How to calculate the power of a welding machine

How much does an inverter welding machine consume?

To choose the right welding machine in Krasnodar, you need to know its characteristics. Preference should be given to a device operating from a single-phase network. You also need to take into account the volume and material of the work when choosing.

For example, when working with cast iron, a welding machine is suitable, which can be rented in our online store, equipped with a current rectifier and a device for regulating it. Do not forget that during such specific work as welding, your eyes need protection from burns.

We have a welding helmet, the rental of which is only now available at an affordable price.

Welding machines for hire: varieties

There are several types of these units. Transformer welding machines are quite heavy and of impressive size, but they are reliable and durable. They supply alternating or direct current through a transformer.

Can be used when cutting ferrous and non-ferrous metals. A small inverter welding machine has been on the market in Krasnodar not so long ago. It works using electrodes and is little dependent on the input voltage.

Used in professional activities, in cutting titanium, cast iron, stainless steel.

Semi-automatic welding machines are universal welding machines that work with inert gas. They will carry out high-quality welding of aluminum and iron. In most cases they are used at home.

Generator welding machines are devices consisting of an engine running on gasoline or diesel fuel and an alternating current generator. These are indispensable assistants in welding various materials.

At RosProkat23 you can rent any welding machine in Krasnodar at the lowest prices!

Main characteristics of welding machines

Any welding machine, regardless of its design, has one important parameter - the on-duration (ON) in accordance with different values of the welding current.

Manufacturers of welding machines use different measurement techniques.

However, when working on a welding machine, no one operates it continuously and at full power, burning several electrodes in a row, and our managers will be able to help in choosing the most suitable option.

The next equally important characteristic of a welding machine is the range of current changes during welding operations. The value of this indicator is an indirect indicator of equipment power. The wider the range, the larger electrodes can be installed, and, accordingly, the longer the duration of switching on the welding machine will be in the case of using small electrodes at the same current strength.

No-load current is also an important parameter of a welding machine. Its indicators are in the range of 60–85 V, and the higher this value, the easier it is to ignite an electric arc.

Is it possible to connect the device through a meter?

Everyone knows that connecting bypassing the meter is theft.

When welding with a “three” electrode, the current consumption is about 12-20 A. When working with a “four” electrode, the current can be 20-30 A and for a meter designed for a current load of up to 40 A this is not dangerous.

Does the device consume a lot of electricity?

Let's do the math. Let's say an electrode with a diameter of 3 mm is used. in welding mode, the device consumes 20 Amps. Which corresponds to a power of 220 Volts x 20 Amps = 4400 Watts = 4.4 kW. For comparison, a kettle consumes 1.5-2 kW.

Consuming this power for 1 hour, we get 4.4 kW x 1 hour = 4.4 kW-hour. At a cost of one kilowatt-hour of 1 ruble, the device will force you to spend 4.4 kWh x 1 ruble = 4 rubles. 40kop.

This calculation can prove that these welds do not consume all the electricity.

How to light an arc correctly?

There are two ways to ignite an arc: direct ignition. This method is similar to striking a match on a box. The second method: we place the electrode perpendicular to the welding site (15-25 degrees from the vertical axis) and it moves up and down. This must be done quickly, otherwise the electrode will “stick”. The electrode must be withdrawn quickly and held at a short distance not exceeding the diameter of the electrode.

Source: https://steelfactoryrus.com/skolko-potreblyaet-invertornyy-svarochnyy-apparat/

What should be the power of the welding machine?

RUSENUKR

The power of the welding machine indicates how much current the device can produce and what thickness of metal can be worked with in the future. Professional devices can output from 300 A, but ordinary household ones give less; they are designed to operate at 200-250 A. If the device is needed for one-time repairs or minor construction work, then it is best to take ordinary household ones.

The power of the welding machine indicates what current the device shows and what thickness of metal it is allowed to work with in the future.

In the passport, manufacturers usually indicate only the maximum power consumption, i.e. peak loads and other indicators. It is this parameter that allows you to determine whether the power of the electrical network is sufficient to operate the equipment. We must not forget that when the network voltage drops, many devices are also able to work, but their performance is lower.

What power welding transformer should I choose?

A welding transformer is equipment that can convert the current needed to operate a device. These mechanisms are inexpensive and reliable. The device is used to weld low-alloy steels; consumable electrodes are used for this. When choosing a welding device, you must carefully determine the power.

Scheme of electrical energy conversion in a welding machine.

Maximum values and some margin should be taken into account, since this limit is often exceeded when turned on . For example, if the unit is used to work with a single-phase network, then it is unlikely that it will be possible to exceed the current value of 200 A; we must not forget about this. In fact, this results in the impossibility of using the welding machine.

When choosing, you must remember that the transformer wears out. The higher the value, the higher the heat and wear. If complex and lengthy work is not required, then high power values are completely unnecessary. It is recommended to give preference to equipment that is designed for 120-130 A - this is the optimal middle ground.

Welding rectifier power

A welding rectifier is a type of transformer that allows you to convert alternating current into the direct current necessary for work. Unlike a conventional transformer, a welding rectifier ensures stable combustion and its quality is higher. It is possible to weld non-ferrous metals and thin parts, and no extensive experience is required.

