How to choose a generator for welding - Metals and their processing

How to choose a generator for a welding inverter

Gasoline generators (gasoline power plants) are miniature autonomous installations for energy production, which are used as a backup or main source of supply. Gasoline generators are divided into several types according to power and direction of use. Below in the article we will figure out how to choose a generator for welding without resorting to specialists.

Types and features of generators

Generators running on gasoline are mainly used as a backup source to supply electricity to any objects or, if necessary, to carry out field work with power tools that cannot be connected.

Gasoline generators for welding are designed for temporary operation (for several minutes or hours). If you need to work for a long time without breaks, it is better to get a diesel generator.

Gasoline generators for summer cottages and recreation - this type of generators is the most popular among buyers. The stations can produce power from 0.7 to 5 kilowatts, and are quite easy to transport.

Gasoline generators for welding machines - a variety with a power of 5 to 10 kilowatts. They are well suited for intensive work for 8 hours. It is very important to know the engine manufacturer so as not to end up with an option that will make its shortcomings known within a month. An important parameter is the size of the fuel tank and the presence of a sound insulation casing and the ability to start the generator with an electric starter.

Modern overhead valve generators can be compared with diesel ones in terms of the quality of the energy released. The units can provide very high performance while minimizing noise, and are compact and durable. It is advisable to buy this generator for welding if you plan to carry out work on a construction site or power a welding machine that periodically requires a powerful flow of energy.

A gas generator with a welding function for a cottage or enterprise produces power from 10 to 20 kilowatts. They are equipped with automatic start and are used as a stationary installation.

Design feature and operating principle

Many experts classify welding gas generators as a separate type of generator; their operating principle is no different from the usual one, and the circuit is quite simple.

When the arc is ignited, the welding current necessary to maintain the arc flows through the armature winding. Current is generated through the transformation of energy due to the rotation of the crankshaft in the power internal combustion apparatus, which converts mechanical energy into electrical energy.

What to look for when choosing

If you need high-quality welding, then you must clearly understand how to choose the right gas generator for welding. The continuity of welding will depend on it, which will directly affect its quality. A generator is also needed when it is not possible to connect to the electrical network. Thus, it will be an indispensable link in welding.

The most basic parameter is the maximum output power of a welding gas generator, which is often confused with power consumption. For some manufacturers, this parameter may be indicated directly in the technical data sheet or operating manual.

Source: https://vi-pole.ru/kak-podobrat-generator-dlja-svarochnogo-invertora.html

Gasoline generator for a welding machine: selection criteria and models

A gasoline generator is an indispensable technical tool used to automate the operation of electrical appliances and other equipment when there is simply no possibility of power supply from the central power grid.

Naturally, the use of a gasoline generator for welding is not limited to electric welding alone - it is possible to connect any electrical appliances in production and construction sites, in suburban areas, etc.

Next, we will talk about the key operational features, characteristics and nuances of choosing this equipment.

Criterias of choice

For many users, it is enough to know that when operating a fuel generator it is possible to generate electrical energy. Professionals distinguish for themselves separate categories of such devices, among which gas generators for welding and their diesel analogues are in the same row. However, it is inappropriate to consider these generators as a separate type of device that generates electricity from a fuel resource.

The principle of operation of a welding gas generator is not much different from conventional household analogues used on the farm. The key essence of its action is that when started, a welding arc is ignited, through the winding of which an electric current flows, sufficient to maintain the arc burning process.

The process of generating current is quite simple. An internal combustion engine is hidden inside the generator. This mechanism involves rotation of the internal crankshaft with the transformation of mechanical energy into electrical energy.

However, the technical simplicity of the process of generating energy for welding is not all that you need to know about such equipment. When choosing a high-quality gas generator for welding, you should rely on more significant criteria.

The most important parameter of the gas generator to which the welding machine will be connected is the maximum level of power generated. It should not be confused with consumption. You should look for this value in the user manual or data sheet.

Naturally, the generated power of the generator should be selected in comparison with the consumption of the existing welding machine. If the latter value is not in the technical documentation, then consumption can be calculated by multiplying the maximum welding current with the arc voltage and dividing this value by the efficiency of the welding inverter.

Important! The output of the generator should have a power value higher than the consumption of the welding machine (by about 30%), which will allow it to work without overload.

It is also worth noting that there are more nuances in the combination “welding unit - generator” than just “buy with a reserve”, and therefore when selecting one device for another, you should have a detailed consultation with a specialist.

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Varieties and power

Gasoline generators are classified depending on the power they produce:

Generator for domestic conditions (from 0.7 to 5 kW) - a mini-power station that allows you to power household appliances, is compact and easy to transport. In general, gasoline generators are excellent for welding under conditions of high mobility and spot distribution of objects.
A synchronous generator (from 5 to 10 kW) is a more universal source of electrical energy, which, with its power, allows you to work with both welding equipment and household appliances. It is quite possible to power one country house/plot.
A welding generator (from 10 to 20 kW) is a full-fledged welding complex that intelligently combines a generating generator set and an inverter. As a rule, due to its size, a gasoline generator with a welding function is used permanently, but it can also be made in a portable format.

Above, the power of the gas generator has already been determined by the key criterion for its selection. Calculation of this value when selecting the desired welding machine is carried out as follows:

We find the maximum level of current consumption by the inverter (Imax). For example, Imax = 21 A. Information can be printed on the housing or written down in technical documentation.
The power of this installation can be calculated using Ohm's law by multiplying the voltage by the resulting Imax value. In the described case: 220 V * 23 A = 4620 W.
In addition to the obtained value, we add 30% of the power reserve. 4620 + 1386 = 6006 W. Thus, the optimal generator power level should be at least 6 kW.

Gasoline generators with welding function

Gasoline generators with a welding function are multifunctional devices characterized by their ability to withstand heavy loads. The design of this device is an anchor that rotates due to an external drive.

A welding generator is also a power plant, but with a wider range of loads to bear. It is primarily used to start arc type welding. However, the above-mentioned versatility of such an installation is manifested precisely in the fact that in addition to power for welding, it can also be used to electrify ordinary household objects.

