IRONMAN240

OM-284833D 2022-05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And Wire

Feeder
IronMan 240
™
www.HobartWelders.com OWNER’S MANUAL

From Hobart to You
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
From Miller t
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 the exact part you may
need to fix the problem. Warranty and service information for your
particular model are also provided.
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
specification sheets. To locate your nearest
distributor or service agency call
1-800-332-3281, or visit us at
www.HobartWelders.com on the web.
For Technical Help call 1-800-332-3281.
Register your product at www.HobartWelders.com

Hobart is registered to the ISO
9001 Quality System
Standard.
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 Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 7
2-4 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-6 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2 Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2 Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3 Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4 Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1 Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2 Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3 Connecting Weld Output Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4 Installing Work Cable And Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5 Connecting MIG Gun/Spool Gun to IronMan 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6 Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7 Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8 Installing Wire Spool And Adjusting Hub Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-9 Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-10 Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-11 Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-12 Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-13 Weld Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-2 Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-3 Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-4 Aligning Drive Rolls and Wire Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-5 Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-6 Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 – GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-17 Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-1 Drive Roll And Wire Guide Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
This group of symbols means Warning! Watch Out! ELECTRIC
could result in death or serious injury. The possible haz-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
ards are shown in the adjoining symbols or explained in
symbols and related instructions below for necessary actions to
the text.
avoid these hazards.
NOTICE – Indicates statements not related to personal injury.
� Indicates special instructions.

1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual (stick) welder, or 3) an AC welder with reduced open-circuit volt-
to call attention to and identify possible hazards. When you age. In most situations, use of a DC, constant voltage wire welder
see the symbol, watch out, and follow the related instruc- is recommended. And, do not work alone!
tions to avoid the hazard. The safety information given be-
low is only a summary of the more complete safety � Disconnect input power or stop engine before installing or servic-
information found in the Principal Safety Standards. Read ing this equipment. Lockout/tagout input power according to
and follow all Safety Standards. OSHA 29 CFR 1910.147 (see Safety Standards).
Only qualified persons should install, operate, maintain, � Properly install, ground, and operate this equipment according to
and repair this equipment. A qualified person is defined as its Owner’s Manual and national, state, and local codes.
one who, by possession of a recognized degree, certificate, � Always verify the supply ground — check and be sure that input
or professional standing, or who by extensive knowledge, power cord ground wire is properly connected to ground terminal
training and experience, has successfully demonstrated the in disconnect box or that cord plug is connected to a properly
ability to solve or resolve problems relating to the subject
grounded receptacle outlet.
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved. � When making input connections, attach proper grounding conduc-
During operation, keep everybody, especially children, tor first—double-check connections.
away. � Keep cords dry, free of oil and grease, and protected from hot met-
al and sparks.
ELECTRIC SHOCK can kill. � Frequently inspect input power cord and ground conductor for
damage or bare wiring — replace immediately if damaged — bare
Touching live electrical parts can cause fatal wiring can kill.
shocks or severe burns. The electrode and work
� Turn off all equipment when not in use.
circuit is electrically live whenever the output is on.
The input power circuit and machine internal cir- � Do not use worn, damaged, undersized, or repaired cables.
cuits are also live when power is on. In semiautomatic or automatic � Do not drape cables over your body.
wire welding, the wire, wire reel, drive roll housing, and all metal parts � If earth grounding of the workpiece is required, ground it directly
touching the welding wire are electrically live. Incorrectly installed or with a separate cable.
improperly grounded equipment is a hazard. � Do not touch electrode if you are in contact with the work, ground,
� Do not touch live electrical parts. or another electrode from a different machine.
� Wear dry, hole-free insulating gloves and body protection. � Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
� Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work � Do not touch electrode holders connected to two welding ma-
or ground. chines at the same time since double open-circuit voltage will be
present.
� Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling. � Wear a safety harness if working above floor level.
� Use AC output ONLY if required for the welding process. � Keep all panels and covers securely in place.
� If AC output is required, use remote output control if present on � Clamp work cable with good metal-to-metal contact to workpiece
unit. or worktable as near the weld as practical.
� Additional safety precautions are required when any of the follow- � Insulate work clamp when not connected to workpiece to prevent
ing electrically hazardous conditions are present: in damp loca- contact with any metal object.
tions or while wearing wet clothing; on metal structures such as � Do not connect more than one electrode or work cable to any sin-
floors, gratings, or scaffolds; when in cramped positions such as gle weld output terminal. Disconnect cable for process not in use.
sitting, kneeling, or lying; or when there is a high risk of unavoid- � Use GFCI protection when operating auxiliary equipment in damp
able or accidental contact with the workpiece or ground. For these or wet locations.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
OM-284833 Page 1
HOT PARTS can burn. WELDING can cause fire or
� Do not touch hot parts bare handed. explosion.
� Allow cooling period before working on equipment. Welding on closed containers, such as tanks,
� To handle hot parts, use proper tools and/or wear drums, or pipes, can cause them to blow up.
heavy, insulated welding gloves and clothing to Sparks can fly off from the welding arc. The flying
prevent burns. sparks, hot workpiece, and hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, ex-
plosion, overheating, or fire. Check and be sure the area is safe be-
FLYING METAL OR DIRT can injure fore doing any welding.
eyes.
� Remove all flammables within 35 ft (10.7 m) of the welding arc. If
� Welding, chipping, wire brushing, and grinding this is not possible, tightly cover them with approved covers.
cause sparks and flying metal. As welds cool, they
can throw off slag. � Do not weld where flying sparks can strike flammable material.
� Wear approved safety glasses with side shields even under your � Protect yourself and others from flying sparks and hot metal.
welding helmet.
� Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
FUMES AND GASES can be
� Watch for fire, and keep a fire extinguisher nearby.
hazardous.
� Be aware that welding on a ceiling, floor, bulkhead, or partition can
Welding produces fumes and gases. Breathing cause fire on the hidden side.
these fumes and gases can be hazardous to your
� Do not cut or weld on tire rims or wheels. Tires can explode if
health.
heated. Repaired rims and wheels can fail. See OSHA 29 CFR
� Keep your head out of the fumes. Do not breathe the fumes. 1910.177 listed in Safety Standards.
� Ventilate the work area and/or use local forced ventilation at the � Do not weld on containers that have held combustibles, or on
arc to remove welding fumes and gases. The recommended way closed containers such as tanks, drums, or pipes unless they are
to determine adequate ventilation is to sample for the composition properly prepared according to AWS F4.1 (see Safety Standards).
and quantity of fumes and gases to which personnel are exposed. � Do not weld where the atmosphere can contain flammable dust,
� If ventilation is poor, wear an approved air-supplied respirator. gas, or liquid vapors (such as gasoline).
� Read and understand the Safety Data Sheets (SDSs) and the � Connect work cable to the work as close to the welding area as
manufacturer’s instructions for adhesives, coatings, cleaners, con- practical to prevent welding current from traveling long, possibly
sumables, coolants, degreasers, fluxes, and metals. unknown paths and causing electric shock, sparks, and fire
� Work in a confined space only if it is well ventilated, or while wear- hazards.
ing an air-supplied respirator. Always have a trained watchperson
� Do not use welder to thaw frozen pipes.
nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is � Remove stick electrode from holder or cut off welding wire at con-
safe. tact tip when not in use.
� Do not weld in locations near degreasing, cleaning, or spraying � Wear body protection made from leather or flame-resistant cloth-
operations. The heat and rays of the arc can react with vapors to ing (FRC). Body protection includes oil-free clothing such as leath-
form highly toxic and irritating gases. er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
� Do not weld on coated metals, such as galvanized, lead, or cadmi- � Remove any combustibles, such as a butane lighter or matches,
um plated steel, unless the coating is removed from the weld area, from your person before doing any welding.
the area is well ventilated, and while wearing an air-supplied respi-
rator. The coatings and any metals containing these elements can � After completion of work, inspect area to ensure it is free of sparks,
give off toxic fumes if welded. glowing embers, and flames.
� Use only correct fuses or circuit breakers. Do not oversize or by-
BUILDUP OF GAS can injure or kill. pass them.
� Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
� Shut off compressed gas supply when not in use. for hot work and have a fire watcher and extinguisher nearby.
� Always ventilate confined spaces or use approved � Read and understand the Safety Data Sheets (SDSs) and the
air-supplied respirator. manufacturer’s instructions for adhesives, coatings, cleaners, con-
sumables, coolants, degreasers, fluxes, and metals.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense NOISE can damage hearing.
visible and invisible (ultraviolet and infrared) rays
Noise from some processes or equipment can
that can burn eyes and skin. Sparks fly off from the
damage hearing.
weld.
� Wear an approved welding helmet fitted with a proper shade of fil- � Wear approved ear protection if noise level is high.
ter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in ELECTRIC AND MAGNETIC FIELDS
Safety Standards). (EMF) can affect Implanted Medical
� Wear approved safety glasses with side shields under your Devices.
helmet.
� Use protective screens or barriers to protect others from flash, � Wearers of Pacemakers and other Implanted Med-
glare, and sparks; warn others not to watch the arc. ical Devices should keep away.
� Wear body protection made from leather or flame-resistant cloth- � Implanted Medical Device wearers should consult their doctor and
ing (FRC). Body protection includes oil-free clothing such as leath- the device manufacturer before going near arc welding, spot weld-
er gloves, heavy shirt, cuffless trousers, high shoes, and a cap. ing, gouging, plasma arc cutting, or induction heating operations.
OM-284833 Page 2
� Never weld on a pressurized cylinder—explosion will result.
CYLINDERS can explode if
damaged. � Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
Compressed gas cylinders contain gas under high and associated parts in good condition.
pressure. If damaged, a cylinder can explode. � Turn face away from valve outlet when opening cylinder valve. Do
Since gas cylinders are normally part of the weld- not stand in front of or behind the regulator when opening the
ing process, be sure to treat them carefully. valve.
� Protect compressed gas cylinders from excessive heat, mechani- � Keep protective cap in place over valve except when cylinder is in
cal shocks, physical damage, slag, open flames, sparks, and arcs. use or connected for use.
� Install cylinders in an upright position by securing to a stationary � Use the proper equipment, correct procedures, and sufficient
support or cylinder rack to prevent falling or tipping. number of persons to lift, move, and transport cylinders.
� Keep cylinders away from any welding or other electrical circuits. � Read and follow instructions on compressed gas cylinders, asso-
� Never drape a welding torch over a gas cylinder. ciated equipment, and Compressed Gas Association (CGA) publi-
� Never allow a welding electrode to touch any cylinder. cation P-1 listed in Safety Standards.
1-3. Additional Hazards For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. WELDING WIRE can injure.

