Hobart IronMan 240 Owner's Manual
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Hobart IronMan 240 Owner's Manual

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IronMan
OWNER'S MANUAL
OM-284833E
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And Wire
Feeder
240
™
2023-11

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Summary of Contents for Hobart IronMan 240

  • Page 1 OM-284833E 2023-11 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder IronMan ™ OWNER’S MANUAL www.HobartWelders.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    Connecting MIG Gun/Spool Gun to IronMan 240........

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    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.
  • Page 6 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 7: Additional Hazards For Installation, Operation, And Maintenance

    � Never weld on a pressurized cylinder—explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition. pressure.

  • Page 8: California Proposition 65 Warnings

    � 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 equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

  • Page 9: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    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.
  • Page 10 � S’assurer que tous les panneaux et couvercles sont correctement LES ACCUMULATIONS DE GAZ en place. risquent de provoquer des blessures � Fixer le câble de retour de façon à obtenir un bon contact métal- ou même la mort. métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

  • Page 11: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    � 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...

  • Page 12: Proposition Californienne 65 Avertissements

    � Affûter l'électrode au tungstène uniquement à la meuleuse dotée LIRE LES INSTRUCTIONS. de protecteurs. Cette manœuvre est à exécuter dans un endroit 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.

  • Page 13: Informations Relatives Aux Cem

    Safety in Welding, Cutting, and Allied Processes, CSA Standard Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: W117.2 from Canadian Standards Association. Website: www. csa- www.osha.gov. group.org. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

  • Page 14: Section 3 - Definitions

    Stop engine before fueling. � Complete Parts List is available at www.HobartWelders.com Safe23 201 SECTION 3 – DEFINITIONS Safe75 201 3-1. Additional Safety Symbol Definitions Do not fuel a hot engine. Warning! Watch Out! There are possible hazards as shown by the symbols.

  • Page 15: Miscellaneous Symbols And Definitions

    � Complete Parts List is available at www.HobartWelders.com 3-2. Miscellaneous Symbols And Definitions Single Phase Static Rated No Load Volt- Frequency Convert- Single Phase age (OCV) er-Transformer- Rectifier Circuit Breaker Amperage Direct Current (DC) Positive Voltage Primary Voltage A complete Parts List is available at www.MillerWelds.com Conventional Load Gas Metal Arc Negative...

  • Page 16: Section 4 - Specifications

    � Complete Parts List is available at www.HobartWelders.com 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.

  • Page 17: Duty Cycle And Overheating

    � Complete Parts List is available at www.HobartWelders.com 4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that MIG OUTPUT DUTY CYCLE unit weld rated load without overheating. If unit overheats, Thermistor (RT1) opens, output stops, and cooling fan runs. Wait fif- teen minutes for unit to cool.

  • Page 18: Section 5 - Installation

    � Complete Parts List is available at www.HobartWelders.com SECTION 5 – INSTALLATION 5-1. Selecting A Location Do not move or operate unit where Movement 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.

  • Page 19: Selecting Cable Sizes

    � Complete Parts List is available at www.HobartWelders.com 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.

  • Page 20: Installing Work Cable And Clamp

    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.

  • Page 21: Connecting Mig Gun/Spool Gun To Ironman 240

    � Complete Parts List is available at www.HobartWelders.com 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.

  • Page 22: Setting Gun Polarity For Wire Type

    � Complete Parts List is available at www.HobartWelders.com 5-6. Setting Gun Polarity For Wire Type 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).

  • Page 23: Installing Wire Spool And Adjusting Hub Tension

    � Complete Parts List is available at www.HobartWelders.com 5-8. Installing Wire Spool And Adjusting Hub Tension Hand tighten knob clockwise. When a slight Installing 8 in. (203 mm) Wire Spool force is needed to turn spool, tension is set OM-284833 Page 19...
  • Page 24 � Complete Parts List is available at www.HobartWelders.com Removing 8 in. (203 mm) Spool Hub And Spool Nut 1 Spindle 2 Spool Hub, Spring, And Nut — For 8 in. (203 mm) Spool Only 3 Spindle Hardware Remove spindle hardware and retain. Re- move spool hub, spring,and spool nut and re- tain for future use.

  • Page 25: Positioning Jumper Links

    � Complete Parts List is available at www.HobartWelders.com 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.