Among the professional areas of operation of such installations, the following stand out:

Pipe welding;
Installation of metal structures;
Connecting autonomous objects to power supply, etc.

Portable welding generators are distinguished by their compactness, mobility, optimal weight and relative “silence” during operation. These qualities make it possible to use such installations in field conditions (welding, metal cutting).

Various models of such devices are distinguished by certain physical and technical characteristics and operational features:

Manual or electric starting drive;
Wide range of battery life;
Certain fuel consumption;
Noise level and other parameters.

Welding generators dominate over simple power plants, since their performance under load is many times higher, and they perform better under instantaneous overload conditions. In general, the functionality of these installations is more flexible compared to simple “household” analogues.

Model examples

Welding generator Eisemann S6401:

single-phase;
power – 5 kVA;
constant current supply up to 220A;
welding tool – piece electrode.

Excellent for welding in places located away from the central electrical network. It is characterized by optimal dimensions, operational reliability and unpretentiousness in terms of service. The systems of this installation are perfectly protected from possible failures, which ensures an extremely long and stable operating period even at sites with increased pollution and high labor intensity (construction sites).

Power station Eisemann S6400:

three-phase switchable;
welding current up to 220A;
wire diameter up to 4mm.

Can work in two formats:

three-phase – power up to 6.2 kVA;
single-phase - 3.7 kVA.

The installation starter is manual. The design and mechanisms are perfectly protected from destructive factors, which implies an extremely long operating period of the station without the need for additional service.

Attention! Among other advantages, the described Eisemann generators are equipped with folding handles, which greatly simplify the transportation process.

Models of gas generators for welders

Among the usual gas generators for a welding inverter are:

Three-phase power station Combiflash 221R with welding function. Welding current 220A (35%), 170A (60% - direct current). In mini-power station mode, the power is up to 5.2 kW (400V) and 3.5 kW (230V). The installation is powered by a Subaru EH-41 four-stroke engine (single-cylinder) and a 19-liter fuel tank. Suitable for both domestic and professional purposes.
Three-phase gasoline power station Eisemann S10000E with welding function. In three-phase mode, power is up to 10 kVA, single-phase - up to 3.7 kVA. The equipment includes an electric starter, which simplifies the starting stage. Powered by a Briggs&Stratton 380447 four-stroke gasoline engine with an air-type cooling system. There is also an automatic safety lock that can withstand 5 times the maximum load within 4 seconds. In general, all these qualities are suitable for specialized use in engineering and installation work.

Operating rules

When operating a gasoline generator for welding machines, you should strictly adhere to the recommendations from the user manual and advice from professional welders. After purchase, you should carry out a run-through check - approximately the first 20 hours of active use allow the parts to fit together.

It is best not to run the device at a power higher than 50% of the rated documented value at this time. If we are talking about working at heights, then it is worth requiring/selecting a device with a modified carburetor capable of operating in conditions of oxygen-enriched air.

It is also worth familiarizing yourself with the rules for the following operating procedures:

Checking the oil level;
Fuel selection;
Refueling and checking fuel level;
Starting the unit;
The procedure for turning on the load;
Stopping the engine, etc.

Competent action in any situation, both normal and emergency, will allow you to maintain the functionality of the installation for the entire operational period without the need for unscheduled repairs.

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What malfunctions can happen?

When connecting and operating a gasoline generator for a welding inverter, you may encounter the following problems due to a number of reasons:

Starting does not work - problems with fuel or lack of spark at the spark plug;
Emergency stops - clogged air filter, oil or fuel filter, possibly insufficient oil level;
Does not reach high/maximum power - the piston wheels are worn out or the air filter is clogged;
The engine smokes - there is general wear of parts (piston, cylinder) or increased fuel supply, excessive oil level in the crankcase;
Too much oil consumption – wear of the cylinder or piston rings.

All of these problems can be easily solved if they are correctly identified.

Conclusion

From the material above, it is not difficult to understand whether inverter welding can be connected to a gas generator (yes!) and what the sequence of user actions should be. If you adhere to all the described criteria and operating nuances, you can extend the service life of gasoline generators and effectively use the welding machines attached to them.

Source: https://voltobzor.ru/generatory/benzinovye/dlya-svarochnogo-apparata

How to choose the right welding generator of the required power

In conditions where there is no electricity supply, there is a need for a backup power source. For this purpose, welding generators of various powers are used. They are designed to work in “special” conditions. For example, at a construction site, the territory of which is remote from the centralized supply of electricity. It is undesirable to work with a transformer in such conditions, as power surges may cause a breakdown of the power plant.

Features of choosing a generator

Before choosing a gasoline generator for a welding machine, it is very important to pay attention to its power . With its large value, the gasoline welding generator operates in normal mode. He will always have a reserve of power.

The following selection criteria should be adhered to:

To select a generator for inverter welding, you need to know the maximum current value. It is indicated on the body of the device. Designated Imax.
Power calculation is determined by the formula of Ohm's law. Let's take Imax 23A. We multiply 23 by 220, we get 5060 W. Add 30% to the result obtained. The final power value of the device will be 6600 W.
Which gas generator is needed for a welding inverter depends on the diameter of the electrodes used. This size must be suitable for the power of the device. For example, the operation of electrodes with a diameter of less than 2 mm requires a power of 2.5 kW. When the diameter increases to 3 mm, the power value also becomes greater - 3.5 kW.
When determining how much power a generator is needed for inverter welding, it is necessary to take into account the voltage of the outlets. The inverter model must match this value. For a household system, an ordinary 220 V outlet is sufficient.
Very powerful inverters with a three-phase connection must be plugged into sockets that can withstand 380 V.
Professionals advise taking into account the weight of the device. The compact wheeled system is suitable for frequent transport.

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Selection of generator for welding

When the design of a gas-welding generator is equipped with cast iron sleeves, its service life increases dramatically. These devices can be used for approximately 1500 operating hours. Aluminum analogues have a shorter service life.