� Do not install or place unit on, over, or near com- � Do not press gun trigger until instructed to do so.
bustible surfaces.
� Do not point gun toward any part of the body, other
� Do not install unit near flammables.
people, or any metal when threading welding wire.
� Do not overload building wiring — be sure power
supply system is properly sized, rated, and protected to handle
this unit. BATTERY EXPLOSION can injure.
� Do not use welder to charge batteries or jump start
FALLING EQUIPMENT can injure.
vehicles unless it has a battery charging feature
� Use lifting eye to lift unit only, NOT running gear, designed for this purpose.
gas cylinders, or any other accessories.
� Use correct procedures and equipment of ad-
MOVING PARTS can injure.
equate capacity to lift and support unit.
� If using lift forks to move unit, be sure forks are long enough to ex- � Keep away from moving parts such as fans.
tend beyond opposite side of unit. � Keep all doors, panels, covers, and guards closed
� Keep equipment (cables and cords) away from moving vehicles and securely in place.
when working from an aerial location. � Have only qualified persons remove doors, panels,
� Follow the guidelines in the Applications Manual for the Revised covers, or guards for maintenance and troubleshooting as
NIOSH Lifting Equation (Publication No. 94-110) when manually necessary.
lifting heavy parts or equipment.
� Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
OVERUSE can cause
OVERHEATING. READ INSTRUCTIONS.
� Allow cooling period; follow rated duty cycle. � Read and follow all labels and the Owner’s Manual
� Reduce current or reduce duty cycle before start- carefully before installing, operating, or servicing
ing to weld again. unit. Read the safety information at the beginning
� Do not block or filter airflow to unit. of the manual and in each section.
� Use only genuine replacement parts from the manufacturer.
FLYING SPARKS can injure. � Perform installation, maintenance, and service according to the
� Wear a face shield to protect eyes and face. Owner’s Manuals, industry standards, and national, state, and lo-
cal codes.
� Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection. H.F. RADIATION can cause
� Sparks can cause fires—keep flammables away. interference.
� High-frequency (H.F.) can interfere with radio navi-
STATIC (ESD) can damage PC gation, safety services, computers, and communi-
boards. cations equipment.
� Put on grounded wrist strap BEFORE handling � Have only qualified persons familiar with electronic equipment per-
boards or parts. form this installation.
� Use proper static-proof bags and boxes to store, � The user is responsible for having a qualified electrician promptly
move, or ship PC boards. correct any interference problem resulting from the installation.
� If notified by the FCC about interference, stop using the equipment
MOVING PARTS can injure. at once.
� Have the installation regularly checked and maintained.
� Keep away from moving parts. � Keep high-frequency source doors and panels tightly shut, keep
� Keep away from pinch points such as drive rolls. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
OM-284833 Page 3
� To reduce possible interference, keep weld cables as short as
ARC WELDING can cause possible, close together, and down low, such as on the floor.
interference. � Locate welding operation 100 meters from any sensitive electronic
� Electromagnetic energy can interfere with sensitive equipment.
electronic equipment such as microprocessors, � Be sure this welding machine is installed and grounded according
computers, and computer-driven equipment such to this manual.
as robots. � If interference still occurs, the user must take extra measures such
� Be sure all equipment in the welding area is electromagnetically as moving the welding machine, using shielded cables, using line
compatible. filters, or shielding the work area.
1-4. California Proposition 65 Warnings

WARNING – This product can expose you to chemicals in- For more information, go to www.P65Warnings.ca.gov.
cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Standard for Fire Prevention During Welding, Cutting, and Other Hot
Society standard ANSI Standard Z49.1. Website: http://www.aws.org. Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
Safe Practice For Occupational And Educational Eye And Face Pro-
tection, ANSI Standard Z87.1, from American National Standards In- OSHA, Occupational Safety and Health Standards for General Indus-
stitute. Website: www.ansi.org. try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-
part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
Safe Practices for the Preparation of Containers and Piping for Weld- www.osha.gov.
ing and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org. OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
National Electrical Code, NFPA Standard 70 from National Fire Pro-
tection Association. Website: www.nfpa.org. Applications Manual for the Revised NIOSH Lifting Equation from the
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P- National Institute for Occupational Safety and Health (NIOSH). Web-
1 from Compressed Gas Association. Website: www.cganet.com. site: www.cdc.gov/NIOSH.
Safety in Welding, Cutting, and Allied Processes, CSA Standard SOM 2022–01
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
1-6. EMF Information

Electric current flowing through any conductor causes localized elec- 4. Keep head and trunk as far away from the equipment in the weld-
tric and magnetic fields (EMF). The current from arc welding (and al- ing circuit as possible.
lied processes including spot welding, gouging, plasma arc cutting,
5. Connect work clamp to workpiece as close to the weld as
and induction heating operations) creates an EMF field around the
possible.
welding circuit. EMF fields can interfere with some medical implants,
e. g. pacemakers. Protective measures for persons wearing medical 6. Do not work next to, sit or lean on the welding power source.
implants have to be taken. For example, restrict access for passers 7. Do not weld whilst carrying the welding power source or wire
−by or conduct individual risk assessment for welders. All welders feeder.
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit: About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a Implanted Medical Device wearers should consult their doctor and the
cable cover. device manufacturer before performing or going near arc welding,
2. Do not place your body between welding cables. Arrange cables spot welding, gouging, plasma arc cutting, or induction heating opera-
to one side and away from the operator. tions. If cleared by your doctor, then following the above procedures
3. Do not coil or drape cables around your body. is recommended.
OM-284833 Page 4
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés

DANGER! – Indique une situation dangereuse qui si on l’é-
vite 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 Ce groupe de symboles veut dire Avertissement! Attention! DAN-
donner la mort ou des blessures graves. Les dangers pos- GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE-
sibles sont montrés par les symboles joints ou sont expli- CES CHAUDES. Reportez-vous aux symboles et aux directives ci-
qués dans le texte. dessous afin de connaître les mesures à prendre pour éviter tout
AVIS – Indique des déclarations pas en relation avec des blessures danger.
personnelles.
� Indique des instructions spécifiques.

