How many kilowatts do you need for welding?

Welding machine power consumption

Energy consumption for the operation of a welding unit may vary depending on various reasons. Firstly, this is the power of the device itself, secondly, the limits of the incoming voltage, etc.

But using a certain formula, the final power of the device is calculated; it has minor discrepancies with the real numbers, but this is not significant. Therefore, for those who monitor the revolutions of the electric meter, this article will be useful.

We will talk in detail about all the points that affect the power consumption of an inverter welder and how its total power is calculated.

Factors affecting energy consumption

Before making calculations, you must clearly understand what quantities make up the total electricity consumption. The power indicated on the box is also taken into account in the calculation; this is an important component, but it is not the only one. You also need to know several quantities in order to more accurately create a formula.

The main factors influencing voltage include:

• device power;
• input voltage range;
• the maximum welding current that the inverter is capable of;
• electric arc voltage parameters;
• efficiency of a specific model;
• duration of work.

The totality of all values ​​will determine the total power of the unit.

Additional components of power consumption include:

• the condition of your wiring;
• welding conditions and modes;
• reliability of wires.

You also need to pay attention that the household electrical network does not always produce the generally accepted voltage of 220 volts. At best, you will get 200. When you turn on the welding machine, the range of welding current required during operation is reduced.

This makes it difficult to make an accurate calculation. First of all, this applies to low-power inverters. If the device is designed to operate within 150-250 volts, then calculations are made with more accurate indicators.

Since the arithmetic average is approximately equal to the mains voltage.

Now let's talk about the operating time of the device. It refers to the basic conditions for calculating power. This important characteristic shows how long the inverter can operate continuously. Each model has different meanings for work and rest.

For example, a welder works for four minutes, but it will take the same amount of time to cool down. But there are welding inverters that work for 5 minutes and rest for 2 minutes. In this case, consumption will be higher.

This fact must be remembered in subsequent calculations.

Calculation formula

To make the calculation correctly, first of all, you need to familiarize yourself with the technical parameters of your welding machine from the instructions included with the product or information on the Internet that applies specifically to this model.

The data you will find in the technical specifications is as follows:

• Power efficiency;
• current strength at maximum value;
• highest arc voltage;
• apparatus efficiency coefficient;
• duration of work.

The formula is:

Max current value* Max voltage value / efficiency = device power consumption

We will make your work easier and say that the power factor is always set to 0.6. Almost all modern inverters have this value. Now substitute the numbers from the data about your welder into the formula, and you will get the power of the device in working condition.

But let’s highlight such moments as replacing electrodes, adjusting power, easy selection of the next surfaces to be welded, and other moments when you do not make the seam itself. For these purposes, the device operation duration parameter, which we discussed above, will be useful.

The resulting result of the device’s power must be multiplied by this figure. Then you will bring the result closer to more accurate values. For example, your first figure was 5 kW.

We multiply by the lower value of the work time (for example, 60%) and get 3 kW, which is the average power of all welding work, including downtime.

This simple calculation procedure will provide you with knowledge of how much electricity your inverter consumes. Let us remind you that this formula is applicable only to welding inverters, and does not work with semi-automatic calculations. But we'll talk about them next time. Let's just say that their power consumption will be higher.

conclusions

Now you can accurately calculate how much electricity is spent on welding work. To save money on your electrical bills, purchase a unit with a lower wattage. Any welding inverter is suitable for small country work, and low electricity consumption will be a pleasant bonus for you.

What calculations do you make to calculate the power of your device? Maybe you have a different approach? We would appreciate your comments.

Source: https://svarka-weld.ru/potreblyaemaya-moshchnost-svarochnogo-apparata

How to calculate the required generator power for a welding machine - calculation of power for welding

Electric inverters are used almost everywhere. Construction sites, utilities, service stations, manufacturing - solving many problems in these areas is impossible without welding.

In most cases, the welding machine is used in conjunction with a gasoline or diesel generator. This is due both to unstable voltage in the centralized network and to the absence of the latter.

For example, on suburban construction sites it is not always possible to connect to the main power supply.

It is important to note that the stability of operation and service life of the equipment, as well as the quality of welding, depend on the correct choice of a mobile power plant. That is why, before purchasing, you need to figure out what type of generator is suitable for solving the tasks.

Power is the main selection criterion

There are two main types of mobile power plants on the modern energy equipment market - gasoline and diesel. The former usually have less power, compact dimensions and light weight. This makes them more mobile and convenient to use. As for diesel units, their power is noticeably higher - such devices will “pull” any welding machine. In addition, due to the low cost of fuel, they are more economical to operate.

It is important to note that power can be considered as the main parameter determining the choice of generator. To ensure that no problems arise during the operation of the power plant, it is necessary to determine:

• active power of power supply equipment. Pay attention to the designation that is present in the accompanying documents of the unit. Apparent power is expressed in kilovolt-amperes (kVA), active power is expressed in kilowatts (kW). When choosing a generator, you need to take into account the active power. If the specification indicates the value in kVA, it should be multiplied by a factor of 0.6-0.7. The resulting number will express the active power of the power plant;
• power consumption. This parameter is specified in the specification for the welding machine. But if documents are unavailable for any reason, you can independently calculate its value. To do this, you need to multiply the arc voltage by the maximum welding current, and then divide the resulting number by the efficiency of the inverter.

Please note that the efficiency of devices is usually 0.85, and the arc voltage is most often 25 A. As an example, let’s calculate the power consumption for a unit that has a welding current of 160 A. So: 25x160/0.85 = 4705 W. If we convert this number into kilowatts, we get 4.7 kW.

Based on these data, we select a gasoline or diesel welding generator that is suitable in terms of power. It should be taken into account that when operating at the limit of its capabilities, the equipment quickly breaks down. Therefore, you need to add 30% to the resulting number. In our case, the recommended power of the power plant is (4.7 kW x 1.3) 6.1 kW.

What else needs to be taken into account?