Today you can purchase inverter units that have power factor adjustment. These systems can work with a variety of generator models as they can be set to low voltage.

Such models are designated by the additional prefix PFC. In principle, welding gas generators are not intended for continuous use. They require a short break.

Diesel models are suitable for daily, long hours of work. A device with a power of 0.7-5 kW is suitable for working on a personal plot. These products do not have much weight. Therefore, they are easy to transport from place to place. A power of 10 kW allows you to perform daily work for 8 hours.

Source: https://pochini.guru/instrument/kak-vyibrat-svarochnyiy-generator

Recommendations on how to choose a generator for a welding machine

To carry out welding work, you cannot do without electricity. It is not always possible to connect to the electrical network. Not all equipment can operate from a regular outlet. And in order to connect to high-voltage wires on the street legally, you will need to obtain the necessary permits.

An electric generator can be a real solution to this problem. It is not surprising that almost every professional installation team has such equipment in a set of necessary tools.

But how to choose a generator for a welding machine? Why isn't a regular station with an additional power reserve suitable?

Design and principle of operation of a welding generator

You can select a generator for a welding machine only if you have a good understanding of the internal structure and operating principle of the equipment. Generator models designed to connect a welding machine have their own characteristic features that distinguish them from all others. But in general, the design of generators remains the same, regardless of their purpose.

Drive - the voltage generated by the electric generator for DC welding is produced thanks to the motor. Usually they use a gasoline diesel or gas engine. The choice of generator for a welding machine should be based on the quality of the drive. Practice has shown that four-stroke engines are more efficient and durable.
Technical characteristics - a welding generator is a device that allows you to convert the mechanical movement of the crank mechanism into electric current. Moreover, depending on the design, both the technical characteristics of the resulting voltage and the methods of its transformation may differ.
Functionality - the difference between a welding generator and a regular one is that to operate a simple generator you will need to install a transformer or an AC rectifier. The generator armature, driven by the rotor, produces alternating voltage with a high wave range. Welding generators with a built-in welding machine usually use a built-in double converter in their design. The result is a voltage that meets the necessary requirements for high-quality arc welding.

There are three main classifications of electric generators used for welding:

inverter
transformer
with rectifier

Of these, only the inverter can be used to connect a welding machine directly; the rest will require the use of additional equipment.

What is the difference between a welding generator and a regular one?

The main difference between gasoline-powered DC welding generators and simple generators is the quality of the generated voltage. The conversion process occurs as follows:

The piston system drives the engine crankshaft. The crankshaft, in turn, transmits rotation to the generator rotor, resulting in the formation of an alternating magnetic field, which, using a coil, is converted into low-quality electric current with a large alternating voltage wave. Conventional models immediately supply this electricity to the user.
To produce a welding arc, a constant voltage with minimal wave fluctuations is required. To obtain a current of this quality, a gasoline welding power station for welding uses additional conversion devices already built into the housing.

If we take into account the quality and stability of the output voltage, no station can compare with an inverter. The inverter-type welding generator has a double converter.

How does this node work?

Alternating current is converted to direct current. As a result, the voltage stabilizes and it acquires the necessary characteristics.
Direct current is transformed into alternating current. But after such a transformation, it has the necessary parameters to ensure high quality arcs during work.

A diesel generator for a welding machine is not the best option. Even if all conditions are met, the voltage quality does not fully meet the requirements. Typically, diesel stations are used when simultaneously connecting several automatic welding machines at the same time.

Is it possible to use a welding generator as a regular one?

Yes, you can, but you will need to take into account some features of connecting the generator to the electrical network at home. A gasoline electric generator for an inverter-type welding machine converts the voltage, thus getting rid of its surges and stabilizing the wave.

This allows the use of such devices even for medical equipment and computer equipment that are sensitive to voltage surges. Although inverter models cost slightly more, they can be used without a rectifier and installed to meet the electricity needs of a private home.

The power of inverter models is sufficient to operate as a completely autonomous power source due to the absence of power lines.

Calculation of generator power for welding

The power of the gas generator for the welding machine must be equal to the maximum power consumption of the arc. Some manufacturers “forget” to indicate this coefficient, leaving buyers to do the calculations themselves. There is nothing complicated in calculating the power of an electric generator for welding work.

You will need to determine the power consumption of the welding machine, and then select the appropriate electric generator. A gasoline welding generator with a built-in welding machine is more convenient, since the installed modules have already been adjusted and selected taking into account optimal performance characteristics.

You can calculate the required arc voltage as follows:

You can find out the maximum power of the device in the technical documentation or on the power regulator itself. The maximum value will be the coefficient required for calculations. So, for a device in which the current can be adjusted from 10 to 160 A, the last indicator is taken.
We multiply the resulting coefficient by the arc voltage of 25V.
We divide the resulting value by the efficiency of the device; for most models it is 0.85%.

As a result, for a welding machine with a maximum current of 160A, the calculations will look like this:

160A × 25V ÷ 0.85 = 4705W

At maximum load, the device will practically not work, so the average power of the equipment will be enough. To determine it, you will need to multiply the maximum on-time by the resulting value. The estimated minimum generator power for the welding machine in this case will be this amount with the addition of 20-30% for reserve.

How to choose a gas generator for welding

In addition to the required power of the selected power generating equipment, you should pay attention to some characteristics that distinguish gasoline-powered generators.

The main purpose is to choose a gasoline generator for welding with a welding module built inside. Equipment with a built-in module for welding work can later be used as an emergency power source for the home. The advantage of such models is that the output voltage is fully consistent with all the necessary parameters for cooking.
Engine's type:
1. a two-stroke motor is cheaper and therefore is most often used for household (amateur) generator models. Push-pull units are not suitable for constant operation, they get very hot and have other limitations, but their performance is sufficient to carry out the necessary work around the house.
2. The four-stroke engine is more powerful and has a water cooling system. A gas generator with a built-in welding machine for welding with a four-stroke engine will last longer, although it costs slightly more than a regular model.

The popularity of gasoline generators is ensured by the high quality of the generated voltage.