2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce métalliques telles que sols, grilles ou échafaudages ; en position
manuel pour attirer l’attention et identifier les dangers pos- coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
sibles. En présence de ce symbole, prendre garde et suivre élevé de contact inévitable ou accidentel avec la pièce à souder
les instructions afférentes pour éviter tout risque. Les ou le sol. Dans ces conditions, utiliser les équipements suivants,
consignes de sécurité présentées ci-après ne font que résu- dans l’ordre indiqué : 1) un poste à souder DC à tension constante
mer l’information contenue dans les Normes de sécurité
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste
principales. Lire et suivre toutes les Normes de sécurité.
à souder AC à tension à vide réduite. Dans la plupart des situ-
L’installation, l’utilisation, l’entretien et les réparations ne ations, l’utilisation d’un poste à souder DC à fil à tension constante
doivent être confiés qu’à des personnes qualifiées. Une per-
est recommandée. En outre, ne pas travailler seul !
sonne qualifiée est définie comme celle qui, par la posses-
sion d’un diplôme reconnu, d’un certificat ou d’un statut � Couper l’alimentation ou arrêter le moteur avant de procéder
professionnel, ou qui, par une connaissance, une formation à l’installation, à la réparation ou à l’entretien de l’appareil. Déver-
et une expérience approfondies, a démontré avec succès sa rouiller l’alimentation selon la norme OSHA 29 CFR 1910.147
capacité à résoudre les problèmes liés à la tâche, le travail (voir normes de sécurité).
ou le projet et a reçu une formation en sécurité afin de re-
� Brancher correctement la mise à la terre et utiliser cet appareil
connaître et d’éviter les risques inhérents.
conformément à son manuel d’utilisateur et aux codes nationaux,
Au cours de l’utilisation, tenir toute personne à l’écart et provinciaux et municipaux.
plus particulièrement les enfants.
� Toujours vérifier la mise à la terre — vérifier et assurez-vous que
le conducteur de mise à la terre du cordon d’alimentation est bien
UNE DÉCHARGE ÉLECTRIQUE peut raccordé à la borne de mise à la terre dans le boîtier de déconne-
entraîner la mort. xion ou que la fiche du cordon est raccordée à une prise correcte-
Le contact d’organes électriques sous tension peut ment mise à la terre.
provoquer des accidents mortels ou des brûlures � En effectuant les raccordements d’entrée, fixer d’abord le conduc-
graves. Le circuit de l’électrode et de la pièce est teur de mise à la terre approprié et contre-vérifier les connexions.
sous tension lorsque le courant est délivré à la sortie. Le circuit d’ali- � Les câbles doivent être exempts d’humidité, d’huile et de graisse;
mentation et les circuits internes de la machine sont également sous protégez-les contre les étincelles et les pièces métalliques
tension lorsque l’alimentation est sur Marche. Dans le mode de sou- chaudes.
dage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau � Vérifier fréquemment le cordon d’alimentation et le conducteur de
et toutes les parties métalliques en contact avec le fil sont sous ten- mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -,
sion électrique. Un équipement installé ou mis à la terre de manière le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraî-
incorrecte ou impropre constitue un danger. ner la mort.
� Ne pas toucher aux pièces électriques sous tension. � L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
� Porter des gants isolants et des vêtements de protection secs et � Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sans trous. sante ou mal épissés.
� S’isoler de la pièce à couper et du sol en utilisant des housses ou � Ne pas enrouler les câbles autour du corps.
des tapis assez grands afin d’éviter tout contact physique avec la � Si la pièce soudée doit être mise à la terre, le faire directement
pièce à couper ou le sol. avec un câble distinct.
� Ne pas utiliser de sortie de soudage CA dans des zones humides � Ne pas toucher l’électrode quand on est en contact avec la pièce,
ou confinées ou s’il y a un risque de chute. la terre ou une électrode provenant d’une autre machine.
� Se servir d’une source électrique à courant électrique UNIQUE- � Ne pas toucher des porte électrodes connectés à deux machines
MENT si le procédé de soudage le demande. en même temps à cause de la présence d’une tension à vide
� Si l’utilisation d’une source électrique à courant électrique s’avère doublée.
nécessaire, se servir de la fonction de télécommande si l’appareil � N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
en est équipé. champ les pièces endommagées. Entretenir l’appareil conformé-
� D’autres consignes de sécurité sont nécessaires dans les condi- ment à ce manuel.
tions suivantes : risques électriques dans un environnement hu- � Porter un harnais de sécurité si l’on doit travailler au-dessus du
mide ou si l’on porte des vêtements mouillés ; sur des structures sol.
OM-284833 Page 5
� S’assurer que tous les panneaux et couvercles sont correctement
en place.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
� Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près ou même la mort.
possible de la soudure. � Fermer l’alimentation du gaz comprimé en cas de
� Isoler la pince de masse quand pas mis à la pièce pour éviter le non utilisation.
contact avec tout objet métallique. � Veiller toujours à bien aérer les espaces confinés ou se servir d’un
� Ne pas raccorder plus d’une électrode ou plus d’un câble de respirateur d’adduction d’air homologué.
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé. LES RAYONS DE L’ARC peuvent
� Utiliser une protection différentielle lors de l’utilisation d’un équipe- provoquer des brûlures dans les
ment auxiliaire dans des endroits humides ou mouillés. yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
LES PIÈCES CHAUDES peuvent génère des rayons visibles et invisibles intenses
provoquer des brûlures. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
� Ne pas toucher des parties chaudes à mains nues.
soudage.
� Prévoir une période de refroidissement avant de
travailler à l’équipement. � Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage (voir
� Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures. � Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
DES PIECES DE METAL ou DES � Avoir recours à des écrans protecteurs ou à des rideaux pour pro-
téger les autres contre les rayonnements les éblouissements et
SALETES peuvent provoquer des les étincelles ; prévenir toute personne sur les lieux de ne pas re-
blessures dans les yeux. garder l’arc.
� Le soudage, l’écaillement, le passage de la pièce � Porter une protection corporelle en cuir ou des vêtements ignifu-
à la brosse en fil de fer, et le meulage génèrent ges (FRC). La protection du corps comporte des vêtements sans
des étincelles et des particules métalliques volantes. Pendant la huile, comme des gants de cuir, une chemise solide, des panta-
période de refroidissement des soudures, elles risquent de proje- lons sans revers, des chaussures hautes et une casquette.
ter du laitier.
� Porter des lunettes de sécurité avec écrans latéraux ou un écran LE SOUDAGE peut provoquer un
facial. incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés
LES FUMÉES ET LES GAZ peuvent tels que des réservoirs, tambours ou des conduites
être dangereux. peut provoquer leur éclatement. Des étincelles
peuvent être projetées de l’arc de soudure. La projection d’étincelles,
Le soudage génère des fumées et des gaz. Leur des pièces chaudes et des équipements chauds peut provoquer des
inhalation peut être dangereux pour votre santé. incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
� Eloigner votre tête des fumées. Ne pas respirer les fumées. un surchauffement ou un incendie. Avant de commencer le soudage,
� À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au vérifier et s’assurer que l’endroit ne présente pas de danger.
niveau de l’arc pour l’évacuation des fumées et des gaz de sou-
dage. Pour déterminer la bonne ventilation, il est recommandé de � Déplacer toutes les substances inflammables à une distance de
procéder à un prélèvement pour la composition et la quantité de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
fumées et de gaz auxquelles est exposé le personnel. soigneusement avec des protections homologués.
� Si la ventilation est médiocre, porter un respirateur anti-vapeurs � Ne pas souder dans un endroit là où des étincelles peuvent tom-
approuvé. ber sur des substances inflammables.
� Se protéger et d’autres personnes de la projection d’étincelles et
� Lire et comprendre les fiches de données de sécurité et les ins-
de métal chaud.
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse- � Des étincelles et des matériaux chauds du soudage peuvent faci-
ment, les dégraisseurs, les flux et les métaux. lement passer dans d’autres zones en traversant de petites fissu-
res et des ouvertures.
� Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours � Surveiller tout déclenchement d’incendie et tenir un extincteur à
à un surveillant dûment formé de se tenir à proximité. Des fumées proximité.
et des gaz de soudage peuvent déplacer l’air et abaisser le niveau � Le soudage effectué sur un plafond, plancher, paroi ou séparation
d’oxygène provoquant des blessures ou des accidents mortels. peut déclencher un incendie de l’autre côté.
S’assurer que l’air de respiration ne présente aucun danger. � Ne pas couper ou souder des jantes ou des roues. Les pneus peu-
� Ne pas souder dans des endroits situés à proximité d’opérations vent exploser s’ils sont chauffés. Les jantes et les roues réparées
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les
les rayons de l’arc peuvent réagir en présence de vapeurs et for- normes de sécurité.
mer des gaz hautement toxiques et irritants. � Ne pas effectuer le soudage sur des conteneurs fermés tels que
� Ne pas souder des métaux munis d’un revêtement, tels que l’acier des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- préparés correctement conformément à AWS F4.1 (voir les Nor-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit mes de Sécurité).
bien ventilé, et en portant un respirateur à alimentation d’air. Les � Ne pas souder là où l’air ambiant pourrait contenir des poussières,
revêtements et tous les métaux renfermant ces éléments peuvent gaz ou émanations inflammables (vapeur d’essence, par
dégager des fumées toxiques en cas de soudage. exemple).
OM-284833 Page 6
� Brancher le câble de masse sur la pièce le plus près possible de � Les porteurs d’implants médicaux doivent consulter leur médecin
la zone de soudage pour éviter le transport du courant sur une lon- et le fabricant du dispositif avant de s’approcher de la zone où se
gue distance par des chemins inconnus éventuels en provoquant déroule du soudage à l’arc, du soudage par points, du gougeage,
des risques d’électrocution, d’étincelles et d’incendie. de la découpe plasma ou une opération de chauffage par
induction.
� Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
Si des BOUTEILLES sont
� En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact. endommagées, elles pourront
exploser.
� Porter une protection corporelle en cuir ou des vêtements ignifu-
ges (FRC). La protection du corps comporte des vêtements sans Des bouteilles de gaz comprimé protecteur
huile, comme des gants de cuir, une chemise solide, des panta- contiennent du gaz sous haute pression. Si une
lons sans revers, des chaussures hautes et une casquette. bouteille est endommagée, elle peut exploser. Du fait que les bouteil-
� Avant de souder, retirer toute substance combustible de vos po- les de gaz font normalement partie du procédé de soudage, les mani-
ches telles qu’un allumeur au butane ou des allumettes. puler avec précaution.
� Une fois le travail achevé, assurez-vous qu’il ne reste aucune � Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
trace d’étincelles incandescentes ni de flammes. des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
� Utiliser exclusivement des fusibles ou coupe-circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter. � Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
� Suivre les recommandations dans OSHA 1910.252 (a) (2) (iv) et de se renverser.
NFPA 51B pour les travaux à chaud et avoir de la surveillance et
un extincteur à proximité. � Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
� Lire et comprendre les fiches de données de sécurité et les ins- � Ne jamais placer une torche de soudage sur une bouteille à gaz.
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse- � Une électrode de soudage ne doit jamais entrer en contact avec
ment, les dégraisseurs, les flux et les métaux. une bouteille.
� Ne jamais souder une bouteille pressurisée - risque d’explosion.
Le BRUIT peut endommager l’ouïe. � Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
Le bruit des processus et des équipements peut les maintenir ainsi que les éléments associés en bon état.
affecter l’ouïe. � Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière lerégulateur lors
� Porter des protections approuvées pour les oreilles de l’ouverture de la vanne.
si le niveau sonore est trop élevé.
� Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Les CHAMPS � Utilisez les équipements corrects, les bonnes procédures et suffi-
ÉLECTROMAGNÉTIQUES (CEM) samment de personnes pour soulever, déplacer et transporter les
peuvent affecter les implants bouteilles.
médicaux. � Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
� Les porteurs de stimulateurs cardiaques et autres Gas Association) mentionné dans les principales normes de
implants médicaux doivent rester à distance. sécurité.
2-3. Symboles de dangers supplémentaires en relation avec l’installation, le