Once you know the required power, you should consider other criteria for choosing equipment. These include:

• Fuel type. As we have already noted, either gasoline or diesel power plants are used in combination with welding machines. The former are cheaper, but more expensive to operate. With the latter, the opposite is true - their price is several times higher, but they are more economical in operation. In addition, diesel units are safer to use. Moreover, both from an environmental point of view (their exhaust is cleaner) and in terms of fire safety.
• Number of phases. Both single-phase and three-phase units are widely represented on the modern market. In addition, if necessary, you can purchase a universal model. The latter option is justified when it is planned to use a generator to power several welding machines of various types.
• Manufacturer. As for this parameter, a reasonable compromise should be sought between the company’s fame and the price of the device. Units produced by trusted manufacturers are more expensive, but their service life is usually longer. In addition, if any breakdown occurs, there are usually no problems with replacement or repair. If you need a cheaper option, you should pay attention to domestic equipment. It is traditionally cheaper, but in many cases it is not inferior to imported units in terms of technical characteristics, service life and other parameters.

By calculating the power of the welding machine, as well as deciding on the type of fuel, number of phases and manufacturer, you can select a generator that will best suit the needs of a particular user. However, there is an easier way to select a device - just turn to professionals. Specialists will clarify the details and offer a model that is optimal for your case.

Source: https://www.GeneraTorg.ru/articles/kak-vychislit-neobhodimuyu-moschnost-generatora-dlya-svarochnogo-apparata/

Power of the welding machine and arc: how is it determined and how much does the inverter consume?

The power of the welding machine is one of the main characteristics that you need to pay attention to when choosing it.

In order to better understand all the intricacies associated with welding devices and understand the main points for calculating this parameter, it is necessary to clarify several important aspects. The information will be useful to know for all those involved in welding.

Main types of welding machines

Inverter device for welding.

Inverter welding machines are divided into three categories:

• household;
• semi-professional;
• professional.

The noted division is made primarily based on the area and frequency of use of the device. To understand what kind of welding machine you need, you need to determine the conditions of its use.

Household ones are designed for short operating times. It is not possible to use such devices for constant and long-term welding. After only 5-10 minutes of use, the device must be allowed to “rest” for the same, and sometimes longer, period of time.

At the same time, the ability to connect such an inverter to a single-phase household network makes it very convenient for use at home. For quick welding of metal structures in the country or for home work, it is not so critical how many breaks the welding inverter takes.

Semi-professional class inverters are able to operate longer, which is achieved due to the features of their design. Such devices are used in the repair of pipes, the manufacture of frames and metal structures. They are usually powered from a three-phase network.

Professional-grade devices are capable of working without interruption throughout the day. Their welding current can reach 500 amperes. This means that the power consumption of a welding inverter of this type will be the greatest.

All household, some semi-professional and professional devices can be powered from a 220 volt network. At the same time, do not forget that the mains current cannot exceed 160 amperes.

When purchasing an inverter, you must calculate in advance how much power it needs and how much current it will consume.

Connecting a device with higher ratings may lead to the machine turning off or to burnout of the socket contacts, since the equipment is designed for a larger number of kilowatts.

So, what should you pay attention to when choosing a household inverter? First of all, on the welding current, the characteristics of which are indicated by the manufacturer in the passport or manual for the device.

This criterion shows at what current the normal operation of the inverter will be ensured without overload, taking into account the continuous load. Of course, it is better to give preference to devices with a power reserve of 30-50% to the operating current.

Dependence of welding current on metal thickness and electrode diameter.

In a regular city power grid, there are often power surges. As a rule, such changes occur in both directions by 15-20% of the nominal value of 220 volts.

Typically, household and professional inverters are not so sensitive to such surges. Even with them, they are able to work effectively.

However, when connected to a generator, fluctuations can be significantly greater. In this regard, it is better to choose a welding machine with protection against voltage surges.

It is quite difficult to check all the parameters of devices directly upon purchase, even if the devices have digital displays. Even they can display incorrect information and mislead the buyer.

Calculation of device power

Before you begin calculating the power of the device, you need to know the following parameters:

• range of input voltage and welding current;
• welding arc voltage;
• Efficiency of a specific device;
• duration of switching on;
• Power factor.

The welding current interval shows at what network parameters you can work. This is due to the fact that in reality the declared 220 volts are not observed in household electrical networks. Sometimes the voltage can be less than 200 V, and sometimes it can significantly exceed 220 V.

When connecting the welding machine to the mains, a voltage drop of 5-10 percent from the nominal value may be observed.

Schematic diagram of the current regulator.

In this regard, it is advisable to pay attention to models for which the operating range is stated to be from 150-170 to 220-250 volts. It is these devices that are able to provide the best power performance.

The welding current range determines its highest and lowest values. The power of the inverter directly depends on this characteristic. For household models, the minimum values ​​can vary from 10 to 50 A, and the maximum - from 100 to 160 A.

One of the important characteristics of the inverter is the on-time. This parameter actually indicates how high quality a particular device is. The meaning of the criterion comes down to the ratio of work time to “rest”.

For example, if this indicator is 50%, then for every five minutes of operation the device should cool for the same period of time. Thus, the lower this parameter, the longer the breaks will be.

A high percentage, on the contrary, indicates that the device can be used for an extended period of time without interruption.

The power factor of a welding inverter directly depends on the duration of switching on. The calculation to determine this characteristic is determined from the ratio of continuous operation time to total time.

Let's look at everything using a simple example. Let's calculate the power of an inverter welding machine that worked for 4 minutes before the protection tripped. It then needed to cool for two minutes before it was ready to go.

So, to find out what coefficient this device has, you need to divide three by five - the total operating time, and multiply by one hundred. We get the desired value. For household mini versions and semi-professional equipment, the coefficient does not exceed 0.6-0.7.

Welding machine characteristics table.

Let's say there is a device that requires a power supply of 160-220 V, and its maximum current is 160 amperes with an arc voltage of 23 volts. Let the efficiency of such a device be 0.89, and the duty cycle 60%.

The parameters listed above are quite sufficient to calculate power consumption. It is necessary to multiply the current by the arc voltage and divide it all by the efficiency. The result is 4135 watts.

This value shows the power consumed directly during operation. However, as mentioned earlier, it is also necessary to take into account the duration of activation. To do this, you need to multiply 4135 by 0.6. The result is 2481.