The quality of generated electricity is mainly related to the specific operation of internal combustion engines, which ensure a more uniform supply of motor torque to the generator rotor. And one more important point. For welding and household needs, it is worth purchasing inverter generator models. They are more economical and have certain advantages that allow them to be used to the greatest advantage.

Namely:

Uniform supply of voltage during work.
Automatic adjustment of voltage release during idling.
Increasing voltage supply during load.

Thanks to automatic adjustment of the generated power in inverter models, fuel consumption is reduced. This makes inverter-type stations the most economical of all types of electric generators.

How to choose a welding diesel generator

The operating principle of a diesel welding generator-power plant is in many ways similar to that used by equipment running on gasoline. But in order to be able to use the resulting voltage for welding work, it is necessary to use additional equipment.

The disadvantages of diesel generators for connecting welding equipment are the intense wave of current produced and the lack of a stable output voltage. Therefore, the manufacturers themselves do not recommend the use of diesel equipment for connecting individual welding machines.

It is necessary to select welding diesel power generators for welding work in the following cases:

Several automatic welding machines will be connected to one point at once. The voltage requirement in this case can only be provided by diesel engines.
Fuel economy - if the main activity of the installation team is welding, then diesel stations will help to obtain significant savings on fuel consumption. Diesel engines are more economical.
Duration of offline operation. It is better to choose a welding diesel generator-electric power station with a built-in welding function if you plan to use it intensively throughout the working day or even over several shifts.

For convenience, some stations are mounted on a frame with wheels with a towing device. Industrial stations thus increase their mobility and, accordingly, their scope of operation.

The choice of a diesel or gasoline generator mainly depends on the actual needs of the buyer and the intensity of use. Both one and the second option have their own advantages and limitations associated with operation.

Source: https://Stroy-Plys.ru/236-kak-vybrat-generator-dlya-svarochnogo-apparata.html

Which electric generator to choose for a welding machine

A generator for welding differs from a conventional household analogue primarily in that it operates with a variable load :

You start the backup source and turn on the device, but there is no load yet;
As soon as the electrode touches the metal, an electric arc occurs and the load jumps to maximum;
As soon as you remove the electrode and the arc disappears, the load drops again and the engine runs idle.

Considering that welding machines have high starting currents, not every generator is designed for them. Often, due to high starting currents, the alternator winding burns out.

In addition, a standard asynchronous gas generator has wave voltage surges. Because of this, efficiency decreases and the service life of the connected equipment is reduced. Stable voltage is important for welding .

Alternatively, you can use inverter generators, but they are too expensive compared to conventional ones. They are intended for high-precision equipment and measuring instruments that require stable voltage. It is irrational to use inverter gas generators for a welding machine.

with a synchronous motor or Duplex - a combination of a synchronous and asynchronous motor - is best suited Duplex technology was invented and patented by Endress, and a whole series of electric generators is now produced under this brand.

For welding machines, both gasoline and diesel power plants are used. Gasoline ones are cheaper, and their range is greater among low-power models up to 10 kW. Nevertheless, with frequent use, diesel engines will be more profitable , since diesel fuel is cheaper than gasoline.

The advantage of gasoline generators is that they can operate at lower temperatures than their diesel counterparts. Summer diesel fuel waxes and freezes at -5°C , which makes it impossible to use diesel generators in winter.

In addition to technical requirements, it is important to calculate the optimal characteristics.

How to choose a generator for welding?

The first thing you need to pay attention to is the rating of the power plant. It is selected according to the maximum power of the consumer. It is best to take it with a margin of 25-30% , because frequent use at maximum load will increase wear on parts.

How to calculate generator power?

The power can be calculated using the formula: Pnom = I × Uarc / η , where I is the maximum current of the device, Uarc is the electric arc voltage, η is the welding efficiency. The values of U and η are almost always stable, the arc voltage is 25V, and the efficiency is on average 85%.

For example, if the maximum current of your device is 150A, then its maximum power consumption will be:

150A × 25V/0.85 = 4412W.

Rounding, we get 4.4 kW. Now let's add another 25% of the reserve:

4.4 kW +1.1 kW = 5.5 kW.

This is exactly the rating you will need for 150A.

Is it possible to use a lower power generator for inverter welding?

The inverter allows you to regulate the current. And it can be powered from an electric generator of less power than the rated one, but before that you need to know the maximum current level.

And so, let’s imagine that you have a 225A inverter, but an electric generator of only 4 kW. Now let's calculate using the inverse formula: I = P × η / U;

The maximum current strength of the inverter at which you can connect it to a 4-kilowatt generator is:

4000W × 0.85 / 25V = 136V.

Thus, you can set the 136V threshold on the inverter and freely use a 4-kilowatt power source. But, if you set the current strength higher, the alternator will burn out and will have to be repaired.

Selecting power by electrode diameter

Larger diameter electrodes require higher current. That is why there is a relationship between the network load and the diameter of the electrodes. So, let's look at the table:

For example, if your inverter welding is powered by 4.5 kW, then the largest electrodes with which you can weld metal are 4 mm. If, for example, you insert a 5 mm electrode, then the power of 4.5 kW will not be enough to melt the metal efficiently, and the seam will be of poor quality or not welded at all. Therefore, autonomous power supply must be selected primarily based on the maximum power of the inverter.

Not all welding machines can be powered by an electric generator and vice versa. Therefore, before purchasing, check with the seller whether the selected welding model can be powered by a power plant. The manufacturer always indicates this in the instructions.

Which manufacturers are suitable for welding machines?

Based on the specifics of the application, not all manufacturers produce power stations for welding machines. Most suitable brands:

AGT - mainly “three-phase” with a rated power of 5 kW. Cheap, gas generators use original Honda engines. According to technical characteristics and fuel quality requirements, adapted for the Eastern European region. Made in Romania;
Endress produces single-phase and three-phase gas generators with a nominal power of 3 kW. Inside there are high-quality engines from Honda, Briggs & Stratton, Yanmar, Kohler. They are mass produced in Germany and have no chronic problems. Good brand reputation;
RID produces both single-phase and three-phase power plants with a capacity of 5 kW and above. Produced using technologies from the German brand Geko. Produced in small quantities. The cost is higher than that of competitors, but the quality leaves no questions. Reliable engines.