fonctionnement et la maintenance
� Tenir l’équipement (câbles et cordons) à distance des véhicules
Risque D’INCENDIE OU mobiles lors de toute opération en hauteur.
D’EXPLOSION.
� Suivre les consignes du Manuel des applications pour l’équation
� Ne pas placer l’appareil sur, au-dessus ou à proxi- de levage NIOSH révisée (Publication Nº94– 110) lors du levage
mité de surfaces inflammables. manuelle de pièces ou équipements lourds.
� Ne pas installer l’appareil à proximité de produits
inflammables
L’EMPLOI EXCESSIF peut
� Ne pas surcharger l’installation électrique – s’assurer que l’alimen-
SURCHAUFFER L’ÉQUIPEMENT.
tation est correctement dimensionné et protégé avant de mettre
l’appareil en service. � Laisser l’équipement refroidir ; respecter le facteur
de marche nominal.
LA CHUTE DE L’ÉQUIPEMENT peut
� Réduire le courant ou le cycle opératoire avant de
provoquer des blessures. recommancer le soudage.
� Utiliser l’anneau de levage uniquement pour soule- � Ne pas obstruer les passages d’air du poste.
ver l’appareil, NON PAS les organes de roulement,
les bouteilles de gaz ou tout autre accessoire.
� Utilisez les procédures correctes et des équipements d’une capa- LES ÉTINCELLES PROJETÉES
cité appropriée pour soulever et supporter l’appareil. peuvent provoquer des blessures.
� En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du � Porter un écran facial pour protéger le visage et
côté opposé de l’appareil. les yeux.
OM-284833 Page 7
� Affûter l'électrode au tungstène uniquement à la meuleuse dotée
de protecteurs. Cette manœuvre est à exécuter dans un endroit
LIRE LES INSTRUCTIONS.
sûr lorsque l'on porte l'équipement homologué de protection du vi- � Lire et appliquer les instructions sur les étiquettes
sage, des mains et du corps. et le Mode d’emploi avant l’installation, l’utilisation
� Les étincelles risquent de causer un incendie - éloigner toute sub- ou l’entretien de l’appareil. Lire les informations de
stance inflammable. sécurité au début du manuel et dans chaque
section.
LES CHARGES � N’utiliser que des pièces de remplacement provenant du fabricant.
ÉLECTROSTATIQUES peuvent � Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
endommager les circuits imprimés. l’industrie, ainsi que les codes municipaux.
� Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces. LE RAYONNEMENT HAUTE
� Utiliser des pochettes et des boîtes antistatiques pour stocker, dé- FRÉQUENCE (H.F.) risque de
placer ou expédier des cartes de circuits imprimes. provoquer des interférences.
� Le rayonnement haute fréquence (H. F.) peut pro-
Les PIÈCES MOBILES peuvent voquer des interférences avec les équipements de
causer des blessures. radio-navigation et de communication, les services de sécurité et
les ordinateurs.
� Ne pas s’approcher des organes mobiles.
� Demander seulement à des personnes qualifiées familiarisées
� Ne pas s’approcher des points de coincement tels avec des équipements électroniques de faire fonctionner
que des rouleaux de commande. l’installation.
� L’utilisateur est tenu de faire corriger rapidement par un électricien
LES FILS DE SOUDAGE peuvent qualifié les interférences résultant de l’installation.
provoquer des blessures. � Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
� Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction. � Effectuer régulièrement le contrôle et l’entretien de l’installation.
� Maintenir soigneusement fermés les portes et les panneaux des
� Ne pas diriger le pistolet vers soi, d’autres person-
sources de haute fréquence, maintenir les éclateurs à une dis-
nes ou toute pièce mécanique en engageant le fil de soudage.
tance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
L’EXPLOSION DE LA BATTERIE peut
provoquer des blessures. LE SOUDAGE À L’ARC risque de
� Ne pas utiliser l’appareil de soudage pour charger provoquer des interférences.
des batteries ou faire démarrer des véhicules à � L’énergie électromagnétique risque de provoquer
l’aide de câbles de démarrage, sauf si l’appareil des interférences pour l’équipement électronique
dispose d’une fonctionnalité de charge de batterie destinée à cet sensible tel que les ordinateurs et l’équipement
usage. commandé par ordinateur tel que les robots.
� Veiller à ce que tout l’équipement de la zone de soudage soit
Les PIÈCES MOBILES peuvent compatible électromagnétiquement.
causer des blessures. � Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
� S’abstenir de toucher des organes mobiles tels bas que possible (ex. par terre).
que des ventilateurs.
� Veiller à souder à une distance de 100 mètres de tout équipement
� Maintenir fermés et verrouillés les portes, pan- électronique sensible.
neaux, recouvrements et dispositifs de protection.
� Veiller à ce que ce poste de soudage soit posé et mis à la terre
� Lorsque cela est nécessaire pour des travaux d’entretien et de dé- conformément à ce mode d’emploi.
pannage, faire retirer les portes, panneaux, recouvrements ou dis- � En cas d’interférences après avoir pris les mesures précédentes,
positifs de protection uniquement par du personnel qualifié. il incombe à l’utilisateur de prendre des mesures supplémentaires
� Remettre les portes, panneaux, recouvrements ou dispositifs de telles que le déplacement du poste, l’utilisation de câbles blindés,
protection quand l’entretien est terminé et avant de rebrancher l’a- l’utilisation de filtres de ligne ou la pose de protecteurs dans la
limentation électrique. zone de travail.
OM-284833 Page 8
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT – Ce produit peut vous exposer à des pro- Pour plus d’informations, consulter www.P65Warnings.ca.gov.
duits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malforma-
tions ou d’autres troubles de la reproduction.
2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding Standard for Fire Prevention During Welding, Cutting, and Other Hot
Society standard ANSI Standard Z49.1. Website: http://www.aws.org. Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
Safe Practice For Occupational And Educational Eye And Face Pro-
tection, ANSI Standard Z87.1, from American National Standards In- OSHA, Occupational Safety and Health Standards for General Indus-
stitute. Website: www.ansi.org. try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub-
part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
Safe Practices for the Preparation of Containers and Piping for Weld- www.osha.gov.
ing and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org. OSHA Important Note Regarding the ACGIH TLV, Policy Statement
on the Uses of TLVs and BEIs. Website: www.osha.gov.
National Electrical Code, NFPA Standard 70 from National Fire Pro-
tection Association. Website: www.nfpa.org. Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Web-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1 from Compressed Gas Association. Website: www.cganet.com. site: www.cdc.gov/NIOSH.
Safety in Welding, Cutting, and Allied Processes, CSA Standard SOM_fre 2022–01
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des 3. Ne pas courber et ne pas entourer les câbles autour de votre
champs électromagnétiques (CEM) à certains endroits. Le courant is- corps.
su d’un soudage à l’arc (et de procédés connexes, y compris le sou- 4. Maintenir la tête et le torse aussi loin que possible du matériel du
dage par points, le gougeage, le découpage plasma et les opérations circuit de soudage.
de chauffage par induction) crée un champ électromagnétique (CEM) 5. Connecter la pince sur la pièce aussi près que possible de la
autour du circuit de soudage. Les champs électromagnétiques pro- soudure.
duits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour 6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir
les porteurs d’implants médicaux doivent être prises: par exemple, ou se pencher dessus.
des restrictions d’accès pour les passants ou une évaluation indivi- 7. Ne pas souder tout en portant la source de soudage ou le
duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- dévidoir.
pliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage: En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
1. Rassembler les câbles en les torsadant ou en les attachant avec
de s’approcher des opérations de soudage à l’arc, de soudage par
du ruban adhésif ou avec une housse.
points, de gougeage, du coupage plasma ou de chauffage par induc-
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câ- tion. Si le médecin approuve, il est recommandé de suivre les procé-
bles d’un côté et à distance de l’opérateur. dures précédentes.
OM-284833 Page 9
� Complete Parts List is available at www.HobartWelders.com
SECTION 3 – DEFINITIONS
3-1. Additional Safety Symbol Definitions
Warning! Watch Out! There are possible hazards as shown by the
symbols.
OM-284833 Page 10
3-2. Miscellaneous Symbols And Definitions
Single Phase Static

