Hobart IronMan 250 User Manual

IronMan
™
250
Complete Single-Phase MIG Welding Package
211805
May 2008
PROCESSES
MIG (GMAW)
Welding
Flux Cored (FCAW)
Welding
T
he IronMan
™
250 is a powerful welding package
that is versatile and easy to use. It is equipped
with many outstanding features.
Welds 22 gauge up to 1/2 in. (13 mm) thick steel.
Excellent aluminum welding with optional
Hobart Spool Gun 3545-20.
Seven-tap voltage control allows for a smooth,
easy-to-control arc.
Infinite wire feed speed control for precise
adjustment of penetration and weld bead shape.
Comes complete with 250 amp gun and built-in
running gear/cylinder rack.
Handles wire spools up to 45 lb. — wire feed
speed adjusts from 90 to 750 IPM.
Built-in thermal overload protects the unit.
Reversible drive rolls: two grooves for three wire
sizes on one drive roll. Decreases spare parts and
changeover time.
Hinged door for easy access to wire drive system
for spool and drive roll changes.
FEATURES BENEFITS
Makes controls easy to see and access.
Excellent short arc performance with easy to control weld puddle.
Increases machine output for higher productivity.
Higher machine output duty cycle, increasing productivity with longer welding periods. Versatile for MIG and
Flux Cored, gas or gasless welding applications. Can weld at higher amps at lower duty cycle.
Simplified and accurate adjustments. Maximizes amount of control. Allows for smooth arc with high operator appeal.
Excellent for pushing soft aluminum wires.
50% less stocking of drive rolls. Standard, one-piece drive roll decreases spare parts and changeover time,
reducing overall costs.
For greater accessibility to wire feeder panel for spool and feed roll changes, increasing productivity and operator appeal.
Allows for precise adjustment of penetration and weld bead shape.
Amperage draw of 35 amps at rated load of 230 V input saves energy.
Ready to set up and weld: comes complete with wire feeder, running gear, cylinder rack, regulator/flow gauge,
MIG gun, cable and clamp, extra tips.
Five-year warranty on transformers, stabilizers and generators; three years on electronics (drive motors, rectifiers);
and one year on guns (MIG and plasma torches).
Sloped front panel
Arc performance
Increased amperage output
Increased duty cycle: rated at
200 amps @ 60% duty cycle,
and wide amperage range
7-position voltage control
Optional Hobart Spool Gun 3545-20
Reversible drive rolls: two grooves for
two wire sizes on one drive roll
Hinged feeder panel
Infinite wire feed control
Low amperage draw
Comes complete with
factory installed features
Hobart’s 5/3/1 Industrial Warranty
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Hobart Welders An Illinois Tool Works Company
U.S. Distributor Sales Phone 920-735-4576 FAX 800-637-2315
Hobart Retail Sales Phone 800-332-3281 FAX 937-332-4161
Canadian Sales Phone 888-489-9353 FAX 519-421-0480
International Sales Phone 920-735-4509 FAX 920-735-4125
Web Site HobartWelders.com
Rated Output
200 A, 24 V DC at 60% duty cycle
Open Circuit
Voltage
35 V
Current Range
30 –250 amps
Dimensions
H: 31-1/4 in. (794 mm)
W: 18-7/8 in. (479 mm)
D: 36-1/2 in. (927 mm)
Amperes Input at Rated Load
200 V 230 V KVA KW
40 35 8 6.8
Wire Feed
Speed Range
90 –750 IPM
Net Weight
195 lb. (88 kg)
SPECIFICATIONS
(SUBJECT TO CHANGE WITHOUT NOTICE.) INDUSTRIAL

Hobart IronMan 250 Specifications

General

Input Voltage	208/230/460 V
Input Hz	60 Hz
Output Amperage Range	30 - 250 A
Duty Cycle	60% at 250 A
Spool Size Capacity	12 in
Welding Process	MIG, Flux-Cored
Wire Feed Speed Range	50 - 600 IPM

Summary

Product Overview and Processes

MIG Welding Process

Gas Metal Arc Welding process for the IronMan 250.

Flux Cored Welding Process

Flux Cored Arc Welding process for the IronMan 250.

Product Features and Benefits

Sloped Front Panel

Makes controls easy to see and access.

Arc Performance

Excellent short arc performance with easy to control weld puddle.

Increased Amperage Output

Increases machine output for higher productivity.

Increased Duty Cycle

Higher machine output duty cycle, increasing productivity with longer welding periods.

7-Position Voltage Control

Simplified and accurate adjustments, maximizing control for smooth arc.

Optional Spool Gun

Excellent for pushing soft aluminum wires.

Reversible Drive Rolls

Reduces spare parts and changeover time by using dual-groove rolls.

Hinged Feeder Panel

Provides greater accessibility for spool and feed roll changes.

Infinite Wire Feed Control

Allows precise adjustment of penetration and weld bead shape.

Low Amperage Draw

Saves energy with an amperage draw of 35 amps at rated load of 230 V input.

Complete Package

Ready to set up and weld with included accessories like wire feeder and cylinder rack.

5/3/1 Industrial Warranty

Provides five-year warranty on transformers, three years on electronics, one year on guns.

Specifications and Performance Data

Technical Specifications

Details rated output, current range, voltage, wire feed speed, input power, dimensions, and weight.

Duty Cycle Chart

Illustrates the machine's output capability across different duty cycles.

Volt/Amp Curves

Shows voltage and amperage relationships for different settings.

Accessories and Consumables

Drive Rolls

Details reversible V-groove and V-knurled drive rolls for various wire sizes.

MIG Gun and Accessories

Lists replacement MIG guns and their specifications for different wire types.

Spool Gun and Accessories

Describes the Hobart Spool Gun 3545-20 for aluminum welding.

Consumables

Lists contact tips, nozzles, tip adapters, and liners with part numbers.

Ordering Information

Included Items

Lists components that come standard with the IronMan 250 power source.

Optional Accessories

Lists available accessories like replacement guns and spool guns.

Replacement Parts

References charts for ordering contact tips, adapters, liners, nozzles, and drive rolls.