This value is the average power. It is considered the most relevant and correct when determining energy consumption.

This approach is closest to reality. After all, it is very rare to encounter a situation where the inverter would work for days on end without interruptions. Pauses and delays always happen; you simply cannot do without them.

It is worth at least taking into account the time required to change electrodes or to prepare parts for welding.

Power table

When choosing a welding inverter, it is necessary to take into account other factors besides the kW consumed. This is especially true for professional models. They are subject to higher demands than household versions.

Required inverter power for welding different metals.

It is necessary to take into account the thickness of the materials being welded. The power of the inverter welding machine and the thickness of the electrodes will also depend on this criterion. The required parameters are shown in the table below.

It greatly simplifies the calculation of power consumption depending on operating conditions. In addition, this table will be useful for beginners who often wonder about choosing an electrode of the correct diameter.

Metal thickness, mm	Welding current, A	Electrode diameter, mm
1,5	30-50	2
2	45-80	2,5
3	90-130	3
4	120-160	3
5	130-180	4
8	140-200	4
10	150-220	4-5
15 or more	160-320	4-6

The intensity and volume of work is the criterion by which a device with a certain duration of operation is selected. As already described above, this parameter shows how long the device can work with wire of a certain thickness under given conditions.

The operating conditions of the inverter determine its protection class. If the device is to be used indoors, then IP21 certification will be sufficient, but if used outdoors, when the temperature is low or there is high humidity, IP21 protection will be required.

Schematic diagram of a welding inverter.

As for the power supply, household appliances can also be plugged into a regular outlet. Professional inverters usually operate from a three-phase network with a voltage of 380 volts.

In addition to the above criteria, you must also pay attention to additional parameters. The functionality of an inverter can greatly simplify certain operations.

For example, arc forcing by optimizing the current strength will prevent sticking. Hot start allows you to quickly ignite the arc. Anti-stick switches off the inverter if the electrode gets stuck.

The presence of a display on the device will never be superfluous. It can display operating modes, which greatly simplifies the operation of the device.

Bottom line

This article describes what parameters of the inverter operating mode determine the power; it is shown that it is influenced by the welding arc voltage, current strength, duration of activation, etc.

In addition, various classes of welding machines are considered, as well as their features and differences. This material will definitely be useful to novice welders who are still thinking about purchasing a welding machine.

Source: https://tutsvarka.ru/oborudovanie/moshhnost-svarochnogo-apparata

Power as an important characteristic of a welding machine

When purchasing equipment for electric arc welding, the power of the welding machine in most cases is the determining factor in choosing the appropriate model. The value of this parameter determines the operating current of the device, as well as the thickness of the metal workpieces with which it is capable of working.

• 1 Selection order
• 2 Rectifier
• 3 Inverter
• 4 Semi-automatic

Selection order

In the accompanying document (passport) for each specific welding machine, the manufacturer indicates the maximum power that ensures its operation under peak loads. That is why, when assessing it, you should focus on the quality of the voltage in the electrical network to which this device is connected.

Page with technical characteristics in the passport of the welding machine

At the same time, one should not lose sight of the fact that even a relatively powerful inverter, with significant fluctuations in voltage in the network, will not be able to guarantee the required operating performance and maximum output.

The procedure for choosing an inverter welding machine, a semi-automatic device or a conventional transformer rectifier that is suitable for its energy intensity has many similar features. Therefore, let us first familiarize ourselves with the general rules for choosing working units, when assessing the power of which we are usually guided by the following considerations:

• For certain models of welding machines, the manufacturer’s passport data is often overestimated by 10-15%. It follows from this that when purchasing, you should choose a device with some power reserve;
• in the absence of a “power” column in the passport, you need to focus on the amount of current that the device consumes in maximum load mode (to estimate its power, this value is multiplied by the current voltage in the network - 220 or 380 Volts);
• when purchasing a welding machine that is not designed for significant overloads (for long-term operation in “heavy” modes), high power is not required; under normal welding conditions, a device with a working load of about 120-130 Amps is sufficient.

When choosing transformer machines for manual welding, you should remember that over time this equipment wears out. Moreover, the greater the power and operating current, the greater the heating of the welding machine and its wear. .

Rectifier

This device is a transformer type device that operates on the principle of converting alternating voltage into a constant value required for welding.

Unlike a standard converter device, when working with a rectifier, it is possible to obtain a more stable arc with good quality indicators and better characteristics.

Thanks to this, it is possible to weld not only ordinary steel products, but also non-ferrous metals, including workpieces of small thickness. When working with a rectifier, no special welding experience is required.

When determining the required power indicator of this device, they usually proceed from the value of the electric arc voltage (for a rectifier it is 24 Volts). This value is then multiplied by the operating current (usually 160 Amps), which results in the so-called “arc power”.

If it is necessary to accurately estimate the energy consumption of the purchased device, an adjustment is introduced into the calculations for unproductive heating of the equipment (efficiency indicator equal to approximately 0.65-0.7). For devices with transformerless output, the power factor must also be taken into account (usually 0.951).

Inverter

When purchasing and choosing such a well-known type of welding equipment as an inverter machine, you should also pay attention to its power indicator. In this case, it is necessary to take into account the rated current value at which the electronic device can work intensively for a long time and not overheat.

To justify the correct choice of an inverter, let’s consider an example of working with a three-millimeter electrode and a working load equal to 120 Amperes. In this mode, it is possible to weld metal workpieces with a thickness of about 3-4 mm.

It follows from this that to expand the functionality and power of welding with an inverter, it is desirable to provide a small margin in the current parameter (up to 160-180 Amperes).

This will allow you to work not in the maximum (critical) mode, but in a gentle mode, which significantly reduces the likelihood of the welding machine failing and will prolong its service life.

When choosing the size of the current reserve, it is important to calculate not only the amount of workload on the welding machine, but also possible deviations of the supply voltage from the nominal value.

A power reserve may also be required in cases where the length of the cables used for power supply exceeds 5 meters. At the same time, their length, reaching a 15-meter mark, is considered critical.

Semi-automatic

Such a common type of equipment as a semi-automatic welding machine allows you to work in a wide range of currents and perform difficult operations on welding sheet blanks and non-ferrous metals.