  • Page 26: Connecting Input Power

    � Complete Parts List is available at www.HobartWelders.com A complete Parts List is available at www.HobartWelders.com 5-11. Connecting Input Power =GND/PE Earth Ground 240 VAC, 1 804912-A 2 Receptacle [NEMA Type 6-50R (Cus- Connect green or green/yellow grounding Installation must meet all National tomer Supplied)] conductor to disconnect device grounding and Local Codes —...

  • Page 27: Threading Welding Wire

    � Complete Parts List is available at www.HobartWelders.com 5-12. Threading Welding Wire philips head wrench crescent wrench tools/ nutdriver allen_wrench allen_set flathead philips head wrench crescent wrench chippinghammer pliers needlenose knife steelbrush nutdriver uty workclamp 1 Wire Spool wirecutter frontcutter Step 2.

  • Page 28: Weld Parameters

    � Complete Parts List is available at www.HobartWelders.com 5-13. Weld Parameters OM-284833 Page 24...
  • Page 29 � Complete Parts List is available at www.HobartWelders.com OM-284833 Page 25...

  • Page 30: Section 6 - Operation

    � Complete Parts List is available at www.HobartWelders.com SECTION 6 – OPERATION 6-1. Controls 284825A 1 Voltage Control Refer to section 7-6 if light is illuminated or � This unit has three automatic timers in- flashing. cluded in its operation to help save Turn control clockwise to increase voltage.

  • Page 31: Section 7 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.HobartWelders.com 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 �...

  • Page 32: Aligning Drive Rolls And Wire Guide

    � Complete Parts List is available at www.HobartWelders.com 7-4. Aligning Drive Rolls and Wire Guide Turn Off power. Correct View is from top of drive rolls looking down with pressure assembly open. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear...

  • Page 33: Troubleshooting

    � Complete Parts List is available at www.HobartWelders.com 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).

  • Page 34: Section 8 - Electrical Diagram

    SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Welding Power Source Circuit Diagram OM-284833 Page 30...
  • Page 35 284828-A OM-284833 Page 31...

  • Page 36: Section 9 - Gmaw Welding (Mig) Guidelines

    SECTION 9 – GMAW WELDING (MIG) GUIDELINES 9-1. Typical GMAW (MIG) Process Connections 1 Wire Feeder/Welding Power Source 5 Gas Hose Weld current can damage electronic parts in vehicles. Disconnect both 2 Gun 6 Shielding Gas Cylinder battery cables before welding on a 3 Workpiece vehicle.
  • Page 37 Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed * 0.023 in. (0.58 mm) 30-90 A 3.5 ipm (89 mmpm) per amp 3.5 x 125 A = 437 ipm (11.11 mpm) 0.030 in. (0.76 mm) 40-145 A 2 ipm (51 mmpm) per amp 2 x 125 A = 250 ipm (6.35 mpm) 0.035 in.
  • Page 38 9-4. Conditions That Affect Weld Bead Shape Gun Angles and Weld Bead Profiles � Weld bead shape depends on gun an- 5-15° gle, direction of travel, contact to work distance (stickout), travel speed, thick- ness of base metal, wire feed speed (weld current), and voltage.
  • Page 39 9-5. Gun Movement During Welding � Normally, a single stringer bead is sat- isfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 Stringer Bead - Steady Forward Move- ment Along Weld Joint 2 Weave Bead - Side To Side Movement Along Weld Joint...
  • Page 40 9-9. Troubleshooting – Porosity Porosity - small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions 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.
  • Page 41 Maintain proper work and travel angles. 9-13. Troubleshooting – Burn-Through Burn-Through - a hole caused by excessive penetration. Possible Causes Corrective Actions Excessive heat input. Select lower voltage 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.
  • Page 42 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- Short Cir-...

  • Page 43: Troubleshooting Guide For Semiautomatic Welding Equipment

    9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates, but wire does not Too little pressure on drive rolls. Increase pressure setting on drive rolls. feed. Incorrect drive rolls. Check size stamped on drive rolls, replace to match wire size and type if necessary.

  • Page 44: Section 10 - Parts List

    � Complete Parts List is available at www.HobartWelders.com 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).
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2023 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num- ber preface of ND or newer. This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.
  • Page 48 Distributor Address City State 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:...

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