Diagram of the welding machine.

It is not difficult to determine how much power a rectifier must consume to ensure proper and high-quality operation. To do this, you need to know that the standard arc voltage of the device is 24 V. This indicator is multiplied by the value of the welding current, i.e. by 160 A.

The figure that will be obtained is the power of the equipment on the arc. Power consumption from the operating electrical network is determined differently. It is necessary to divide the previously obtained result by the efficiency (usually taken as 0.65-0.7).

This will be an indicator of the maximum operating current.

When purchasing, it is recommended to always check the value with the declared one, since manufacturers sometimes inflate the indicators in order to sell the device. In reality, the situation is not the best when, when performing work not even at maximum values, severe overheating is observed, and the power drops sharply.

Welding inverter: power selection

The selection of an inverter welding machine is carried out in accordance with such a parameter as power. The rated current at which the device will operate uninterruptedly without overheating is taken into account, even if the use is intensive. Overheating will not occur even in repeated short-term mode, i.e. at the maximum current value.

Welding machine control.

For example, when using a 3 mm electrode, the operating current will be 120 A. Such conditions will allow you to weld parts 3-4 mm thick. This means that when choosing, you should take into account the power when the inverter can operate with a rated current of 160-180 A, but at the same time having a reserve of 30-50%.

Why exactly these values? It is not recommended to operate at maximum values, as this leads to overheating and the inverter fails. When the voltage of the electrical supply network decreases to 170-180 V, the power of the equipment drops, and the welding current is reduced to a minimum.

The reserve is needed in case the load is heavy.

A margin is also required when long cables of 5 m or more are used. If the margin is not maintained, the characteristics of the welding machine will drop below the nominal operating level. Such conditions are especially important when cables of 15 m or more are used.

When choosing an inverter, you should take into account that manufacturers usually overestimate the figures, but in fact the current is at a lower value.

What does this lead to? If the characteristics are selected incorrectly, the device overheats during operation and fails, which entails unnecessary financial costs.

What power semi-automatic welding machine should I buy?

Functional diagram of the power source of an inverter welding machine.

A modern semi-automatic machine allows you to perform even the most complex work, for example, high-quality welding of sheet iron and non-ferrous metals. The parameters of this type of device are such that it becomes indispensable when welding thin-layer metals.

It is used in auto repair shops where accuracy is high. To obtain the necessary power, gas cylinders can be connected to the equipment, but this is not necessary. It is possible to use cored wire.

Some models combine 2 types of equipment - welding generators and semi-automatic machines.

When choosing equipment, you should pay attention to power.

We must not forget about what the power consumption should be at the moment of switching on.

It is always greater than that used during normal operation of the device. Typically, the cost of mechanisms with low power levels is much less. But it is with the help of this device that even the thinnest parts can be welded, and this is important when performing high-precision work.

Welding combined unit

A combined welding machine is a unit with the functions of a working rectifier or transformer combined with a diesel generator. Such equipment can produce high-frequency or direct current; it is excellent for various types of welding work. This unit allows you to work in the absence of electricity. For example, when building a house on a country site, when the power grid has not yet been connected.

Connection diagrams for welding machines.

In addition to diesel, gasoline generators are used. The characteristics of this device may vary slightly depending on the manufacturer and model, but in general they remain at the same level. When choosing a unit for welding, it is necessary to take into account that they are mainly used on construction sites and for carrying out repair work in conditions where there is no permanent electrical network. Compared to professional ones, they may not be as powerful.

Equipment characteristics:

The frequency is at 50 Hz.
The device can operate at alternating voltages of 110 V, 220 V, 230 V, 240 V (you must carefully read the instructions before purchasing).
The rated power is 4.2 W, and the maximum consumption during operation is 4.8 kW.
The power of the equipment has a coefficient equal to 1.
At idle the voltage is 65 V.
The arc voltage during welding is 25-30 V.
The welding current of the unit is 180 A.
The operating current range for uninterrupted operation is 50-180 A.

Power for a welding inverter is an important indicator. It can be different, depending on the type of device and its purpose. When choosing, you should familiarize yourself with the parameters of different welding units in order to purchase the most suitable option.

Welder power means which could give current power device, with a metal thickness can be run in the future. Professional devices can issue 300 A, but ordinary household produce less, they are designed to operate at 200-250 A. If the machine is needed for a single repair, minor construction work, it is best to take a common household.

Welder power means amperage which shows the device with a thickness of metal is permitted to operate in the future.

Source: https://stroystory.ru/instrumenty-15/svarochnyj/5225-kakoj-dolzhna-byt-moshhnost-svarochnogo-apparata.html

Power as an important characteristic of a welding machine - Welding Profi

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.

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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.

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.

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://fgpip.ru/pravila-i-bezopasnost/moshhnost-kak-vazhnaya-harakteristika-svarochnogo-apparata.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.

We said that more than one factor influences the current. An important one is the duration of welding work. It determines how long the device can operate continuously. As a rule, inverters have the same time for both work and rest.