Rated No Load Volt- Frequency Convert-
Single Phase
age (OCV) er-Transformer-
Rectifier
Direct Current (DC) Circuit Breaker Amperage
Primary Voltage Positive Voltage
A complete Parts List is available at www.MillerWelds.com

Conventional Load Gas Metal Arc
Negative
Voltage Welding (GMAW)
SECTION 3 DEFINITIONS
Gas Metal Arc
Rated Welding
Duty Cycle Welding (GMAW)
Current
MIG / Gun Control
eous Symbols And Definitions
Self-Shielded Flux
Input Power or Input
Amperage Three Phase
Voltage
% Line Connection
Percent
Cored Arc Welding
(FCAW)
Negative
Voltage
Increase
Increase Wire Feed Spool
Gas Input
Gun
Foot Control
On
Output
Internal Protection
Single Phase Hertz Gas Postflow
Off Rating
Shielded Metal
Positive Arc Welding
Remote
(SMAW)
Gas Tungsten Arc
Welding
oltage Input Lift-Arc Operation
(GTAW)
e Connection Pulsed
OM-284833 Page 11
SECTION 4 – SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements
and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.hobartwelders.com/eula and are incorporated by reference herein.
4-3. Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriate-
ness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific require-
ments. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warran-
ties including any implied warranty of fitness for a particular purpose.
4-4. Welding Power Source Specifications

Maximum Open- Amperes Input At Rated Load Output, 60 Hz, Single Phase
Rated Welding Amperage
Circuit Voltage
Output Range 208 VAC 240 VAC KVA KW
DC
280 A,
28.2 volts DC, 30-280 A 40 62.4 55.3 13.13 11.26
30% Duty Cycle
250 A,
26.5 volts DC, 30-280 A 40 61.4 54.2 12.6 9.4
40% Duty Cycle
200 A,
24.0 volts DC, 30-280 A 40 53.9 47.5 11.4 7.1
60% Duty Cycle
150 A,
21.5 volts DC, 30-280 A 40 44.9 38.4 9.22 4.98
100% Duty Cycle
Wire Feed Net Weight

Wire Type and Diameter Dimensions
Speed Without Gun
Solid Steel Stainless Steel Flux Cored Aluminum* H: 30 in. (762 mm)
50-700 IPM
.023 - .045 in. .023 - .045 in. .030 - .045 in. .030 - .047 in. W: 19 in. (483 mm) 205 lb (93 kg)
(1.3-17.8 m/min)
(0.6 - 1.2 mm) (0.6 - 1.2 mm) (0.8 - 1.2 mm) (0.8 - 1.2 mm) D: 40 in. (1016 mm)
*Spoolrunner 200 required for welding aluminum
4-5. Environmental Specifications

A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
B. Temperature Specifications
Operating Temperature Range* Storage/Transportation Temperature Range

–4 to 104°F (–20 to 40°C) –22 to 122°F (–30 to 50°C)
*Output is derated at temperatures above 104°F (40°C).
OM-284833 Page 12
4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that

MIG OUTPUT DUTY CYCLE unit can weld at rated load without
overheating.
If unit overheats, Thermistor (RT1) opens,

output stops, and cooling fan runs. Wait fif-
teen minutes for unit to cool. Reduce amper-
age or voltage, or duty cycle before welding.
NOTICE – Exceeding duty cycle can damage
unit and void warranty.
10 20 30 40 50 60 70 8090 100
60% Duty Cycle at 200 Amperes
6 Minutes Welding 4 Minutes Resting
40% Duty Cycle at 250 Amperes
4 Minutes Welding 6 Minutes Resting
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
OM-284833 Page 13
SECTION 5 – INSTALLATION
5-1. Selecting A Location
Movement Do not move or operate unit where

it could tip.
Special installation may be re-
quired where gasoline or volatile
liquids are present - see NEC Ar-
ticle 511 or CEC Section 20.
1 Line Disconnect Device
Locate unit near correct input power supply.
te Parts List is available at www.MillerWelds.com
Location And Airflow
OM-284833 Page 14
5-2. Selecting Cable Sizes*
NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***
350 ft 400 ft
100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m)
(105 m) (120 m)
10 - 60% 60 - 100%
Welding
Duty Cycle Duty Cycle 10 - 100% Duty Cycle AWG (mm2)
Amperes
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
2x4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
(2x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use.
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org. Complete Parts List available at www.MillerWelds.com
5-3. Connecting Weld Output Cables
1 2
Turn off power before connecting
to weld output terminals.
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
6 machine.
3
� Do not place anything between weld

cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
1 Correct Weld Cable Connection
4 2 Incorrect Weld Cable Connection
3 Weld Output Terminal
5
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
3/4 in. (19 mm) Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld out-
philips head wrench crescent wrench put terminal and secure with nut so that weld
cable terminal is tight against copper bar.
nutdriver
chippinghammer
OM-284833 Page 15
workclamp wirecutter frontcutter
A complete Parts List is available at www.HobartWelders.com
Installing Work Cable And Clamp� Complete Parts List is available at www.HobartWelders.com
5-4. Installing Work Cable And Clamp
Turn off power before connecting

to weld output terminals.
Do not use worn, damaged, under-
sized, or repaired cables.
1 Work Cable
2 Boot
Route cable through front panel opening.

Slide boot onto work cable.
1
3 Negative (-) Output Terminal
Connect cable to terminal and cover connec-

tion with boot.
2
Close door.
804909-B
3/4 in.
ps head wrench crescent wrench
nutdriver
chippinghammer
clamp wirecutter frontcutter
greasegun filterwrench
OM-284833 Page 5
OM-284833 Page 16
5-5. Connecting MIG Gun/Spool Gun to IronMan 240
1 MIG Gun
2 Spool Gun
3 Drive Assembly
4 Gun End
5 Gun Securing Knob
Loosen gun securing knob. Insert gun end

through opening until it bottoms against the
drive assembly. Tighten the gun securing
knob.
6 Gun Trigger Plug
Insert plug into receptacle, and tighten

threaded collar.
Correct
5 3 4
Incorrect
5 3 4
OM-284833 Page 17
5-6. Setting Gun Polarity For Wire Type
1 2 1 Wire Drive Assembly Lead

2 Work Clamp Lead
3 + Positive Terminal
4 – Negative Terminal
Shown as shipped — Electrode Positive

(DCEP): For solid steel, stainless steel, alu-
minum, or flux core with gas wires (GMAW).
Electrode Negative (DCEN): Reverse lead

connections at terminals from that shown for
3 4 gasless flux core wires (FCAW). Drive as-
sembly becomes negative.
3/4 in. Always read and follow manufacturer’s rec-
ps head wrench ommended polarity.
crescent wrench
5-7. Installing Gas Supply
nutdriver Obtain gas cylinder and chain to running

chippinghammer gear, wall, or other stationary support so cyl-
inder 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.
clamp wirecutter frontcutter
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 be-

greasegun tween regulator/flowmeter gas hose connec-
filterwrench tion, and fitting on rear of welding power
source.
7 Flow Adjust
Typical flow rate is 25-45 cfh (cubic feet per

hour). Check wire manufacturer’s recom-
mended flow rate.
8 CO2 Adapter (Customer Supplied)

9 O-Ring (Customer Supplied)
file paintbrush Install adapter with O-ring between regula-
tor/flowmeter and CO2 cylinder.
5/8, 1–1/8 in.
ps head wrench crescent wrench
OM-284833 Page 18
flashlight ruler
5-8. Installing Wire Spool And Adjusting Hub Tension
Hand tighten knob clockwise. When a slight

force is needed to turn spool, tension is set.
To install either a 1 lb or 2 lb wire spool, fol-

low the procedure as shown in the
illustration.
1 Spindle
2 Remove these components from spindle.
Installing 1 Or 2 lb Wire Spool 3 Order two additional 5/8 washers Part
1 No. 605941
4 Install these components onto spindle.
5 Order additional spring Part No. 186437
282945A
OM-284833 Page 19
5-9. Positioning Jumper Links
Check input voltage available at site.

