Hobart Ironman 240 Review 2021 – A Closer Look

Hobart Ironman 240 is a noteworthy update from Hobart Ironman 230. Although the key differences may not be super-obvious, there are some significant changes that Hobart has brought into. Being one of the leading brands of the welding industry, it’s doubtlessly going to be a game-changing one.

The Ironman 240 now offers higher power, better control, and significantly more capacity. If you are checking out the Ironman 240 for your next welding project, you better read this article till the end. We have covered all the nooks and corners of the device, covering both the thumbs-ups and thumbs-downs.

So, if you are on the same page, let’s get started!

Hobart Ironman 230 Vs Ironman 240 – What’s New?

Even though the basic mechanism and operation remain the same, the Hobart Ironman 240 comes with a better duty cycle, more power output capacity, and more voltage control options. Here’s a quick look.

Hobart Ironman 230Hobart Ironman 240
Power Output RangeMin 30 amps, Max 250 ampsMin 30 amps, Max 280 amps
Voltage Settings12 SettingsUnlimited
Duty Cycle60% at 175 amps60% at 200 amps
Circuit Voltage38V40V
Run-in TechniqueNoYes
Problem IndicatorNoYes
PriceCheck Price Check Price

Overall, the Ironman 240 comes with wider power output and circuit voltage. Then again, its unlimited voltage setting also sets you free in terms of controlling the machine. The new run-in technology makes it quite easier to start the machine more than ever.

A new blinking indicator is also added on board to warn you if there’s any overheating, overloading, or any other issue that requires diagnosis.

Pros and Cons of Hobart Ironman 240

Here is a quick look at the advantages and disadvantages of the Hobart Ironman 240 welding machine.


  • From 30 to 280 amp power
  • Excellent run-in technology for an easy and safe start
  • Welds from 24 gauges to 0.50-inch steel
  • Easy storage compartment
  • Built-in settings chart
  • Indicator light for diagnosis
  • Running wheels for portability
  • 60% duty cycle with 200A power
  • Simple two-knob design
  • Easy to operate


  • Weighing 186 pounds, the device is pretty heavy to move without the wheels
  • Considering the features and comparing with other options in the market, this one comes at a higher price.

What’s Impressive About Hobart Ironman 240?


As the Ironman 240 comes as a significant upgrade from Ironman 230, it was clearly an exciting task for us to try it out. The device is obviously smoother to operate and more effective when in need. Let’s break down what we have noticed in this machine that is worth your attention.

Operating Power

Hobart Ironman 240 allows 240V input for its operation. That means if you are a home user, you may not directly connect the device to your existing power outputs. So, you may not like this one if you are planning on using it in a residential setup. Considering the power and operation it offers, it’s more of a device for commercial settings.

As for the power input, the Ironman 240 allows you to go up to 280 amps for the thickest welding you need. As the device can weld through both Flux Cored and MIG welding, you can use the higher amps to weld up to a half-inch in steels in one pass.

It also allows you to drop down the amps as low as 30, but that’s not quite a piece of useful information for many users. However, if you need to weld some extremely thin materials, lowering the amps may make it a lot easier for you.

New Run-In Technology

Often users mess up the starting of a welding machine, and it can be sometimes hazardous, as well. That’s why Hobart has engineered a new technology that slows down the wire feeding speed until you have formed an arc.

When you hit the trigger, the motor delays 5 to 6 seconds, and then it starts as normal. Once you strike the arc, it adapts to the regular speed you have set and starts the machine. It has been engineered in this way to ensure a better and smoother arc start. It also mitigates spatters.

Welding Methods and Materials

The Hobart Ironman 240 can weld in two different methods – Flux Cored and MIG. This makes it really easy for you to weld on nearly any regular welding material. From regular thin and thick steels to stainless steels, this machine is just the perfect one to work with. Apart from these steels, the welder can also work well on aluminum,

Two Switches Only

Although the Ironman 240 is one of the most advanced welding devices to work with, the setup is pretty simple and neat. The key controlling knobs of the device are only two – the wire feed speed knob and the voltage controller knob. You can easily control these two by just turning right and left.

However, it would have been better if there were a display on the front to see what’s going on. This is one of those features where Ironman 240 should have paid a bit attention, even if it pushes the price a bit higher.

Infinite Controlling of Knobs

Apart from being simple, the knobs are a bit different than other knobs, especially from its predecessor Ironman 230. You don’t need to limit yourself to 10 or 12 clicks for the knob; rather you can now turn them 360-degrees without any stoppage.

That means you get to push the voltage or wire-speed output higher or lower just by turning the knob according to your comfort. It may cause a bit of confusion at first, but it will pass. After a few sessions of using the device, you will understand the mechanism more than anyone else.

Diagnosis Indicator

One of the most significant additions to the Ironman 240 is its diagnosis indicator lights. This is a life-saver from Hobart as it makes it really easy to check and diagnose if there’s an issue that you need to concentrate on.

If the light on the device is showing a steady light, you must check for overheating in the machine. For a double-flashing blink, it’s time to check if there’s a wire sticking into the machine. And if the light is blinking three times at once, you must check the wire drive option and the gun, as well.