With the help of semi-automatic welding equipment, it is possible to fuse difficult-to-process products from thin-sheet material, which are usually worked with in auto repair shops.

This type of welding machine allows you to weld in a protective atmosphere of argon or carbon dioxide, which increases the efficiency and quality of welding by blocking the oxygen contained in the air.

Sometimes, for these purposes, a special flux-cored wire is used, which acts as a filler material and also improves the quality of the weld.

The operating power of the semi-automatic device is selected taking into account all the previously discussed factors, to which should be added the peculiarity of this device.

The fact is that at the moment the semi-automatic device is turned on, a pulse jump in current consumption is observed, which must be taken into account when evaluating the purchased equipment.

It is also important to navigate the cost of the welding machine you choose, which is directly related to its power rating. However, in the case when it is necessary to work with thin-sheet workpieces and non-ferrous metals, you can quite accept the additional costs when purchasing a semi-automatic machine.

When assessing the parameter of the current consumed by the unit (regardless of the model and class), specialists also take into account such a parameter little known to amateurs as the power factor of a welding inverter or any other welding device. This value takes into account the reactive nature of the load on the network when one or another welding machine is connected to it.

For some of them (inverter, in particular), capacitive indicators of reactive losses predominate, and for transformer circuits, inductive components are more noticeable.

As a result, it should be noted once again that the power of any welding unit is the most important indicator of its operating efficiency in various operating modes . That is why special attention should be paid to the choice of this parameter.

Source: https://svaring.com/welding/apparaty/moshhnost-svarochnogo-apparata

How to choose the right generator for a welding inverter | Tiberis

“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:

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. In this case, the Huter DY8000LX gasoline generator model will be one of the best options.

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 REAL ARC 200 (Z238N) 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 150 welding inverter, you can safely purchase the Fubag BS 5500 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 160 welding inverter, the Fubag BS 7500 A ES generator seems to be a worthy partner, which is equipped with a powerful engine, an AVR unit and is equipped with a spacious fuel tank for long-term operation without refueling.

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.

1. 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.
2. 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%.
3. 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.
4. 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.

It is quite possible to select a generator for a welding inverter yourself, using common sense and our advice. And for complete confidence, contact the consultants and managers of our welding hypermarket, who will tell you which generator is suitable for welding in each specific case. Our specialists have the right answers to the most tricky and difficult customer questions!

Source: https://www.tiberis.ru/stati/vybor-generatora-dlya-svarochnogo-invertora

Which generator will power an inverter welding machine?

Inverter-type welding machines are widely used in many areas of economic activity of modern people.

With their help, it is possible to solve most issues related to the construction and maintenance of metal structures used not only in production, but also in everyday life.

New welding technologies are especially in demand on construction sites, where until recently the main problem for a welder was bulky and inconvenient to use electrical devices (see photo below).

Transportable welding units

Due to their large weight and dimensions, these devices had to be transported on special carts or vehicles, which created certain problems with moving them from place to place within the work area.

Generator for mobile inverter

Thanks to the use of modern inverter technologies, the design of the welding unit was significantly simplified, and its dimensions were reduced several times. At the same time, the mobility of such a device has also increased noticeably, which is explained not only by the compactness of the device itself, but also by the possibility of its operation from an independent generator source.

Important! In conditions where inverters for a generator are a common load, it was possible to implement a mode in which electronic equipment operates without being tied to the power grid.

A typical generator for an inverter-type welding machine is traditionally made in the form of a gasoline engine with a drive that provides electrical energy. Anyone who even occasionally visits a forum on relevant topics should know how pressing the issue of switching to a mobile inverter is.

At the same time, many of the interested users who visit this forum very often ask a natural question about which generators will power an inverter welding machine. The answer for all those interested in this problem is the calculations given in special sources, a summary of which can be found in the following sections.

Note! The ability to use a gas generator for a welding machine is also attractive for those who often have to work in the field, away from power lines.

Note that in urban conditions, stationary welding equipment operates from mains voltage sources, the stability of which can be assured (see figure below).

Inverter in the workshop and in production

In field conditions, when a gasoline generator is needed for a welding inverter, there is not and cannot be complete confidence in the stability of the power supply. To avoid this inconsistency, it will be necessary to calculate in advance the generating system for its ability to provide the specified operating characteristics (what current is needed at its output, for example).

Deciding on how to choose a generator for welding machines depends on a number of criteria, the main ones being:

• Welding inverter power (or current consumed by it);
• Conditions of its operation (normal or critical);
• Characteristics of the gasoline generator itself.

The main requirement in this case for the generating set is its operating power. In the next section, we will look at how this parameter is calculated and which generator is best to choose based on its results.

Maximum value

Before you begin calculating the parameters associated with the electric generator, you should carefully study the operating characteristics of the welding inverter itself, given in its passport (photo of the appearance of the unit below in the text).

Inverter welding unit Inverter generator or conventional: which is better

If it states that this device produces an output of 160 Amperes, then based on this parameter the maximum power consumption can be determined. Its indicator (P max) is calculated as the product of the arc voltage (it is usually equal to 20-25 Volts) and the output current.

Additional Information. These calculations also take into account the efficiency of the welding unit, the value of which is, as a rule, 0.85-0.9.

For our case, we choose the maximum efficiency = 0.9 and as a result we get:

P max = 160 x 20 x 0.9 = 2880 watts.

Rounding the result obtained, we can say that the power consumed by the inverter will be approximately 3 kW. Based on the results of this calculation, the generator for an inverter welding machine P max should not be lower than the specified one (it is better if it is a little higher, that is, with a small margin).

Effective and reactive power

When assessing this indicator, it should be borne in mind that during the welding process the operator never works in the maximum current mode, but always leaves a small margin for the work he performs. This circumstance is also taken into account before choosing a generator for inverter welding that is suitable for current and output power.

It is believed that the so-called temporary correction of its use, denoted as VP, should be taken as a real indicator of the energy spent on welding. Usually it is given in the passport for this device and is about 40%. Taking this correction into account, the power selected in the example above should be only 1.2 kilowatts.