For example, you carry out welding work for 5 minutes, and after that the machine needs to rest for the same amount. It is important not to forget about this characteristic and take it into account while working. It will come in handy when we calculate data using the formula.

Another significant point: the wider the difference between labor and the break in the direction of labor, the greater the consumption figures will be. Let's look at this issue in more detail.

Consumer billing

For information on the consumption of your welding unit and power calculation, read the instructions for the inverter mechanism. If it is not there, you need to look for information that is publicly available.

To do this you will need to know the model of the unit. But usually the device is given printed technical specifications.

To calculate the power of a welding inverter, you need the following information about the machine:

Power factor
Maximum current ratings
Highest welding arc voltage
Efficiency of the device
Unit operation period

The formula for calculating the power of the welding machine will be:

Maximum current value * maximum voltage readings / efficiency = machine power (during the welding period)

The power factor is usually the same for all household machines and is equal to 0.6. Remember this number. The maximum current ratings are 160 A (for example). Take this value from the technical information about your device.

Let's say the highest voltage of the arch is 25 V. But you must indicate your data.

The efficiency is 0.90. When mentioning the operating time, it corresponds to 60% of the total volume. These figures are correct if we weld for 3 minutes and then rest for 120 seconds.

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

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.

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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

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 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/

How to choose a generator for repair and welding work?

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:

Minimum generator power

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.

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Flaws:

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://svarkagid.com/kak-vybrat-generator-dlya-remontnyx-i-svarochnyx-rabot/

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.

https://www.youtube.com/watch?v=ZlOj3ebCsbw

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

Welding inverter power consumption

The power consumption of a welding inverter greatly depends on the thickness of the electrode you will use for welding, as well as the efficiency of the device used and the selected current strength.

There are several formulas that allow you to determine the power consumption indicators very accurately, but it seems to us that buyers will not be too inspired by the prospect of such calculations, so we will give approximate indicators of the power consumption of a welding inverter, provided that electrodes with a diameter of 3 millimeters are used.

So, experienced welders for welding from a household single-phase electrical network (220 Volts) advise using electrodes with a diameter of 3 millimeters. Usually, welding with such electrodes is relatively well tolerated by the household electrical network, although, according to professionals, both the equipment and the electrical network need to be given a rest so that there is no overload. We cooked with one electrode, it ran out, give the equipment about twenty minutes of rest, change the electrode and you can cook again.

The power in the arc when using an electrode with a diameter of 3 millimeters will range from two to three and a half kilowatts.

If you make all the necessary calculations using existing formulas, it turns out that the device will “pull” two and a half kilowatts per hour from the electrical network at a welding current of 80 Amps and four kilowatts per hour at a welding current of 130 Amps.

With a network voltage of 220 Volts, this will correspond to a current of 11 to 19 Amperes. Power data is approximate and may vary depending on the efficiency of each specific welding machine, but it can be taken as a starting point.

Similar calculations using formulas can be made for electrodes of larger diameter. However, it is worth mentioning that professionals do not recommend using wire with a diameter of 4 millimeters in household welding without precise confidence in the quality of the wiring.

Increasing the diameter of the electrode used entails an increase in power consumption and will require wiring consisting of copper wires with a cross-section of at least 4 mm/sq. It is also advisable to have a good electrical circuit breaker. When using a welding inverter with thick wire and a poor-quality electrical network, there is a danger of short circuits and fires in the wiring.

Be that as it may, you can easily choose a welding inverter to your taste in our online store, and then use it to weld metal with electrodes no more than 3 millimeters thick in complete peace.

Criteria: which welding inverter to choose for your home and reviews from experts

Inverter units are another matter - they are small in size and weight, and are also easy to operate. Almost all welding inverters and reviews of which one is best to buy correspond to the points listed below:

High efficiency, allowing you to connect the device to a household outlet.
The unit does not affect the mains voltage level.
The devices remain operational even with significant voltage drops.
Affordable price.

Things to consider

Typically, summer residents who know which inverter device is best to buy already have practical experience. Based on their opinion, you can make a list of parameters that should be taken into account when purchasing.

Welding power or rated current

Homeowners who have not yet decided which welding inverter to choose for their home should take into account the reviews, and they say that the rated current is the condition under which the unit will operate without overload.

Let’s say that to work with a 3 mm electrode and 4 mm thick metal, you need a current of 120 A, but the welding device should generate a nominal 170-180 A.

Thus, a current reserve of 30-50% is required so that the device does not overheat and functions when the network voltage drops to 170 V.

Power supply

Inverter units for welding are divided into devices that can only work with a stable household power supply of 220 Volts ±15-20%, and welders that can be powered from an unstable voltage source from 150 to 260 volts. Working even from a backup voltage source, a high-quality machine should provide optimal welding conditions.

Availability of additional functions

Arc Force – arc stabilization, preventing electrode sticking.
Hot Start - a short-term increase in the current level at the moment of arc ignition.
Anti Stick - switches off the current when the electrode gets stuck and immediately re-energizes it after it comes off.

Source: https://MyTooling.ru/instrumenty/svarochnyj-invertor-potrebljaemaja-moshhnost

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/