If you do not yet have a welding machine, you can alternatively purchase a special welding generator instead.

What is better, select welding and generator separately or buy a welding generator?

A welding generator is a structure consisting of a gas generator and a welding machine paired with it. The power plant is designed in such a way as to serve welding, so it has a longer service life. Other advantages :

Short circuit protection installed;
It is possible to work in areas remote from the central power supply (city outskirts, field, road);
The design is more compact than if you connect welding separately;
The cost is lower than a diesel generator of similar power.

Such an electric generator can only be used for welding;
Gasoline has better fuel consumption and is more expensive than diesel;
Cannot be powered from the central network;
Low motor life.

The most significant limitation is that it cannot be used as a backup power source for other consumers. It is intended for welding only .

If you select separate power for welding, it is better not to use it for other purposes, and vice versa, if you have a power station at home for backup power, try not to connect welding to it. This can result in breakdowns and costly repairs.

A welding generator is the best option if you are professionally engaged in repair work, constantly traveling to open areas without access to electricity. You don't have to connect or configure anything - just start the engine and adjust the current to the diameter of the electrode. Fewer wires and easier to manage.

But, on the other hand, this way you will not be able to connect the structure to the central network. The average gasoline consumption is 0.5-0.6 l/kWh, and this will cost 10 times more than when connecting the device to the central network. In addition, with such a consumption, electric generators have limited autonomy. On average it is only 3-5 hours.

If you carry out most of your welding work with access to the central power grid, it is cheaper and more profitable to buy a generator separately

Source: https://moy-instrument.ru/instrumenty/kakoj-elektrogenerator-vybrat-dlya-svarochnogo-apparata.html

Gasoline generator for welding - which welding machine to choose - articles Energoprof

A gasoline generator is a fuel-powered autonomous equipment that makes it possible to use electrical equipment in places where there is no access to a central power line. Almost any device can be connected to the electric generator, including an electric welding machine. In this article we will figure out which gas generator is needed for welding, what power it should be and consider the most popular models of mini-power plants.

Everyone knows that gasoline, diesel and gas generators are used to generate electricity. However, upon closer examination, it is clear that this equipment has many types and varieties and can differ in dozens of different parameters. Special generator models are usually used for welding, but they can also support the operation of other equipment.

The operating principle of a gasoline welding generator is almost the same as that of standard household stations. Its main difference is the need to constantly maintain voltage at the level for burning the welding arc. The operating principle of the electric generator is quite simple.

The fuel engine transforms thermal energy into mechanical energy, and the generator module transforms mechanical energy into electrical energy.

To choose a gas generator for welding that will be reliable, durable and energy efficient, you must rely on certain criteria.

The main parameter is the power of the gas generator for welding. The required power level will be indicated on the consuming device itself or in its instructions. It should be taken into account that the power of the generator should be 25-30% higher than the energy consumption of welding, since long-term operation in intensive mode has a negative impact on this equipment.

But choosing a gas generator for welding is a painstaking process in which it is necessary to take into account not only power, but also many other features. The ideal option is a detailed consultation with an experienced specialist who can take into account all the factors and calculate the parameters.

The classification of electric generators takes into account their rated power:

Household (0.5 - 5 kW) - small power stations that are designed to power household electrical appliances, lighting devices and tools. Such units are distinguished by their compact design and low weight, which greatly simplifies the process of transporting them.
Synchronous (5 - 10 kW) are reliable and universal sources of electric current, which are at a power level that allows both to power household electrical appliances and to be a source of electricity for welding equipment. Such a device is capable of supplying electricity to a private house or plot.
Welding machines (4-20 kW) are a full-fledged technical complex, which consists of a generator set and an inverter. The market offers both stationary models of electric generators for welding and mobile stations.

Calculating the power required for your welding machine is quite simple. First, you need to find on the case or in the instructions of the welding device its maximum current consumption level I max (for example, 21 Amperes), multiply this number by the voltage (220 Volts) and get 21*220=4600. To this number you need to add a power reserve of 30%, as a result, to power a welding machine with a consumption of 21 A, you will need a 6000 W (6 kW) generator.

Gasoline generators with welding function

The market offers a wide range of gas generators with a welding function (pre-installed welding machine). The main feature of such equipment is the ability to withstand intense loads for a long time.

The welding generator is not particularly different from conventional mini-power plants, except that it has a wide range of loads to be carried. A useful feature of such equipment is the ability to power not only welding machines, but also ordinary household electrical appliances, construction and other tools.

Most often, such units are used for:

Pipeline welding;
Installation of metal structures;
Connecting equipment in places where there is no central power line.

Another advantage of most welding generators is their portability. They do not take up much space, have a fairly low weight and operate quietly, which allows them to be used both in the field and on city streets or in workshops.

To understand which gas generator is best suited for welding, you need to take into account several features:

Starter type (manual or electric);
Execution (open or noise-absorbing casing with moisture protection);
Fuel consumption;
Fuel tank volume;
Noise level and so on.

Welding gas generators are in many ways superior to conventional stations because they are able to operate stably under load and withstand peak surges. In general, the functionality of such equipment is much wider than that of conventional gasoline generators.

Possible faults

During commissioning and operation of a gasoline welding generator, certain technical problems may arise:

The power plant engine does not start. The problem may be in the fuel system or spark plugs;
Sudden engine stops. First of all, it is necessary to check the air and fuel filters, and also measure the oil level;
Insufficient power level. There may be problems with the air filter, fuel quality or wear of the piston rings;
Smoke from the engine. General wear of the mechanisms is possible; in addition, this problem may arise due to too high an oil level or an excessive fuel supply;
Excessive oil consumption. Engine wear (cylinders, piston rings).

With proper troubleshooting and diagnostics of the system, all these problems are quite easy to fix.