In addition, the difference between the active component of power (consumed in the form of heat) and its reactive component should be taken into account.

Necessary clarification. This component is understood as that part of the total energy that is associated with the processes occurring in the reactive elements of the load (in capacitances and inductances, in particular).

Since the gasoline generator is loaded onto a standard welding inverter, the design of which contains a sufficient number of reactive elements, taking this component into account will affect the final result of the assessment. The correction made to the calculation formulas is introduced in the form of the so-called “power factor” (it is denoted in the formulas as the cosine of the phase shift angle between the reactive and active components).

Power factor (PF), depending on the device used, can range from 0.75 to unity. For those who want to know how much power is required for the purchased device, let us remind you that for industrial inverter units this figure is indicated in the passport and is approximately 0.8.

Industrial products

Industrial designs of generators used to supply power to mobile welded equipment can have a wide variety of designs. From the point of view of economy and efficiency, the option of a gasoline unit of the same inverter type is considered optimal. In this case, preference is usually given to devices from the same manufacturers, designed specifically for working with inverter welding equipment (figure below in the text).

Inverter type generator

It is believed that it is this combination of these two components of the working complex that makes it possible to obtain a sufficiently stable arc and provide the required parameters of high-frequency voltage and pulse current. According to their class and intended purpose, all existing welding devices are divided into the following types:

• Purely industrial designs;
• Professional models;
• Inexpensive household products.

Industrial and professional models are mainly used for the manufacture of volumetric metal structures and are designed for round-the-clock operation for long periods of time. For their normal functioning, significant operating currents will be required, capable of ensuring high-quality assembly of industrial structures. This type of welding device will require gasoline generators capable of delivering currents of up to 250-500 Amperes (see photo below).

Summarizing the consideration of possible options for choosing a generating device for an inverter, it is necessary to note the following. When thinking about the question of which generator is best to choose for welding, most users give preference to small-sized gasoline units in inverter design.

Source: https://amperof.ru/elektropribory/generator-potyanet-invertornyj-svarochnyj-apparat.html

Which generator will power the welding machine?

One of the most common methods of creating various metal structures is welding. To perform them efficiently, specialists use such types of equipment as welding inverters connected to an alternating current network. However, cases often arise when it is necessary to weld metal far from sources of electricity. In such a situation, generator equipment comes to the rescue.

On the market of specialized devices for providing power to welding inverters, there is a huge number of different devices presented by domestic and foreign brands. It is very easy for an ordinary user to get confused when choosing them, especially when the buyer does not know what criteria should be used to select a device.

What kind of generator is needed for metal welding and will the existing inverter support the equipment? How to calculate the power of the device? We will try to answer these questions in this article.

Why is power reserve necessary?

It is widely known that when choosing a generator for a welding inverter, it is worth choosing a device with a power reserve. However, not every consumer knows why this is necessary.

The fact is that with long-term operation of generating equipment at maximum intensity, its service life is significantly reduced. Rapid wear leads to a quick breakdown of the generator.

But when using the unit in medium and moderate intensity mode, it will last much longer. That is why experts propose a simple formula for calculating generator power, which we will discuss later.

What power reserve should the generator have?

To answer this question you need to know which generator you have decided to buy. In the case of operating an inverter that requires a power of less than 10 kW, you should give preference to gasoline units.

They are characterized by economical fuel consumption, ease of maintenance, reliability and durability. Such devices are excellent for welding work for domestic needs.

For a gas generator, an output power reserve of 15 to 25% above the maximum consumed by the welding machine is quite sufficient.

However, if the inverter is designed for power consumption of more than 10 kW, then pay attention to diesel units. This device is better suited for large volumes of work, for example on construction sites and when creating large metal structures. The welding diesel generator must have a power reserve equal to 30-50% of that consumed by the inverter.

How to calculate the power of a welding gas generator?

To calculate the power of any welding generator, experts recommend using a simple formula, for which you need to find out the maximum value of the inverter current, as well as the arc voltage and efficiency. Most often, the last two values ​​are constant and equal to 25V and 0.85, respectively.

So, the power consumption of the inverter is equal to the product of the maximum current and the arc voltage, divided by the efficiency. For example, let's look at the case in which the current value is 100A.

100 x 25 / 0.85 = 2941

This calculation means that the power consumption of the inverter is 2.9 kW. Next, we calculate the required output power of the gas generator. To do this, we will add another 15 and 25% to the inverter power consumption. After calculation, we obtain values ​​approximately equal to 3.4 and 3.7 kW, respectively. It is within these limits that the required output power of a gas generator for welding with a machine with a current of no more than 100A will be located.

How to calculate the power of a diesel generator for welding?

To calculate the power of a diesel generator for a welding inverter, we will use the same formula, however, the percentage of reserve in this case, as we have already found out, will be slightly higher than the values ​​​​for gasoline units. For example, consider a welding machine whose maximum current is 500A.

500 x 25 / 0.85 =14705

Thus, we calculated the power consumption of the inverter, which is equal to 14.7 kW. Note that in this case we correctly chose a diesel generator, since such an inverter will require a fairly powerful device to operate.

Next, we will determine the output power values ​​of the power supply unit, which should exceed the inverter output by 30-50%.

By multiplying the value of power consumption by 30 and 50%, we obtain a range from 19 to 22 kW, which corresponds to the criterion for selecting a diesel generator for welding with an inverter at a maximum current of 500A.

Thanks to such simple calculations, you can easily select a generator for welding with any inverter and ensure full and safe operation of both units. If you have difficulties using the formula, or other questions related to the selection and purchase of generating equipment, then you can safely seek advice from the specialists of our company.

Source: https://energoplaza.com/statji/vychislyaem-moschnost-generatora-dlya-svarochnogo-apparata/

What power generator is needed for a welding inverter?

What kind of generator is needed for a welding inverter?

“Which generator to buy for inverter welding” is the question asked by most people who dream of mastering electric welding if they do not have the opportunity to connect a welding inverter to a household power supply. At the same time, if you buy any generator you come across, it won’t work, since it must meet a number of requirements, including being suitable in terms of power.