208 VOLTS 240 VOLTS
1 Jumper Links Access Door
Open door.
284705- A
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.
philips head wrench crescent wrench

NGO’s
tools/
Philips Screwdriver #1
d philips head wrench crescent wrench
3/8 in.
h nutdriver
chippinghammer
5-10. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen-
dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual
steelbrush branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
nutdriver
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12. chippinghammer
ht-duty workclamp wirecutter frontcutter
60 Hz 1-Phase
Rated Supply Voltage (V) 208 240
Rated Maximum Supply Current I1max (A) 62.4 55.3
Rated Effective Supply Current I1eff (A) 44.9 38.4
Maximum Recommended Standard Fuse Rating In Amperes1
mp light-duty workclamp wirecutter frontcutter
Time Delay Fuses 2 70 60
Normal Operating Fuses3 90 80
Maximum Recommended Supply Conductor Length In Feet (Meters)4 79 (24) 105 (32)
Raceway Installation
greasegunSupply Conductor
Minimum Size In AWG (mm2)5
filterwrench 8 (10) 8 (10)
Minimum Grounding Conductor Size In AWG (mm2) 5 8 (10) 8 (10)
Reference: 2020 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
am 2 "Time-Delay" fuses are UL class "RK5" . See UL 248.
3 "Normal Operating" (general purpose - no intentional delay) fuses are UL class "K5" (up to and including 60 amps), and UL class "H" ( 65 amps
and above).greasegun filterwrench
4 Maximum total length of copper input conductors in entire installation, raceway and/or flexible cord.
5 Raceway conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment
per NEC Table 310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 75°C (167°F)
with not more than three single current-carrying conductors in a raceway.
awlhandream file paintbrush
OM-284833 Page 20
�
Complete Parts List is available at www.HobartWelders.com
5-11. Connecting Input Power
2-7. Connecting Input Power
5 =GND/PE Earth Ground
L1
8
7 L2
3
1
L2 L1
240 VAC, 1
804912-A
Installation must meet all National 2 Receptacle [NEMA Type 6-50R (Cus- Connect green or green/yellow grounding
and Local Codes — have only quali- tomer Supplied)] conductor to disconnect device grounding
fied persons make this installation. terminal first.
3 Input Power Cord
Disconnect and lockout/tagout input Connect input conductors L1 and L2 to dis-
power before connecting input con- Connect directly to line disconnect device if connect device line terminals.
ductors from unit. Follow estab- hard wiring is required.
lished procedures regarding the
9 Over-Current Protection
installation and removal of lockout/ 4 Disconnect Device (switch shown in the
tagout devices. OFF position) Select type and size of over-current protec-
Always connect green or green/yel- tion using Electrical Service Guide (fused
low conductor to supply grounding 5 Disconnect Device Grounding Terminal
disconnect switch shown).
terminal first, and never to a line 6 Disconnect Device Line Terminals
terminal. Connect plug to receptacle if hard wiring
See rating label on unit and check input volt- 7 Green Or Green/Yellow Grounding method is not used.
age available at site. Conductor
Close and secure door on disconnect de-
8 Black And White Input Conductor (L1 vice. Follow established lockout/tagout pro-
1 Plug (NEMA Type 6–50P) And L2) cedures to put unit in service.
OM-284833 Page 21
OM-284833 Page 9
5-12. Threading Welding Wire
NGO’s
tools/
nutdriver allen_wrench allen_set flathead philips head wrench crescent wrench

chippinghammer
pliers needlenose
workclamp 1 Wire Spool
wirecutter frontcutter Step 2. Pull andknife steelbrush Step 5. Removenutdriver
hold wire; cut off end. gun nozzle and contact tip.
2 Welding Wire chippinghammer
3 Inlet Wire Guide � Hold wire tightly to keep it from
unraveling.
Step 6. Turn power on.
4 Pressure Adjustment Knob Step 7. Press gun trigger until wire comes
Step 3. Push wire through guides into gun; out of gun. Reinstall contact tip and nozzle.
5 Drive Roll
continue to hold wire.
6 Outlet Wire Guide Step 8. Feed wire onto a non-conductive
Step 4. Close and tighten pressure assem- surface (e.g. wood) to check drive roll pres-
7 Gun Conduit Cable
bly, and let go of wire. sure. Tighten knob enough to prevent
Lay gun cable out straight. slipping.
solderiron
Step 1. Open pressure assembly.
�
stripcrimp
Use pressure indicator
heavy-duty
drive roll pressure.
to set a desired
workclamp light-duty workclamp wirecutter
Step 9. Cut off wire. Close and latch door.
frontcutter
greasegun filterwrench
OM-284833 Page 22
OM-284833 Page 23
5-13. Weld Parameters
OM-284833 Page 24
OM-284833 Page 25
SECTION 6 – OPERATION
6-1. Controls
1 2
284825A
1 Voltage Control Refer to section 7-6 if light is illuminated or

Turn control clockwise to increase voltage.
flashing. � This unit has three automatic timers in-
cluded in its operation to help save
4 Power On Light contact tips, gas, and wire:
2 Wire Feed Control Tip Saver - Weld output shuts off if tip
Turn control clockwise to increase wire feed Power should be on when S1 is turned on. is shorted to work surface.
speed. Safety shut-off - Weld output will shut
off if no arc is detected within 3 sec-
3 Diagnostic Light onds after gun trigger is depressed.
OM-284833 Page 13
OM-284833 Page 26
Complete Parts List is available at www.MillerWelds.com
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
Disconnect power before maintaining.
� Maintain more often during severe conditions.

� = Check ◇ = Change � = Clean � = Replace
1/2 in.
(13 mm)
Every 3
Months
FUEL
� Unreadable Labels �SLUDGE

Weld Terminals � � Weld Cables
Every 6
Months
� Inside Unit � Apply Light Coat Of Oil Or � Clean Drive Rolls

Grease To Drive Motor Shaft
*To be done by factory authorized service agent.
7-2. Unit Overload

Thermistor RT1 in SCR1 protects the unit from damage due to overheating. If Over Temp light illuminates, output and wire feed will shut down.
Wait for unit to cool down allowing fan motor to run until Over Temp light turns off. If unit is cool and no weld output continues, contact Factory Au-
thorized Service Agent.
TION 4 MAINTENANCE
7-3. Changing Drive Roll&TROUBLESHOOTING
and Wire Inlet Guide
ing Drive Roll and Wire Inlet Guide
1 Securing Screw
2
2 Inlet Wire Guide
Loosen screw. Slide tip as close to drive rolls

as possible without touching. Tighten screw.
3 Drive Roll
4
The drive roll consists of two different sized
grooves. The stamped markings on the end
surface of the drive roll refers to the groove
on the opposite side of the drive roll. The
1 groove closest to the motor shaft is the prop-
er groove to thread (see Section 5-12).
4 Drive Roll Securing Nut
Turn nut one click to secure drive roll.

OM-249336 Page 1
3
907728
7/16 in.
OM-284833 Page 27
OM-278215 Page 33
7-4. Aligning Drive Rolls and Wire Guide
Turn Off power.

Correct
3 4 View is from top of drive rolls looking down
with pressure assembly open.
2
1 1 Drive Roll Securing Nut
2 Drive Roll
5 3 Wire Guide
4 Welding Wire
5 Drive Gear
Insert screwdriver, and turn screw in or out
NGO’s until drive roll groove lines up with wire
guide.
tools/
Incorrect Close pressure roll assembly.
allen_wrench allen_set flathead philips head wrench crescent wrench
Ref. 800412-A
pliers needlenose knife steelbrush nutdriver
chippinghammer
7-5. Jog Mode
When using the internal motor, if the trigger is held for more than 3 seconds without striking an arc, the unit will automatically shut off weld power
and shielding gas, but will feed wire continuously at the preset wire feed speed for up to 20 feet (6.1 m). Once 20 feet (6.1 m) of wire is delivered,
a trigger error will occur until trigger is released. When using a spoolgun , if the trigger is held for 3 seconds without striking an arc the unit will au-
tomatically shut off weld power and shielding gas, but will feed wire continuously at the preset wire feed speed for up to 10 seconds. After 10 sec-
onds, a trigger error will occur until the trigger is released.
7-6. solderironLight
Diagnostic stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter
The Diagnostic light provides diagnostic modes to help troubleshoot various malfunctions with the unit.
Status Condition Error Remedy

Off Normal Unit working properly None
On Over Temperature Unit overheated and output Release trigger and allow cooling
stopped. fan to run until diagnostic light
turns off.
Flashing torque
1 TimescrewdriverTrigger Error Gun trigger is closed or shorted Release trigger, then pull trigger
when unit power is turned on. again to continue welding.
Spoolrunner 200 gun trigger was
held closed for more than 10 sec- greasegun
torque wrench socket wrench drillonds without striking an arc. filterwrench
Standard MIG gun trigger was
held closed while more than 20
feet (6.1 m) of wire was delivered
without striking an arc.
Flashing 2 Times Shorted Secondary handream
Contact tip is directly shorted to Release trigger, move contact tip
the workpiece. Arc shuts off in off of workpiece and then pull
this condition. trigger again to continue welding.
Flashing 3 Times Motor Overcurrent Malfunction in wire drive system Release trigger, then pull trigger
or motor overcurrent. again to continue welding.
Check for proper spool brake ad-
strapwrench hammer awl in the
justment or obstruction file paintbrush
airgun wire feed system.
Check wire guides, gun liner and
contact tip for obstruction.
Flashing 6 Times Thermistor Error Malfunction in thermal protection Contact factory authorized serv-
system. ice agent.
OM-284833 Page 28
7-7. Troubleshooting
Trouble Remedy
No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 5-11).
Check and replace power switch if necessary.
Replace building line fuse or reset circuit breaker if open (see Section 5-11).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see welding gun Owner's
Manual).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Replace contact tip (see welding gun Owner's Manual).
Check connections at output terminals of welder.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 5-11).
Low, high, or erratic wire speed. Adjust front panel settings (see Section 6-1).
Change to correct size drive roll (see Section 7-3).
Adjust drive roll pressure (see Section 5-12).
Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner's Manual).
Wire Drive/Gun Trouble Remedy
Wire feeding stops during welding. Straighten gun cable and/or replace damaged parts (see welding gun Owner's Manual).
Adjust drive roll pressure (see Section 5-12).
Readjust hub tension (see Section 5–8).
Replace contact tip if blocked (see welding gun Owner's Manual).
Clean or replace wire inlet guide or liner if dirty or plugged (see welding gun Owner's Manual).
Replace drive roll if worn or slipping (see Section 7–3).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see welding gun Owner's
Manual).
Check and clear any restrictions at drive assembly and liner (see welding gun Owner's Manual).
Have nearest Factory Authorized Service Agent check drive motor.
OM-284833 Page 29
SECTION 8 – ELECTRICAL DIAGRAM
Figure 8-1. Welding Power Source Circuit Diagram
OM-284833 Page 30
284828-A
OM-284833 Page 31
SECTION 9 – GMAW WELDING (MIG) GUIDELINES
9-1. Typical GMAW (MIG) Process Connections
1
5
4
7 3
2
6
Weld current can damage electronic 1 Wire Feeder/Welding Power Source 5 Gas
5
parts in vehicles. Disconnect both 2 Gun 4
6 Shielding Gas
battery cables before welding on a 3
vehicle. Place work clamp as close 3 Workpiece
7 Regulator/Flowmeter
to the weld as possible. 4 Work Clamp
6
9-2. 1
Typical GMAW (MIG) Process Control
1/16 in. Settings
(0.0625 in.)
1 1/16 in. � These settings are guidelines only. Ma-