Popular models

Among the generators for welding work, there are several popular models:

Welding generator Eisemann S 6401. S 6401 Power: 4 kW Fuel: gasoline Degree of automation: 1 - manual start Voltage: 230 V More details This station is equipped with an electric starter for easy starting and a four-stroke air-cooled gasoline engine. One of the features of this electric generator is the presence of a special protective interlock that can withstand fivefold loads within four seconds. This equipment can operate in two modes: welding and generator. Accordingly, this equipment is capable of performing the function of an autonomous source of electrical energy in a private house, country house or plot. Thanks to its compact dimensions, you can easily transport this generator for technical work in the field.
Welding generator Atlas Copco QEP W210. QEP W210 Power: 4.2 kW Degree of automation: 1 - manual start Voltage: 230/400 V Fuel: gasoline More detailsPortable equipment with low weight and dimensions, which is characterized by low operating noise. It should be noted that this model is equipped with a Japanese engine from Honda, which is characterized by high energy efficiency and a long service life. This welding generator is often used at construction sites, as well as for road repair work. The station is equipped with a fuel tank with a capacity of 6 liters, which is enough for 3 hours of continuous operation in intensive mode. On the generator body you will find one single-phase and one three-phase socket for 380V networks.
Welding generator Fubag WS 230 DDC ES. WS 230 DDC ES Voltage: 230/400 V Fuel: gasoline Degree of automation: 1 - manual start Power: 5 kW More Powerful three-phase mini-power station for welding, which is equipped with an electric engine starting system, a socket for single-phase consumers at 220V and a socket for three-phase equipment at 380V . This equipment is in great demand on the market and is often used for emergency repair work in places where there is no access to the central power line. With a maximum welding current of 230 A and a power of 6.3 kW, this generator can be used to perform work of any complexity. This equipment has stable operating parameters and a long service life.
Welding generator Geko 6401 EW-S/HEBA. 6401 EW-S/HEBA Voltage: 230 V Fuel: gasoline Degree of automation: 1 - manual start Power: 5 kW Read more Gasoline electric generator for welding from a well-known German manufacturer is designed to supply electrical energy to a house or site, as well as to perform welding work on construction sites, field and other objects. The fuel tank volume of this equipment is 6.5 liters, with fuel consumption at a rate of 2.3 liters per hour, this volume is enough for almost 3 hours of continuous operation. It should be noted that this station is equipped with a powerful engine from the manufacturer Honda, as well as a special oil sensor that will prevent jams and other problems associated with the engine.
Welding generator SDMO VX 220/7.5 HC. VX 220/7.5 HC Power: 6.4 kW Fuel: gasoline Degree of automation: 1 - manual start Voltage: 230/400 V More Reliable and energy-efficient gasoline equipment with a rated power of 6.4 kW. This device is equipped with a fail-safe manual starting system and can power both single-phase and three-phase electrical equipment. This station is perfect for welding work in places where there is no access to a central power line. This equipment is also equipped with a durable engine from the Honda brand and has a long service life. Thanks to its light weight and compact dimensions, this unit can be quickly transported from site to site.

How to choose a generator (power station) for a welding inverter. Articles of the company "ChUP

Oct 20, 2017

“Which generator is suitable for welding” is a question that often arises among people who have decided to seriously engage in welding on their own and at the same time do not have the opportunity to connect the welding machine to the network. It’s easy to get confused, especially after we see a huge list of available models on the online store page.

It would seem that it is very difficult to understand this diversity, especially if you have a liberal arts education behind you. In fact, any of us can choose the right generator for a welding inverter; to do this, you just need to know a few small but very important nuances. They will be discussed in this article.

What points must be taken into account when choosing a generator?

As befits a serious unit, each generator for inverter welding has a huge number of different technical characteristics, among which it is very easy for a beginner to get confused. But for the right choice, only five of them are most important:

power consumption;
welding current;
diameter of the electrodes used;
compatibility of the generator with inverter equipment;
the generator must be synchronous or with Duplex technology, manufacturer

It is these parameters that you should pay special attention to in order to use the generator for a long time and safely.

Generators differ by type into synchronous, inverter and asynchronous, as well as a symbiosis of asynchronous and synchronous Duplex series (manufactured by Endress); synchronous or Duplex series generators are suitable for welding . Inverter engines, as a rule, have insufficient power and are not designed for high starting loads. You can find out more about the types of generators in a separate article here.

Generator power for welding - what is the reserve for?

In most cases, the power of the welding inverter and generator is indicated by the manufacturer in the technical data sheet. Therefore, even a child can easily find these values and compare them. The main thing is not to confuse the power units kVA and kW, as well as the declared rated and maximum power of the generator.

It should be remembered that when buying a generator, you need to choose a model that has 25-50% more power than the inverter you have. This is explained quite simply - constant operation of the generator at the limit of its capabilities will very quickly disable it and will not make it possible to use the full potential of the welding machine.

If for some reason you do not have information about the power of your welding inverter, you can calculate it yourself using a simple formula:

Maximum current * arc voltage / efficiency of the welding inverter - maximum power.

In this case, you only need to know the value of the maximum current, since the other two components are almost always constant (the arc voltage is 25V, and the inverter efficiency is 0.85).

For example, if your welding machine has a maximum current of 180 Amps, then approximately its power is:

180A*25V/0.85=5294 W, which means that in this case, the optimal value for the generator will be a power of 5294 W + 25% reserve = 6617.5 W, or if converted to kW - 6.6 kW.

Welding current - it must be taken into account

Another good news is that you can very well use a generator for inverter welding, which has less power than your inverter. However, in this case, you will have to use it with some restrictions, namely, reduce the current strength to an acceptable value.

Take, for example, the case if you decide to purchase a 4 kW generator model.

We use the same formula as when determining power, but in reverse order:

Power*Efficiency/Arc Voltage = Current or 4000*0.85/25 = 136 A

Thus, on a 4 kW generator you will be able to weld on your welding inverter without any noticeable loss of quality with a current of up to 130A.

