifications
Amps Input at Rated Output, 60 Hz, Single-Phase
Max. Open
Rated Output Circuit Voltage 200 V 230 V KVA KW
* While idling
No Load
Wire Feed
Wire Type and Diameter Speed Dimensions Weight
100
50
30 40 50 60 70 80 90 100
% DUTY CYCLE
60%dutycycle
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 227 953-A
40.0
35.0
30.0
25.0
Voltage
20.0
15.0
10.0
5.0
0.0
0 50 100 150 200 250 300
Amperage
4
2
1 2 3
Do not place
anything between
Tools Needed: weld cable terminal
and copper bar.
3/4 in. (19 mm)
803 778-A
Correct Installation Incorrect Installation
! Turn off power before connecting to 1 Weld Output Terminal output terminal and secure with nut so that
weld output terminals. 2 Supplied Weld Output Terminal Nut weld cable terminal is tight against copper
3 Weld Cable Terminal bar. Do not place anything between weld
! Failure to properly connect weld cable terminal and copper bar. Make
cables may cause excessive heat 4 Copper Bar
sure that the surfaces of the weld cable
and start a fire, or damage your Remove supplied nut from weld output ter- terminal and copper bar are clean.
machine. minal. Slide weld cable terminal onto weld
Tools Needed:
1/2, 3/4 in.
Ref. 242 145-A
Changing Polarity
+ Positive Terminal
Work Clamp Lead
− Negative Terminal
Tools Needed:
3/4 in.
Ref. 242 145-A
242 146-A
242 147-A
242 148-A
Rear Panel
Tools Needed:
1-1/8, 5/8 in.
242 687-A
S-153 980
2
1
Tools Needed:
3/8 in.
242 688-A
60 Hz Single
Phase
Input Voltage (V) 200 230
Input Amperes (A) At Rated Output 37.0 32.5
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 45 40
Normal Operating Fuses 3 60 50
Min Input Conductor Size In AWG 4 10 10
77 102
Max Recommended Input Conductor Length In Feet (Meters)
(23) (31)
Min Grounding Conductor Size In AWG 4 10 10
8
L1
5 4
L2
1 2
L2 L1
230 VAC, 1
! Installation must meet all National 4 Plug (NEMA Type 6-50P) 11 Disconnect Device Line Terminals
and Local Codes − have only quali- 5 Receptacle NEMA Type 6-50R) Connect green or green/yellow grounding
fied persons make this installation. conductor to disconnect device grounding
Connect plug to receptacle.
! Special installation may be terminal first.
required where gasoline or volatile 6 Input Power Cord. Connect input conductors L1 and L2 to dis-
liquids are present − see NEC Ar- connect device line terminals.
7 Black And White Input Conductor (L1
ticle 511 or CEC Section 20.
And L2) 12 Over-Current Protection
! Disconnect and lockout/tagout in-
8 Green Or Green/Yellow Grounding
put power before connecting input Select type and size of over-current
Conductor protection using Section 3-13 (fused dis-
conductors from unit.
9 Disconnect Device (switch shown in connect switch shown).
! Always connect green or green/yel-
the OFF position)
low conductor to supply grounding Close and secure door on disconnect
terminal first, and never to a line 10 Disconnect Device Grounding device. Remove lockout/tagout device,
terminal. Terminal and place switch in the On position.
Tools Needed:
1 2 3 5 6
6 in.
(150 mm)
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
ON
ON
OFF
POWER
Close and tighten pressure Lay gun cable out straight and Turn power ON.
assembly, and let go of wire. remove gun nozzle and contact tip.
Tighten
WOOD
Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire approximately 5/16 in.
comes out of gun. Reinstall Tighten knob enough to prevent slipping. (8 mm) from contact tip. Close door.
contact tip and nozzle
242 692-A
4-1. Controls
1 Wire Speed Control
Control varies the rate of wire being
fed through the welding gun.
2 Voltage Control
Control varies the voltage level of
the welding arc. The voltage range
is 1 (minimum) to 12 (maximum).
3 Power Switch
The fan is thermostatically
controlled and only runs when
cooling is needed.
ÇÇÇÇÇ
4 Power Light
5 Gun Trigger Receptacle
ÇÇÇÇÇ
50
40 60 1
ÇÇÇÇÇ
30 70
ÇÇÇÇÇ
20 80
ÇÇÇÇÇ
10 90
0 100
WIRE FEED
6
5 7 2
4 8
3 9
2 10
1 12
DO NOT SWITCH
WHILE WELDING
VOLTAGE
POWER
ON
3
OFF
OFF
POWER
TRIGGER
5
.024” ( 0.6mm ) 1 / 22 2 / 26 3 / 34 3 / 40 4 / 40 5 / 50 6 / 70 7 / 70 8 / 74 9 / 90
4-2. Weld Parameters
Every
3
Months
l Damaged Or Unreadable l Cracked Parts n l Cables n ~ Tighten Weld
Labels Terminal
OR
Every
6
Months ~ Inside Unit n Remove drive roll
and apply light coat
of oil or grease to
drive motor shaft
242 533-A
242 693-A
Tools Needed:
Tools Needed:
Tools Needed:
Remove nozzle,
contact tip, and
adapter.
Unscrew and
remove liner.
Reassemble gun in
reverse order from
taking it apart.
Install
Liner
3/4 in.
(20 mm)
Liner
Stickout
Tools Needed:
No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 3-15).
Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 5-2).
Replace building line fuse or reset circuit breaker if open (see Section 3-15).
Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Sections 3-4 and/or
Parts List).
Thermostat open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (see
Section 3-2).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-15).
Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-3, 5-6 and/or 5-8).
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section 5-8).
welding or wire feeding intermittently.
Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 5-2).
Clean or replace wire inlet guide or liner if dirty or plugged (see Sections 5-3 and/or 5-8).
Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 3-4 and/or
see Parts List).
Check and clear any restrictions at drive assembly and liner (see Section 5-8).
mig1 2009−12
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gun
Shielding Gas
Gas
Workpiece
Work Clamp
0°-15°
90° 90°
GROOVE WELDS
45° 0°-15°
45°
10°
Push
10°
Perpendicular Drag
S-0054-A
2 3 4
5
S-0053-A
5
S-0052-B
S-0636
Wire feed speed too high. Select lower wire feed speed.
Electrode extension (stickout) too long. Use shorter electrode extension (stickout).
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0635
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.
S-0637
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
S-0640
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
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
Argon X
Argon + 25% CO2 X
80% or greater Argon +
X X1
balance CO2 or Oxygen
100% CO2 X
Tri-Mix2 X
1 Limited short circuiting use
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.
240 907-A
11
15
14
12
13
8
7
10 − Fig. 8-3
6
9 − Fig. 8-2
16
21
23
24
22
5
17 − Fig. 8-4
19
18
20
4
21
3
1
2
242 214-A
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
1
9
2
3
4 10
5
6 17
7 18
8
23 19
24 12
11
13
16 20
25
26 15
27 14
21
22
242 215-A
9
4
10
242 510-A
4
5
11
6
7
8
12
10
9
242 216-A
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
11
22
12
5 14
10 8
3
4 9
21
1
15
16
17
20
18 19
7 6
13 242 526-A
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-235 281 Page 48
1
2
3
4
5
6
16
15
14
13
12
11
10
242 630-A
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
♦OPTIONAL
Distributor
Address
Resources Available
Always provide Model Name and Serial/Style Number.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.