terial and wire type, joint design, fitup,
(0.0625 in.) position, shielding gas, etc. affect set-
2 tings. Test welds to be sure they comply
to specifications.
1 Material Thickness
Material thickness determines weld

parameters.
Convert material thickness to amperage (A):
2 0.001 in. (0.025 mm) = 1 ampere
0.0625 in. (1.59 mm) ÷ 0.001 = 62.5 A
3 4 2 Select Wire Size
See table below.
3 Select Wire Feed Speed (Amperage)
Wire feed speed (amperage) controls weld

penetration. See table below.
3 4 4 Select Voltage
Voltage controls height and width of weld

bead.
Low Voltage: wire stubs into work
High Voltage: arc is unstable (spatter)
Set voltage midway between high and low
voltage.
OM-284833 Page 32
Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed *
0.023 in. (0.58 mm) 30-90 A 3.5 in. (89 mm) per amp 3.5 x 62.5 A = 219 ipm (5.56 mpm)
0.030 in. (0.76 mm) 40-145 A 2 in. (51 mm) per amp 2 x 62.5 A = 125 ipm (3.19 mpm)
0.035 in. (0.89 mm) 50-180 A 1.6 in. (41 mm) per amp 1.6 x 62.5 A = 100 ipm (2.56 mpm)
*62.5 A based on 1/16 in. (1.6 mm) material thickness. ipm = inches per minute; mpm = meters per minute
lding And Positioning

9-3. Holding Welding Gun
And Positioning Welding Gun
1
� Welding wire is energized when gun
trigger is pressed. Before lowering hel-
met and pressing trigger, be sure wire
is no more than 1/2 in. (13 mm) past
3 end of nozzle, and tip of wire is posi-
2 tioned correctly on seam.
1 Hold Gun and Control Gun Trigger
2 Workpiece
5
3 Work Clamp
4 Electrode Extension (Stickout)
Solid Wire – 3/8 to 1/2 in. (9 to 13 mm)
4 5 Cradle Gun and Rest Hand on
Workpiece
6 Groove Welds 7 6 7
0°-15° 45° 0°-15° 6 End View Of Work Angle
7 Side View Of Gun Angle
6 7 6 7
90° 0°-15° 45° 0°-15°
45°
90° 90°
45°
Fillet Welds
OM-4419 Page 1
6 7
45° 0°-15°
45°
OM-284833 Page 33
9-4. Conditions That Affect Weld Bead Shape
10°
10°
Gun Angles and Weld Bead Profiles
10° 1 � Weld bead shape depends on gun an-
gle, direction of travel, electrode exten-
sion (stickout), travel speed, thickness
10° of base metal, wire feed speed (weld
1 10° current), and voltage.
1 Push
1 10° 2 Perpendicular
1 3 Drag
2 10° 3
4 Short
10°
5 Normal
2 3
6 Long
2 3 7 Slow
2 3 8 Normal
9 Fast
Electrode Extensions (Stickout)
4 5 6
4 5 6
4 5 6
4 5 6
Fillet Weld Electrode Extensions (Stickout)
4 5 6
4 5 6
4 5 6
Gun Travel Speed
4 5 6
7 8 9
7 8 9
7 8 9
7 8 9
OM-284833 Page 34
9-5. Gun Movement During Welding
2
� Normally, a single stringer bead is sat-
isfactory for most narrow groove weld
1 joints; however, for wide groove weld
2 2 joints or bridging across gaps, a weave
1 1 bead or multiple stringer beads works
better.
1 Stringer Bead - Steady Movement Along
Seam
2 Weave Bead - Side To Side Movement
3
Along Seam
3 3 3 Weave Patterns
Use weave patterns to cover a wide area in

one pass of the electrode.
9-6. Poor Weld Bead Characteristics
2 3 4 1 Large Spatter Deposits

1 23 3 4 2 Rough, Uneven Bead
2 4
1 1 3 Slight Crater During Welding
4 Bad Overlap
5 5 Poor Penetration
5 5
9-7. Good Weld Bead Characteristics
2 3 4
1 1 Fine Spatter
2 2 3 4 3 4
1 1 2 Uniform Bead
3 Moderate Crater During Welding
5
Weld a new bead or layer for each 1/8 in.
5 (3.2 mm) thickness in metals being welded.
5
4 No Overlap
5 Good Penetration into Base Metal
OM-284833 Page 35
9-8. Troubleshooting – Excessive Spatter
Excessive Spatter - scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.
Voltage too high. Select lower voltage range.
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.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power
source.
9-9. Troubleshooting – Porosity
Porosity - small cavities or holes resulting from gas pockets in weld metal.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before
welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
9-10. Troubleshooting – Excessive Penetration
Excessive Penetration - weld metal melting through base metal and hanging underneath
weld.

Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-284833 Page 36
9-11. Troubleshooting – Lack Of Penetration
Lack Of Penetration - shallow fusion between weld metal and base metal.

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.
Keep arc on leading edge of weld puddle.
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.
Reduce travel speed.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power
source.
9-12. Troubleshooting – Incomplete Fusion
Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceeding
weld bead.

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.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
9-13. Troubleshooting – Burn-Through
Burn-Through - weld metal melting completely through base metal resulting in holes where no
metal remains.

Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
9-14. Troubleshooting – Waviness Of Bead
Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base
metal.

Welding 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 hand on solid surface or use two hands.
OM-284833 Page 37
9-15. Troubleshooting – Distortion
Distortion - contraction of weld metal during welding that forces base metal to move.
Illustration: Base metal moves in the direction of the weld bead.

Excessive heat input. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
9-16. 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 devel-
oped over the years. The most commonly used shielding gases are listed in the following table.
Application
Short Cir-
Gas Short Cir- Spray Arc GMAW-P Short Cir-
Spray Arc GMAW-P cuiting Spray Arc GMAW-P
cuiting Stainless Stainless cuiting
Steel Steel Stainless Aluminum Aluminum
Steel Steel Steel Aluminum
Steel
All All All All
Argon
Positions Positions Positions Positions
Argon + 1% Flat & Hori- All Flat & Hori-
O2 zontal Fillet Positions zontal Fillet
Argon + 2% Flat & Hori- All Flat & Hori-
O2 zontal Fillet Positions zontal Fillet
Argon + 5% Flat & Hori- All
CO2 zontal Fillet Positions
Argon + Flat & Hori- All All
10% CO2 zontal Fillet Positions Positions
Argon + All
25% CO2 Positions
Argon + All
50% CO2 Positions
All
CO2
Positions
All
Helium
Positions*
Argon + All
Helium Positions*
90% HE +
7-1/2% AR All
+ 2-1/2% Positions
CO2
65% AR +
All
33% HE +
Positions
2% CO2
* Heavy Thicknesses
OM-284833 Page 38
9-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem Probable Cause Remedy
Wire feed motor operates, but wire does not Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.
feed.
Incorrect wire feed rolls. Check size stamped on wire feed rolls, re-
place to match wire size and type if
necessary.
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 wire feed rolls Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
(bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable lin-
er length and diameter, replace if necessary.
Gun end not inserted into drive housing Loosen gun securing bolt in drive housing
properly. and push gun end into housing just enough
so it does not touch wire feed rolls.
Dirty or damaged (kinked) liner. Replace liner.
Wire feeds, but no gas flows (GMAW). Gas cylinder empty. Replace empty gas cylinder.
Gas nozzle plugged. Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not Open gas valve at cylinder and adjust flow
adjusted. 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 re-
pair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent re-
place gas solenoid valve.
Incorrect primary voltage connected to weld- Check primary voltage and relink welding
ing power source. power source for correct voltage.
Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Re-
place worn drive rolls if necessary.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and
type.
Incorrect voltage setting for selected wire Readjust welding parameters.
feed speed on welding power source.
Loose connections at the gun weld cable or Check and tighten all connections.
work cable.
Gun in poor shape or loose connection inside Repair or replace gun as necessary.
gun.
OM-284833 Page 39
SECTION 10 – PARTS LIST
10-1. Drive Roll And Wire Guide Kits
Base selection of drive rolls upon the following recommended usages:
6 V-Grooved rolls for hard wire (solid steel and metal cored).
7 U-Grooved rolls for soft and soft shelled cored wires (aluminum).
8 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
9 V-Knurled rolls for hard shelled cored wires (flux cored).
10 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
Wire Diameter Drive Roll