Electrode diameter - a label that is easy to remember

Another important nuance that should be taken into account is the correspondence of the electrode diameter to the minimum power of the generator. These data are approximate and fit into a simple table:

Electrode diameter (mm) Minimum generator power (kW)

2	2,5
3	3,5
4	4,5

That is, if you plan to carry out welding work with a 4 mm electrode, then the minimum power of the generator for welding should be at least 4.5 kW and higher.

Which generators are suitable for working with a specific welding machine?

You have read the main rules for choosing a generator for welding in the previous sections. Using them, you can safely start purchasing a power plant. But to make it easier for you to navigate the assortment, let’s take a closer look at the most popular inverters for household tasks and determine which generators are most suitable for them.

For inverters Svarog

Unpretentious and inexpensive Svarog inverters stand out among other brands with a long five-year warranty. Buyers also often prefer them due to their low price, so purchasing budget options for Huter and Fubag generators seems like a completely reasonable decision.

The welding inverter Svarog ARC 205 (J96) will work perfectly in tandem with the Huter DY6500L generator. This high-quality and useful unit can successfully operate on natural gas, which significantly increases the efficiency of the generator.

For Resanta inverters

The popular inverter manufacturer Resanta also produces products intended for the mass consumer. A distinctive feature of this brand is the compact size and light weight of welding machines.

For the household welding inverter Resanta SAI-190, you can use the BRIMA LT 8000 B gasoline generator, which, in addition to this purpose, will, if necessary, serve you as a backup power source at the dacha or in a country house.

For Kemppi inverters

Finnish Kemppi inverters have proven themselves worthy when working in harsh natural conditions and in production. They are rightfully the leader in sales among imported premium models. They are bought by people who know how to value real quality and reliability.

In addition to the popular model of the Kemppi Minarc Evo 150 welding inverter, you can safely purchase the ERGOMAX ER 6600 generator, which is characterized by very low fuel consumption, a durable frame and reliable overload protection.

For EWM inverters

Products of the famous German brand EWM appeared on our market back in Soviet times. From then until now, EWM inverters have brought real pleasure to the people who work with them. Such a device needs an excellent generator.

Therefore, for the EWM Pico 162 welding inverter, the ENDRESS ESE 606 HS-GT generator, which is equipped with a Honda engine and equipped with a spacious fuel tank for long-term operation without refueling, seems to be a worthy partner.

Useful tips for choosing a generator

There are several other useful tips based on the recommendations of welding professionals that will be useful to you when purchasing a generator for an inverter welding machine.

generators with a power of up to 10 kW on a gasoline basis . They are most widely represented in this segment. And more powerful power plants run on diesel fuel.
The power reserve of a gasoline generator, at least 15-25%, greatly facilitates ignition of the arc. For power plants running on diesel fuel, it is desirable to have a larger reserve - up to 50%.
The most functional are power plants equipped with cast iron sleeves. Their minimum service life is 1500 hours . Aluminum blocks can withstand significantly less load - up to 500 operating hours.
Inverters with the abbreviation PFC in the name have a built-in power factor corrector in their circuit design, so they can operate at reduced voltage and are excellent for operation from a generator, for example the Svarog ARC 160 PFC model.

The information provided in the article is intended for conventional welding inverters, which are often used in domestic conditions.

For professional equipment (semiautomatic welding machines and inverters designed for argon-arc welding), certain problems may arise when operating from a generator. Many manufacturers explicitly state this in the user manual. Therefore, it is highly advisable to consult with specialists before purchasing in order to avoid serious consequences.

Source: https://stroitelplus.by/a46677-kak-podobrat-generator.html

How much power does a generator need for inverter welding?

When choosing a welding generator, you need to take into account many characteristics. But from the total number it is worth highlighting those that are really important and decisive:

Power;
Welding current;
Electrode diameter;
Can the generator work with inverter equipment?

There are synchronous, asynchronous and inverter installations on the market. For welding, you need a synchronous generator, since an inverter generator cannot handle a high starting load, and it is weaker in power.

Calculating power

The power of the welding generator and inverter can be found in the technical documentation. You definitely need to take care of its reserve (at least a quarter of the maximum value). If this is not done, then prolonged operation of the generator at maximum values may negatively affect its performance and characteristics.

It is important to understand the difference between rated and maximum power parameters, and not to confuse the units of measurement (kVA and kW).

Confusion in this issue arises due to the fact that the power consumed by the inverter is always indicated in kW, and on some generator models the manufacturer may indicate kVA (kilo Volt Ampere).

This is most often practiced by Chinese manufacturers. To correctly calculate equipment compliance, you need to recalculate the kVA values using the formula:

1 kW = 1 kVA x KM (power factor)

For reference, the power factor of a welding inverter can be in the range of 0.6 – 0.7.

Example of power calculation

Let's calculate the parameters of an inverter welding generator for a welding machine with a welding current of 160A. Inverter units allow you to adjust the welding current over a wide range. This means that the station can operate at both maximum and minimum current. To calculate the maximum power consumption, you need to take the maximum welding current, multiply it by the arc voltage (usually 25 V) and divide the result by the efficiency of the inverter (usually 0.85).

In our example it would be: 160 A x 25 V / 0.85 = 4,705 W.

In this way we obtained a maximum power value of 4.7 kW.

Current strength

When organizing inverter welding, it is allowed to use a generator with a power lower than that of the inverter. But in this case, you will have to reduce the current to an acceptable level.

Electrode diameter

When choosing a welding generator, you need to remember that its power corresponds to the permissible diameter of the electrodes used. To figure out which unit you need, study the simple table:

diameter, mm	generator power, kW
2	2,5
3	3,5
4	4,5

Recommendations for choosing a generator

When purchasing an installation for an inverter welding machine, listen to several recommendations from experienced professionals. So, which unit and when will be the best choice:

If you need a station with a power of up to 10 kW, it is better to pay attention to gasoline units. In this range, the market offers a wide choice of models. If it is necessary to purchase more powerful stations, a diesel modification becomes a profitable purchase.
The presence of even a small power reserve of a gasoline station, 10-20%, will significantly facilitate the process of igniting the arc. If we are talking about a diesel generator, the reserve should be greater - up to 50%.
The most practical and functional will be installations with cast iron sleeves. Such stations have a minimum service life of 1.5 thousand engine hours. If the generator has an aluminum block, then you can count on a power reserve of about 500 hours.