Welding is essentially a short circuit. Therefore, the generator will react accordingly to a short circuit. Not only will it constantly turn off when welding, but there is also a risk of the inverter failing. Therefore, you need to approach the choice of generator consciously. And if we don’t go into the types of existing generators, we can only say that only a synchronous type generator is suitable for welding with an inverter.

In addition, it is better to give preference to a generator with a copper alternator winding than one with aluminum. Generators with copper winding are more reliable in operation, they are able to carry loads much better. Well, we’ll talk about other parameters that influence the choice of a generator for welding with an inverter below, in this article from the construction magazine samastroyka.ru.

What kind of generator is needed for a welding inverter?

A generator for inverter welding must meet a number of the following requirements:

• Have a sufficient power reserve (about 20%);
• Be a synchronous type;
• Be compatible with inverter equipment.

When choosing a generator for welding, you must be guided by the following points:

• Inverter power consumption;
• The current required for welding;
• The diameter of the electrodes (depending on the thickness of the metal being welded).

It is precisely these nuances that you need to be guided by when choosing a generator for a welding inverter. At the same time, the power of the generator comes first, so that’s where we’ll start.

How much power does a generator need for inverter welding?

The selected generator for welding must have a power no lower than that of the inverter, but on the contrary, slightly higher, taking into account the required margin of 25%. Typically, the power of the generator and welding inverter can be found in the technical data sheet. At the same time, you should not make mistakes in the units of measurement, since very often the power of electrical appliances is indicated not in kW, but in kVA.

kW is active power, and kVA is the apparent power of an electrical appliance. If the power of the welding inverter is indicated in kVA, and you need to convert it to kW, then it is enough to use the following formula for calculation: where 10 kVA * 0.8 = 8 kW.

At the same time, you need to understand that the welding inverter will not always operate at full power, and here everything largely depends on the required current strength. And since the efficiency of the inverter for welding and the arc voltage always have a constant value, then calculating the power of the generator for welding is not so difficult.

The efficiency of the welding inverter is 85%, and the arc voltage is 25V.

Knowing these parameters, you can independently calculate how much power a generator is needed for inverter welding, based on the strength of the welding current. If the inverter for welding has a maximum current of 160 Amperes, and you need exactly this current for welding, then the power of the inverter will be equal to: 160A * 25V / 0.85 = 4705 W. Considering the required power reserve for the generator, which is at least 25%, you can easily calculate its optimal power: 4705 W + 25% = 5881 W, which is almost exactly 6 kW.

From all of the above, it becomes clear how exactly the current strength of the welding inverter affects the required power of the generator. Consequently, by reducing the current on the inverter, it will be possible to use a generator of much lower power, for example, 2.5 or 3 kW.

Here everything depends on the diameter of the welding electrodes and the thickness of the metal being welded.

For example, using electrodes up to 2 mm, you can weld from a 2.5 kW generator, the power of which will be quite enough for the welding inverter to produce the required current for welding.

Source: https://samastroyka.ru/kakoj-nuzhen-generator-dlya-svarochnogo-invertora.html

Calculation of the power of a welding machine: how it is carried out, formulas and coefficients, algorithm

The amount of power of an inverter device varies. The performance is affected by the power of the mechanism itself, as well as the volume of incoming current. Regardless of the existing issues, consumption can be measured and calculated using a simple formula.

Please note that the result may be inaccurate, with a small error. The formula is more likely to be useful during everyday activities. You won't have to worry so much about your electricity bills.

In our article we want to tell you what the power of an inverter depends on. You will know how to calculate the power indicator of welding equipment when working at home.

We will teach you how to save money when using a welding machine.

Introduction

Have you ever thought about what determines your electricity consumption? We are talking specifically about welding. You will be surprised, but the volume depends not only on what power the manufacturer has determined.

Yes, this moment plays a role, but it is far from the main and not the only one. The formula for calculating the power of a welding machine depends on several variables.

Here are the factors influencing electricity consumption:

• unit power;
• input voltage range;
• the impulse that the mechanism produces;
• arch tension;
• unit efficiency;
• period of operation of the mechanism.

The basic factors that influence the final calculation figure are exactly these.

Indirect reasons have less influence, but they are also present:

• condition of the electrical network;
• working conditions of the welder;
• characteristics of the cable used.

Features and nuances

It must be remembered that the household electrical network does not always provide 220V. In 8 cases out of 10, these indicators drop to 180-200 Volts. This leads to the fact that when connecting an inverter, the voltage required for operation is reduced.

It becomes more difficult to make the necessary calculations. This point especially applies to powerful units. The figure will be accurate when the mechanism is designed for 150-250 Volts. Most often, the power of the machine will be comparable to a conventional electrical network.

Source: https://prosvarku.info/tehnika-svarki/raschet-moshchnosti-svarochnogo-apparata

We select a high-quality gas generator for welding

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.

Scheme and structure of the device

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.

If the maximum power consumption is not indicated anywhere, then it is easy to calculate it yourself. You need to multiply the maximum welding current by the arc voltage. We divide the result obtained by the efficiency of the inverter itself.

Watch the video, selection criteria:

Example. Let the inverter to which the welding unit is connected have a maximum welding current of 180 A. The arc voltage of the inverter is usually 25 V, although it is different for each inverter. Before making calculations, be sure to check it with the value specified in the technical data sheet. The efficiency of almost all inverters is 0.85. Now we calculate the power: 180 x 25 / 0.85 = 5294 (W). This is the maximum power consumption.

To determine which gas generator with welding function is suitable for a specific inverter, you should add another 30% to the received power. This is necessary so that the generator does not operate at the limit, but in cruising mode. In our example, a generator with a power of 6882 W or 6.9 kW is suitable.

When calculating, you need to remember that power consumption is always expressed in “kW”. If you see the designation “kVA”, then this value indicates the generated power of the generators.

To convert generated power into consumed power, you need to use a simple conversion formula:

• 1 kW = 1 kVA x KM, where
• KM is the power factor, and kVA is the power consumption of the inverter.
• The KM of inverters always lies in the range of 0.6-0.7.