Kit No. Inlet Wire Guide
Decimal Metric Part No. Type
0.023 / 0.025 in. 0.6 mm 087131 087130 V-Grooved 056192
0.030 / 0.035 in. 0.8 / 0.9 mm 204579 203526 V-Grooved 056192
0.030 in. 0.8 mm 079594 053695 V-Grooved 056192
0.035 in. 0.9 mm 079595 053700 V-Grooved 056192
0.045 in. 1.2 mm 079596 053697 V-Grooved 056193
OM-284833 Page 40
Notes
Notes
Effective January 1, 2022
5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num-
ber preface of NC or newer.
This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or
warranties expressed or implied.
Hobart products are serviced by Hobart or Miller Authorized Service Agencies.
LIMITED WARRANTY - Subject to the terms and � Field Options (NOTE: Field options are cov- Hobart’s/Miller’s written approval. Return shipment
conditions below, Miller Electric Mfg. LLC, dba Ho- ered for the remaining warranty period of the shall be at customer’s risk and expense.
bart Welding Products, Appleton, Wisconsin, war- product they are installed in, or for a minimum
rants to its original retail purchaser that new of one year — whichever is greater.) The above remedies are F. O. B. Appleton, WI, or
Hobart equipment sold after the effective date of � HF Units Hobart’s/Miller’s authorized service facility. Trans-
this limited warranty is free of defects in material portation and freight are the customer’s responsi-
and workmanship at the time it is shipped. THIS � MIG Flowgauge Regulators (No Labor) bility. TO THE EXTENT PERMITTED BY LAW,
WARRANTY IS EXPRESSLY IN LIEU OF ALL � MIG Guns/TIG Torches THE REMEDIES HEREIN ARE THE SOLE AND
OTHER WARRANTIES, EXPRESS OR IMPLIED, � Plasma Cutting Torches EXCLUSIVE REMEDIES REGARDLESS OF THE
INCLUDING THE WARRANTIES OF MER- LEGAL THEORY. IN NO EVENT SHALL HO-
� Remote Controls BART/MILLER BE LIABLE FOR DIRECT, INDI-
CHANTABILITY AND FITNESS.
� Replacement Parts (No labor) - 90 days RECT, SPECIAL, INCIDENTAL OR
Within the warranty periods listed below, Hobart/ � Running Gear/Trailers CONSEQUENTIAL DAMAGES (INCLUDING
Miller will repair or replace any warranted parts or LOSS OF PROFIT) REGARDLESS OF THE LE-
� Spoolguns
components that fail due to such defects in materi- GAL THEORY. ANY WARRANTY NOT PRO-
al or workmanship. Hobart/Miller must be notified VIDED HEREIN AND ANY IMPLIED WARRANTY,
4 6 Months — Parts
in writing within thirty (30) days of such defect or GUARANTY, OR REPRESENTATION, INCLUD-
failure, at which time Hobart/Miller will provide in- ING ANY IMPLIED WARRANTY OF MERCHANT-
� 12 Volt Automotive-Style Batteries
structions on the warranty claim procedures to be ABILITY OR FITNESS FOR PARTICULAR
followed. Notifications submitted as online war- PURPOSE, ARE EXCLUDED AND DISCLAIMED
5 Engines and tires are warranted separately by
ranty claims must provide detailed descriptions of BY HOBART/MILLER.
the manufacturer.
the fault and troubleshooting steps taken to diag-
nose failed parts. Warranty claims that lack the re- Some US states do not allow limiting the duration
Hobart’s 5/3/1 Limited Warranty shall not apply to:
quired information as defined in the Miller Service of an implied warranty or the exclusion of certain
Operation Guide (SOG) may be denied by Miller. damages, so the above limitations may not apply
1. Consumable components; such as contact
to you. This warranty provides specific legal rights,
tips, cutting nozzles, contactors, brushes,
Hobart/Miller shall honor warranty claims on war- and other rights may be available depending on
relays, work station table tops and welding
ranted equipment listed below in the event of a de- your state. In Canada, some provinces provide ad-
curtains, or parts that fail due to normal
fect within the warranty coverage time periods ditional warranties or remedies, and to the extent
wear. (Exception: brushes and relays are
listed below. Warranty time periods start on the de- the law prohibits their waiver, the limitations set out
covered on all engine-driven products.)
livery date of the equipment to the original retail above may not apply. This Limited Warranty pro-
purchaser, or 12 months after the equipment is 2. Items furnished by Hobart/Miller, but manufac- vides specific legal rights, and other rights may be
shipped to a US or Canada distributor, or 18 tured by others, such as engines or trade ac- available, but may vary by province.
months after the equipment is shipped to an inter- cessories. These items are covered by the
national distributor, whichever occurs first. manufacturer’s warranty, if any.
3. Equipment that has been modified by any party Warranty Questions?
1 5 Years — Parts and Labor other than Hobart/Miller, or equipment that has
been improperly installed, improperly operated
� Original Main Power Rectifiers only to include or misused based upon industry standards, or
Call 1-800-332-3281
SCRs, diodes, and discrete rectifier modules
in non-inverter products
equipment which has not had reasonable and 8 AM – 5 PM EST
necessary maintenance, or equipment which
� Reactors has been used for operation outside of the Service
� Stabilizers specifications for the equipment.
� Transformers 4. Defects caused by accident, unauthorized re- You always get the fast, reliable response you
pair, or improper testing. need. Most replacement parts can be in your
2 3 Years — Parts and Labor Unless Specified hands in 24 hours.
HOBART PRODUCTS ARE INTENDED FOR
� Drive Systems COMMERCIAL AND INDUSTRIAL USERS Support
� Idle Module TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT. Need fast answers to the tough welding ques-
� PC Boards tions? Contact your distributor or call 1-800-
� Rotors, Stators and Brushes The exclusive remedies for warranty claims are, at 332-3281. The expertise of the distributor and
� Solenoid Valves Hobart’s/Miller’s option, either: (1) repair; or (2) re- Hobart is there to help you, every step of the
� Switches and Controls placement; or, if approved in writing by Hobart/Mill- way.
er, (3) the pre-approved cost of repair or
3 1 Year — Parts and Labor Unless Specified(90 replacement at an authorized Hobart/Miller service Assistance
days for industrial use) station; or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon Visit the Hobart website:
� Accessories (Kits) use). Products may not be returned without www.HobartWelders.com
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Thank you for purchasing Hobart. Our trained technical support team is dedicated to your
satisfaction. For questions regarding performance, operation, or service, contact us!
Resources Available
Always provide Model Name and Serial/Style Number.
To locate a Service Center:

Call 1-800-332-3281
or visit our website at www.HobartWelders.com/wheretobuy
For Technical Assistance:

Call 1-800-332-3281 Miller Electric Mfg. LLC
An Illinois Tool Works Company
8 AM to 5 PM EST – Monday through Friday 1635 West Spencer Street
Appleton, WI 54914 USA
For Assistance:
Call 1-800-332-3281
ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-05

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IRONMAN240

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Available Formats

OM-284833D 2022-05

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source And Wire

www.HobartWelders.com OWNER’S MANUAL

Hobart Welders manufactures a full line of

For Technical Help call 1-800-332-3281.

Register your product at www.HobartWelders.com

1-1. Symbol Usage

� Indicates special instructions.

1-3. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. WELDING WIRE can injure.

1-4. California Proposition 65 Warnings

1-5. Principal Safety Standards

1-6. EMF Information

2-1. Symboles utilisés

� Indique des instructions spécifiques.

2-3. Symboles de dangers supplémentaires en relation avec l’installation, le

2-5. Principales normes de sécurité

2-6. Informations relatives aux CEM

Single Phase Static

Direct Current (DC) Circuit Breaker Amperage

Primary Voltage Positive Voltage

A complete Parts List is available at www.MillerWelds.com

4-2. Software Licensing Agreement

4-3. Information About Default Weld Parameters And Settings

4-4. Welding Power Source Specifications

Wire Feed Net Weight

*Spoolrunner 200 required for welding aluminum

4-5. Environmental Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

Duty Cycle is percentage of 10 minutes that

If unit overheats, Thermistor (RT1) opens,

60% Duty Cycle at 200 Amperes

6 Minutes Welding 4 Minutes Resting

40% Duty Cycle at 250 Amperes

4 Minutes Welding 6 Minutes Resting

Movement Do not move or operate unit where

Locate unit near correct input power supply.

te Parts List is available at www.MillerWelds.com

Location And Airflow

5-3. Connecting Weld Output Cables

� Do not place anything between weld

Turn off power before connecting

Route cable through front panel opening.

Connect cable to terminal and cover connec-

clamp wirecutter frontcutter

Loosen gun securing knob. Insert gun end

6 Gun Trigger Plug

Insert plug into receptacle, and tighten

1 2 1 Wire Drive Assembly Lead

Shown as shipped — Electrode Positive

Electrode Negative (DCEN): Reverse lead

5-7. Installing Gas Supply

nutdriver Obtain gas cylinder and chain to running

Remove cap, stand to side of valve, and

Install so face is vertical.

5 Regulator/Flowmeter Gas Hose

Connect customer supplied gas hose be-

Typical flow rate is 25-45 cfh (cubic feet per