This whole blinking system makes it really easy to maintain the machine as it readily informs you about anything you need to take care of. It saves you from spending a lot of troubleshooting later.

Spool Amount

As the Hobart Ironman 240 is a powerful machine to work with, you will definitely need to use a heck of a spool in it. That’s why the machine can house as much spool as you need with different sizes.

It can easily consume 2, 10, 33, and 45 pounds of spool roll in it. You can easily change the spool with a snap using the brake tension knob. This is the easiest and simplest way to interchange the spools on a MIG welder.

Spool Gun Ready

For those of you who want to weld aluminum with the Ironman 240, there’s great news for you. The machine comes as spool gun ready, which means it can easily feed soft aluminum wires.

Plus, it will effectively reduce the bird’s nest on the wires and avoid any kind of mess the wires may create. If you want to connect the SpoolRunner 200 gun, you can easily connect it to the machine as it doesn’t need any adapter or a control box for this.


Right beneath the WFS and Voltage knobs, there is a compartment that can be clicked open. After you open the door, you will find a hollow space inside that can be used to keep short and tiny parts inside. This is a great space for storage and helps you organize things a bit more smartly and easily.

Opening up the box reveals another feature – the settings chart. The chart will guide you in setting the amps, wire speed, and voltage. After opening the door, the chart will flip out and display itself.

As the setting knobs are right above the chart, Hobart planned it quite brilliantly. You can easily change the settings using the knob while looking at the chart at the same time.

Flexible Fan System

Termed as the ‘fan on-demand’ by Hobart, there is a fan inside the machine that works as a default cooler for the welder. This is quite crucial that a welding machine has to have a fan system that cools it down in the case of overheating or heating in general.

However, most devices with a fan system don’t allow you to control the fan in any way. That means it will run and operate along with the machine until the device is fully switched off. Interestingly Ironman 240 chose to walk on a different route here.

The fan here is a flexible one, and it gives you the option to switch it off and turn it on as per your need. If you think that the device needs a cooling system for some reason, you can instantly turn it on.

On the other hand, if you don’t need the fan to run, just a push of a button will turn it off immediately. That’s what we call the power of control.


One of the key perks of Hobart Ironman 240 is its portability. Although this 186-pound device is not quite easy to move with your hands, the welder has a set of pick-up handle on its top. You can easily pull it up by holding the handles if you are to move it within a smaller distance.

However, if you need to mobilize it between longer distances, the couple of wheels beneath the machine will come in handy in this case. All you need to do is simply push the machine ahead, and the device will move on the wheels pretty much effortlessly.

Warranty Offers

Although the warranty offers may change and get altered over time, in general, Hobart welder offers a range of warranty packages for the device. You can pick any of the 1, 3, or 5 years of warranty packages.

It offers these warranty packages for different parts of the machine like the Spool gun, diodes, reactors, stabilizers, transformers, valves, switches, controls, etc. You can easily pick a package while buying one.

Hobart Ironman 240 vs Miller Ironman 252

Miller 252 is one of the most powerful welding devices currently available on the market. It’s an ideal alternative to the Hobart Ironman 240, just in case you want to switch from your existing machine. Although the difference is not like the day and night, there are some key perks and concerns that you may need to consider between these two.

Here, in this chart below, we are putting down the key differences between Hobart Ironman 240 vs Miller 252 welding machines.

 Hobart Ironman 240Miller 252
Product Weight186 pounds207 pounds
Output Range30-280A30-300A
Welding ThicknessMild Steel – 24 Gauge to 1/2 inMild Steel – 22 Gauge to 1/2 in
Welding TypeFlux Cored and MIGFlux Cored and MIG
Input Voltage220/230/240 V208/220/230/240 V
Input Phase11
Max Open Circuit Voltage40V38V
Current TypeDCDC
Weldable MaterialSteel, Stainless Steel, AluminumSteel, Stainless Steel, Aluminum
Size30 X 40 X 1930 X 40 X 19
PriceCheck Price Check Price

As per the comparison above, Miller 252 can be a good choice if you are planning to switch from the Hobart Ironman 240. Although it comes as heavier than the Ironman 240, you can easily carry it around with the wheels.

Frequently Asked Questions

Is Hobart made by Miller?

No, not at all. Hobart and Miller are completely different brands. Some people tend to mix those up but it’s not correct.

Where are Hobart Welders made?

Hobart devices are manufactured today in Troy, Ohio, USA. It’s been there since the beginning of the brand.

Which welder is better Lincoln or Hobart?

There are very few differences between Hobart and Lincoln when it comes to head-to-head comparison, but Hobart comes with the advantage of better warranty cover than Lincoln. Plus, Hobart devices are more user-friendly.

Final Words

So, that was all we had on our Hobart Ironman 240 review. We hope you have a clear idea of how the Ironman 240 can bring about changes in your welding project from now on. It’s an impressive upgrade from the previous Ironman 230 and does a pretty decent job at both Flux Cored and MIG welding.

Although it’s a bit expensive considering the price, the safety features may be considered as compensation for the trade-off. Overall, the Hobart Ironman 240 is definitely going to be a go-to welding machine for any serious welder.

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