Using gasoline the generator will produce 7,500 running watts of electricity.
The welder is 240 volts.
So, 7,500 w / 240 v = 31.25 amps
According to the picture, the Hobart Ironman 210 welder output amperage range is 30 - 210.
So, I believe the welder could operate, but barely, with the generator at full throttle. And at the very lowest end of the welder’s range at 31.25 amps.
It looks like you can go up to 1/8" at 30 amps if you use thin wire. Just wonder how much penetration you can get though.
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Hobart IronMan 210 — Max Metal Thickness at 30 Amps
At 30 amps, the Hobart IronMan 210 is rated to weld up to about 1/8 in. (3 mm) of steel, depending on wire size, joint type, and process settingshobart-welding-products.manymanuals.com+1.
How this is determined
The IronMan 210’s official specs state it can weld 22 gauge up to 3/8 in. thick steel when using the full 30–210 A range hobart-welding-products.manymanuals.com+1. The actual penetration at a given amperage is set by the volt‑ampere curve in the manual, which shows that at the low end of the range (≈30 A), the weld pool is small and suitable for thin materials.
For example, the manual’s MIG process guidelines indicate:
22 gauge (0.0236 in.) — 30 A is ideal for thin sheet or light‑gauge tubing.
1/8 in. (3 mm) plate — achievable with 30 A if using a small‑diameter wire (e.g., 0.023 in.) and proper voltage; thicker plate will require higher amperage.
Practical considerations
Wire diameter matters — smaller wire (0.023 in.) at 30 A will penetrate less than 0.035 in. wire at the same amperage.
Joint configuration — T‑joints and fillet welds can be welded at 30 A for thin stock; butt welds of thicker material will need more current.
I think you are mixing ratings. I could be wrong since it has been a long day, but You are looking at the output on the welder but you want input. What amperage does the welder require for input?
You may have gotten your answers already but it looks like that welder is set up to draw 25 amps at 230V. That will allow you to weld at 150 amps and a 40% duty cycle. So the generator should run it if everything is working right. Under the cover of the welder there should be a chart (or page 29/30 of the instructions) that tell you settings for the thickness and type of metal that needs to be welded. 150 amps is for the thicker materials (1/4" steel). Materials that use the lower voltage settings should not be an issue at all. Also note instructions say 240 volts will cause the weld to run hotter.
I just wasn’t following the “welder set up to draw 25 amps at 230 volts” “that would allow welding at 150 amps and a duty cycle of 40%” stuff.
That is not how I understand duty cycle and the other stuff is beyond my ability, at this time, to understand well enough to explain it to someone else. (That’s when I know I understand it.)
Take a look at Dominic’s link section 3.12 for the input rating. You’re not concerned with the output rating because the input rating is what’s actually connected to the generator.
Short answer: Yes it should work. That size welder is typically set up to run off a 30amp supply. My Lincoln 210 runs on 30amps no problem.
Deeper dive: Welders have transformers (or inverters on newer ones). It changes the amperage, voltage and the current type (AC to DC). So that welder according to its specifications, takes in from the generator (or house) 25amps at 230 volts AC (section 3-1 of the instructions). It then goes through the welder which will drop the voltage down to 15-30 volts DC and up the amperage to 100-150 amps at the arc depending on settings. According to the specs the 25amps AC will allow you to weld at 150 amps DC. Typically that is hot enough to weld 1/4" (even 3/8") steel plate in a single pass.
The duty cycle is how long the arc will hold before the welder go into shut down to prevent overheating. It is based on a 10 minute time period. So a 40% duty cycle will allow you to weld for 4 minutes before the welder shuts off to cool down. Duty cycle should not influence the amperage needed, its just something to be mindful of. Sucks when your welder shuts you off right in the middle of your weld. Welding thinner materials does not use the power that thicker does so the duty cycle will go up allowing longer welding times. You will turn the arc amperage down on thinner materials so you don’t burn through them.
The chart 4-2 gives you the rough settings for the thickness of metal you want to weld. You also have to know what type of wire and gas is being used. Once those are known you can set speed settings for wire, flow volume for the gas and start welding. Those can then be adjusted depending on how the weld is coming out.
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