If your budget does not allow you to purchase a gasoline generator with a welding machine of the required power, you can go backwards and calculate which generator will handle the welding machine without damaging the welding process. To do this, you need to know the permissible current limit of the inverter, which should not be exceeded.

Example. Let's say you purchased a generator for a 3 kW inverter welding machine. To calculate the maximum current, you need to multiply this value by the efficiency of the inverter itself (0.85) and divide by its arc voltage. So, 3000 x 0.85 / 25 = 102 (A). Thus, working up to 102 A, you can safely weld with a 2-3 mm electrode.

It is also useful to know the dependence of the peak power of a gas generator with a welding function on the diameter of the electrode:

• Peak generator power - 2.5 kW = 2 mm electrode diameter
• Peak generator power - 3.5 kW = 3 mm electrode diameter
• Peak generator power - 4.5 kW = 4 mm electrode diameter
• Peak generator power - 5.5 kW = 5 mm electrode diameter

Popular models

After considering the basic principles of selection, it is worth familiarizing yourself with the manufacturers. For evaluation, we took several different manufacturers in terms of unit power and price range.

Gasoline welding generators, based on the operating principle of the engines, are divided into:

1. Two-stroke;
2. Four-stroke.

Gasoline generators like HUTER DY6500L are especially effective in domestic conditions: at home, in the country, in the garage. They are not designed for long-term operation, but have distinctive characteristics. These mini-stations work perfectly in tandem with Svarog inverters.

Brima LT 8000B is a target device that works ideally with many Resanta inverters. When testing work together with Resanta SAI-190, it gave fairly good performance. In some cases, Brima can serve as a backup power source for a country house.

Endress ese 606 is a generator with a huge fuel tank in a high price category. Can work up to 2-3 times longer compared to conventional generators. The engine from the world famous Honda company minimizes fuel consumption. Works great with EWM inverters.

Generator care

Caring for gasoline generators for welding machines does not require significant time spent on maintenance. All you need to do is periodically check the oil level and add it if necessary. From time to time it will be necessary to recharge the generator battery.

Watch a video about the HUTER DY6500L model:

It is better to carry out operation indoors to protect from precipitation or use a special cover for installation. You can place it in a corner of the garage and not worry about precipitation getting on the unit.

You should not start the gas generator too many times in severe frosts (from -20 and below), such neglect of temperature changes in the device is fraught with rapid wear of the engine.

Results

It is worth saying that the above information is presented for conventional welding machines that are used in domestic conditions. When selecting a professional welding generator like the DDE DRV 160, it is worth referring to the advice in the instruction manual, since quite often some problems are observed when welding with a certain type of generator and manufacturers indicate this in the documentation.

The main reason for the incompatibility of generators and welding machines is considered to be the difference in characteristics in terms of power, however, this is far from the only parameter, although it is the main one. You can, of course, select a generator yourself using the above calculations, but it is advisable to contact specialists before purchasing.

Source: http://GeneratorVolt.ru/benzinovyjj/podbiraem-kachestvennyjj-benzogenerator-dlya-svarki.html

Which generator is suitable for operating a welding inverter - calculation of characteristics

Often, when working with an inverter welding machine, difficulties arise in connecting to the electrical network. This problem can be solved by using an autonomous electric generator. But how to choose the right generator for a specific inverter, and what characteristics should be taken into account?

Generator parameters

A common mistake when choosing an electric generator is the incorrect selection of rated power. Analyzing reviews, you can often come across the problem of a station shutting down due to excess load. In addition, unstable operation affects the quality of welding and the maintenance-free life of the inverter.

To minimize these problems, it is recommended that you familiarize yourself with the basic parameters of an autonomous power supply station before purchasing.

These include the following characteristics:

• Rated power, kW or kVA.
• Short-term reserve power.
• Number of phases.
• Voltage, V.

These characteristics must correspond to those of an inverter welding machine. However, in addition to them, the specifics of each model should be taken into account. First of all, the stability of the generated power. It is this characteristic that will directly affect the quality of operation of the inverter. To determine the optimal value, it is necessary to perform a series of calculations.

Characteristics calculation

There are two options for selecting equipment - an inverter for a generator or vice versa. The most common is the second, although the first is not excluded. So, before purchasing the optimal model, calculations of its power are performed in accordance with the inverter’s passport data.

The most important of these is the welding current. For small volumes of work, it is enough to purchase a device with a maximum value of 160 A. This figure will be needed to calculate the power of the future generator.

To calculate this parameter, you will need the following quantities:

• Arc voltage. Most often it is 25 V.
• Efficiency of the device. Does not exceed 0.85.

To calculate power you need to use the formula:

However, the device will operate in this mode extremely rarely. Most often, the range of welding current varies from 80 to 110 A. In order to avoid making calculations for each of the possible modes, you can apply the “On duration” factor. Usually it is 40%. Those. The rated power of the inverter will be:

It is best to choose a generator whose short-term reserve power exceeds the rated capacity of the welding machine by 25-35%. For the example under consideration, this parameter will be:

Rounding up we get a value of 3 kW. But manufacturers do not always indicate kW power. In budget models you can find the definition of kVA. Despite their apparent identity, these quantities are not equal to each other. To correctly calculate the optimal generator power, a reduction factor should be applied. Usually it is 0.6-0.7. For a 3 kVA generator the actual value will be:

This will clearly not be enough for the inverter to operate. Therefore, you need to choose a station with other, higher parameters.

Adviсe

What else needs to be considered when operating the inverter from an electric generator? First of all, the presence of a payload. Welding does not happen all the time, i.e. during periods of no arc, the load on the generator will be minimal. This will automatically turn off the station. Therefore, it is advisable to connect an additional device with a nominal consumption of 0.8-1 kW for stable operation.

If you plan to purchase the entire set of equipment, you can consider the option of purchasing an autonomous station with a welding function. This will make it possible to perform work without connecting several devices to a common network. However, such models have one significant drawback - high cost. On average it is 70-80 thousand rubles. Therefore, most often they opt for purchasing 2 devices.

Source: https://ismith.ru/welding-equip/generator-dlya-svarochnogo-invertora/

How to choose a generator for a welding machine

Welding work is impossible without a source of electricity. In places remote from civilization or simply in places where there is no access to a central power grid, gasoline and diesel generators are used. Not every electric generator is suitable for connecting a welding machine, but we will now find out which one is needed.