Our experienced staff will help you significantly simplify the task of choosing equipment with the desired parameters and characteristics. Depending on the situation, we will recommend exactly the model that suits you best. Call now!

Source: https://energoplaza.com/statji/vybor-generatora-dlya-svarochnogo-invertora/

How to choose the right generators for welding inverters: power and current

A large share of welding work takes place in places remote from electrical networks. Even when building a house in a village, permission to connect to a power line is issued after the construction of the building, when there is somewhere to connect the cable. The generator for the inverter is used for welding work. In the remaining time, it can serve as a source of current in the country and for working with power tools.

Structure

Generators convert the energy of mechanical movement into electrical energy. The simplest example is a car generator, which uses the torque of the wheels to charge the battery.

The gas generator for the welding inverter is driven by an internal combustion engine, which rotates the shaft and the current collector and frame . When the rotor rotates, an electromagnetic current with alternating polarity is alternately excited on the magnet coils and supplied to the output cable.

Operating principle of the inverter

The welding inverter converts 220 V current with a frequency of 50 Hz into high-frequency alternating current with low voltage.

The current from the network is supplied to a rectifier - a diode bridge.
The filter smooths out peak values, leveling the current to a straight-line value.
The transistor unit turns it into an alternating, but high-frequency one.
The voltage in the transformer is reduced. The current increases.

Additional current regulator and stabilization units ensure a uniform high-frequency output flow. As a result, in case of any voltage drops in the network, the inverter produces a stable current . This makes it easier to choose which generators are needed for the welding inverter.

To excite current in the windings, pull the starting cord. The hand makes a sharp movement towards itself. If you have a battery, just press the button.

Selecting a Power Source

Inverters are capable of operating not only from a 220 V network, but at a strong voltage drop to 0.165 kV. The minimum current drop data is indicated in the technical data sheet . This feature of the equipment allows you to cook not only from a stationary power source. You can connect a generator for welding with an inverter. The choice is made according to the following parameters:

inverter power;
electrode diameter;
current strength;
compatibility of the generator with the welding machine.

According to the principle of generated current, generators are divided into: synchronous, asynchronous and Duplex type. You should choose only synchronous models , they are suitable for electric arc welding as a power source.

Power calculation

The power of a generator for an inverter-type welding machine is determined according to technical characteristics, or is calculated using the formula:

PG = (AC · 25V ÷ 0.85) · 1.25;

where: PG – power;

AC – rated current;

0.85 – efficiency;

1.25 – the minimum power reserve is 25%;

25V – arc voltage.

For example, with a current of 180 A, indicated within the regulation limits as a large value, a generator with a capacity of 6.7 kW should be connected.

Maximum value

The maximum power of the power plant must exceed the rated power of the inverter by 25 - 50% . Otherwise, the equipment will operate for a long time at maximum power, and the generator will quickly fail - it will burn out.

When the arc is ignited, a short-term voltage surge occurs. It significantly exceeds the rated voltage specified in the technical specifications of the device. The energy reserve protects against overloads.

Effective and reactive power

On the bodies of the devices you can see the value of the active power and the sine of the angle ϕ. From these values, reactive power is calculated - the value of the current that the oscillating circuit releases back into the system . Reactive power does not perform any work.

Active power is used for useful work and heating - consumed by the resistance of the internal components of the equipment. It is the amount of active power that should be known to select equipment. The value of the angle ϕ determines the magnitude of the phase shift.

Sockets

When connecting the welding machine to the generator, a cable is used, at one end of which there is a grounded socket, at the other end there is a special plug, which is inserted into the output socket of the power source. Such a cable is usually found among the components of the generator and inverter.

Fuel type

A generator is a power plant with an internal combustion engine . Diesel fuel or gasoline generator for welding, which one is better to choose and how they differ. From the point of view of weld quality and the ability to weld alloy steels and aluminum, a gasoline engine is better.

The diesel generator is designed for long-term or continuous operation. It can be used in the country as a power source for home electricity, and at the same time for welding and operating various power tools. It must be selected according to the maximum simultaneous load.

The disadvantage of diesel engines is their large size and weight. You can’t take such a generator from the garage to the dacha or to the construction site to weld the structure.

The gasoline engine is not suitable for long-term use with heavy loads. At the same time, it ensures stable operation of the inverter. It can be used in the welder operating mode of 40%. How to choose a gas generator for inverter welding, taking into account long-term use. To connect to your home and dacha, you should choose a power plant with a power reserve of 25% of the peak network load .

It is rational to install a gas generator for welding with an inverter under the condition of short-term operation or with a power reserve of 50 - 75%. You should follow the recommended operating mode for the inverter and the generator, alternating load with rest.

Frame

For better cooling, generator components can be mounted on a rigid frame and partially covered with a housing . This unit heats up less and requires special conditions. It can be used in indoor conditions with clean, dust-free air. Light weight allows the generator to be moved freely.

Solid-body equipment has a fan installed and slots for air circulation. It is less demanding on dust and moisture, but requires daily maintenance.

The housing contains a control unit, a start button, a grounding bolt and cable connectors.

Types of generators

Only synchronous generators are suitable for welding. The best way to rotate an armature is with a 2 or 4 stroke engine .

The 2 stroke diesel engine can run continuously. The voltage is not stable, which negatively affects the quality of the seam.

The four-stroke gasoline engine has smoother current output characteristics, provides a stable arc and smooth adjustment of modes.

Models

Popular types of welding gas generators are suitable as a power source in the country. It can power the tool during periods when welding is not working.

The most popular models in stores are from Germany:

RID RH5221 S – gasoline power station has a built-in welding machine;
RID RH7220 S – constant welding current up to 220 Amps.

RF equipment from Svarog is popular among professionals and amateurs..

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