What electrical installations are needed for welding?

A regular household diesel or gasoline generator is not suitable for welding work. A unit that operates with variable loads is required. When you turn on the generator and welder, no energy is consumed and no load is created. It suddenly appears at the moment when you touch the metal with an electrode, igniting an electric arc.

After the electrode is removed and the arc disappears, the load is reduced again, and the electric generator engine idles. Not every installation is designed for such starting currents and loads, so by connecting the welding machine to a household generator, you can damage it (the alternator winding will burn out).

Conventional asynchronous gasoline and diesel generators produce wave-like voltage surges that greatly reduce the efficiency of the connected equipment and also shorten its service life. Welding requires a stable voltage.

How to choose a welding generator by type

To operate a welding machine on a de-energized construction site or at sites remote from the central power grid, you need one of two types of generators:

• Synchronous. This energy source is universal, so you can connect not only welding to it, but also any other household appliances and power tools.
• Welding. There are special welding generators that include two devices at once: a welding machine and an electric generator. Both devices match each other in terms of power and other parameters.

Note that transformer welding should not be connected even to synchronous gas generators, as it produces strong voltage surges.

engine's type

All power plants suitable for welding are divided into two large groups according to engine type:

• Two-stroke. Installations with such motors are cheaper. These are mainly household models, and they are not suitable for constant long-term operation, as they get very hot and have a number of performance limitations.
• Four-stroke. These engines are more powerful and water cooled. A welding generator with such a motor will last a long time, but it costs more than a 2-stroke model.

Fuel consumed

The type of fuel on which the electrical installation operates plays an important role. Which generator is needed for electric welding, choose taking into account the pros and cons of each type of model:

• Gasoline units start quickly and easily at ambient temperatures down to -15 degrees. They cost less than diesel engines and have a long service life.
• Diesel units are economical and make less noise, especially if they have a protective casing. Fuel poured into the tank does not lose its properties even during long periods of equipment downtime, but in cold weather it is more difficult to start the engine.

How much power does a generator need for a welding machine?

What power generator is needed for inverter welding - you need to decide on this question before purchasing the installation. This indicator is calculated using a simple formula: P = I * U / n

• I is the current strength of the welding connected to the generator;
• U – arc voltage;
• n – efficiency of the welding machine.

The U and n values ​​are generally stable, and the arc voltage is 25 volts and the efficiency is approximately 85%. Based on these data and the technical parameters of the welding machine, it is possible to calculate the power of a suitable generator.

Let's assume that the current limit of the device is 150 amperes. We substitute the data into the formula and get: 150A * 25V / 0.85 = 4412 watts.

To the obtained parameter you need to add 20-25% as a reserve, and in the end it turns out that for welding with a 150-amp machine you need a gasoline or diesel generator with a power of 5.5 kW.

Electrode diameter

When determining which generator to choose for a welding inverter, consider the diameter of the electrodes used during operation. It must match the minimum power of the installation.

Professional welders recommend adding a factor of 0.5 to the diameter of the electrode in millimeters. In this case, it turns out that when working with 3 mm electrodes, you need a generator with a minimum power rating of 3.5 kW (3 + 0.5), and for 4 mm electrodes, the power of the electric generator must be at least 4.5 kW.

Additional parameters of generators for welding machines

When choosing which generator is suitable for welding, in addition to the above basic characteristics, consider additional:

• welding current range – from 40 to 400 amperes;
• maximum welding current – ​​from 140 to 400 amperes;
• rated power – from 2 to 10 kW;
• number of phases – 1 (220 volts) or 3 (380 volts);
• type of starter for starting the generator (manual, automatic);
• type of sockets and their number;
• operating time without refueling is from 2 to 9 hours.

Which generator to buy for welding, regular or welding?

A welding electric generator that combines a gasoline/diesel generator with welding has a number of advantages:

• built-in short circuit protection;
• ease of use;
• more affordable price compared to the total cost of a separately purchased generator and welding machine;

Unfortunately, you can only use a welding generator for welding, and you cannot power the welding machine from a regular electrical outlet. You will not connect other equipment to the electric generator.

Welding electric generators of the 2-in-1 type are used by professionals who are forced to work in de-energized areas and on construction sites. For domestic conditions, it is better to buy a generator and a compact inverter welder separately.

Review of the best models of welding generators

To make it easier for you to choose which electric generator to choose for welding, we will consider the features of several popular installations in 2018-2019.

• Fubag WS 230DC ES. The unit has a high-strength frame made of powder-coated pipes. The maximum welding current is 230 amperes, and the 25-liter tank is enough to work for 9 hours. The device with a stabilizer produces 220 volts with constant voltage and is equipped with an electric starter for easy starting. The engine runs quite quietly - only 77 dB, and idling up to 65 volts ensures easy arc ignition. You can work with electrodes with a diameter of up to 5 mm.
• Huter DY6500LXW. Reliable and inexpensive German generator with a durable housing. The installation is suitable for open-air operation, since all components are protected from precipitation. The current reaches 200 amperes and the power is 5.5 kW. There is an electric and manual starter, and the tank capacity is 22 liters. The generator consumes about 2 liters of fuel per hour, starts quickly and operates at sub-zero temperatures or in extreme heat. Allows you to cook with electrodes up to 4 mm.
• EuroPower EP 300 XE. A powerful welding generator with high technical characteristics, suitable for any construction work. The device is capable of generating 2 voltage streams, which is distributed to sockets with a voltage of 220 and 380 volts. The DC power reaches 300 amperes, and the total power of the installation is 7 kW. The electric generator is powered by a reliable Honda motor and allows the use of electrodes up to 6 mm in diameter. There is an hour meter that indicates the need for engine maintenance - this allows you to avoid breakdowns in the midst of work.

Welding generators Foxweld, TCC, Vepr are also popular. If you have difficulty choosing, you can always contact our managers. They will help you make the right choice, taking into account the client's needs.  

Source: https://www.faznik.ru/articles/kak-vybrat-generator-dlya-svarochnogo-apparata/