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

Which electric generator to choose for a welding machine

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

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

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

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

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

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

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

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

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

How to choose a generator for welding?

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

How to calculate generator power?

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

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

150A × 25V/0.85 = 4412W.

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

4.4 kW +1.1 kW = 5.5 kW.

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

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

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

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

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

4000W × 0.85 / 25V = 136V.

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

Selecting power by electrode diameter

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

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

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

Which manufacturers are suitable for welding machines?

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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/

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

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

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

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

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

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

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

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

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

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

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

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

Gasoline generators with welding function

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

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

Most often, such units are used for:

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

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

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

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

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

Operating rules

When operating a gasoline generator with a welding function or a welding electric generator, you must strictly adhere to all factory instructions, regulations and recommendations.

After purchasing the equipment, it is necessary to perform a run-through test (about 20 hours of active use, allowing the system to start working without restrictions). During this test, it is not recommended to subject the equipment to loads above 50% of the rated power.

It is also necessary to take into account that to work in the mountains and at other altitudes, it is necessary to select an electric generator with a carburetor, which takes into account the high oxygen content in the air.

It is also necessary to familiarize yourself with the rules for performing the following procedures:

• Checking the quality and level of oil;
• Selection of optimal fuel and its storage;
• Correct refueling with gasoline;
• Starting and warming up equipment;
• The procedure for turning on the load;
• Turning off the unit.

If in all situations, both normal and emergency, the operator performs actions competently and taking into account factory instructions, then the equipment will be operational throughout the entire operational period.

Possible faults

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

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

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

Conclusion

Today, the market offers a wide range of welding generators with gasoline engines. This equipment is in great demand because it can be used both as equipment for performing welding work and as an autonomous source of energy in a house, country house or other facility. Generators for welding have stable operating parameters and are able to withstand intense loads for a long time.

To choose a gas generator for a welding machine, it is necessary to determine the required power, since this parameter is key for welding work. You need to make sure that your welding machine is compatible with the selected generator model (if you do not purchase 2in1 equipment).

In this article, we have suggested several excellent models of fuel-burning welding generators that are suitable for various operating conditions. These are universal devices that will be useful both on the farm and during field work. If you want to receive detailed information on the technical features of welding generators, contact our consultants who will provide you with all the necessary data.

Source: https://www.sklad-generator.ru/informacija/statji/kakoy-benzogenerator-vybrat-dlya-svarki/

How to choose the right welding generator of the required power

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

Features of choosing a generator

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

The following selection criteria should be adhered to:

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

Selection of generator for welding

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

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

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

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

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

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

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

Structure

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

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

Operating principle of the inverter

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

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

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

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

Selecting a Power Source

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

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

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

Power calculation

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

PG = (AC · 25V ÷ 0.85) · 1.25;

where: PG – power;

AC – rated current;

0.85 – efficiency;

1.25 – the minimum power reserve is 25%;

25V – arc voltage.

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

Sockets

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

Fuel type

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

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

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

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

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

Frame

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

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

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

Types of generators

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

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

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

Gasoline generators with welding function

Welding gas generators provide a full guarantee of identical characteristics . In one housing are connected: an inverter-type welder and a generator with a gasoline engine.

Amateur models produce current up to 170 A, professional 220 A and higher.

Models

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

The most popular models in stores are from Germany:

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

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

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

Oct 20, 2017

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

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

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

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

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

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

 

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

Generator power for welding - what is the reserve for?

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

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

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

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

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

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

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

Welding current - it must be taken into account

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

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

 

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

 

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

 

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

Electrode diameter - a label that is easy to remember

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

Electrode diameter (mm) Minimum generator power (kW)

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

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

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

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

For inverters Svarog

 

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

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

For Resanta inverters

 

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

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

For Kemppi inverters

 

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

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

For EWM inverters

 

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

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

Useful tips for choosing a generator

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

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.

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

What should be the generator power for inverter welding: calculation and setup

Using inverter welding, you can create structures of any complexity. She can help with home repairs, soldering large plumbing structures, fixing metal fencing, and many other types of work.

It doesn’t matter whether the inverter is connected separately or is already included in the power source, its use always helps. It doesn’t take up much space, and you don’t have to take a welding course to learn how to work with it.

The inverter, which is connected to the system separately, is powered from a regular power supply without requiring special conditions. But, if the work needs to be done urgently, and the light goes out, the socket will have to be replaced by an electricity generator.

It will also be needed when the network at the place of work is not provided at all. Generators for welding differ from conventional ones because the entire welding process is “built” at high temperatures and voltage.

The generator for the inverter is also not easy to choose. We will tell you what to look for in a generator store so that working with an inverter does not cause inconvenience.

Generator selection

When you choose a generator on websites or in a hardware store, you need to carefully consider its parameters.

Look at the power that the device consumes, the highest possible current strength of the inverter, and the cross-section of the electrode rods with which you will work. Also note that not every generator may be compatible with your welding machine.

If the maximum current of the inverter and the power of the generator are related, then compatibility raises more questions. The generator can be inverter, synchronous and asynchronous; there are also hybrid types in which the properties of the last two are combined.

A beginner may think that an inverter generator is needed in this situation, but this is a common mistake. Either a synchronous or a hybrid option is suitable here, since they have quite high power.

It is better if your generator runs on gasoline rather than diesel fuel. This is not an economical option, but under the same conditions it will definitely work better than a diesel one.

In addition, finding the right version of a device with suitable power on gasoline is much easier, since there are more variations on the market.

Professional semi-automatic welding equipment does not always work well when powered by a generator. Manufacturers talk about this in technical data sheets and instructions for devices.

If you are not sure whether your device can run on a generator, talk to a store consultant about this.

What power?

The power of the generator will directly depend on the capabilities of the inverter equipment. It should be “with a reserve” - 25-35% more. This will evenly distribute the resources of the power source and ensure constant ignition of the welding arc.

“At the limit” the device will not last long. And if it is a little more powerful than necessary, you can set it to spare mode, keeping it in working condition for a long time. Also, the arc will melt without interruption.

It will be clearer with an example. If your inverter has a maximum current of 180 amperes, then the generator must be selected so that its power is at least 6 kilowatts.

If you cannot calculate all these characteristics yourself, you can always talk to a consultant or a familiar master about help in the selection.

Proven low-cost options

We will tell you about four models of generators of different capacities that have been successfully on the equipment market for many years.

There is no absolute leader among them, this is just a list of equipment that is not expensive, but helps the welder do the job right.

HUTER DY6500L

This device will perform well in the household, solving your everyday problems. It is synchronous and runs on gasoline. If you have a compact inverter with low power (140-150 amperes), then the HUNTER DY6500L is just right for it.

Its maximum power is 5 kilowatts, and it just fits with the calculations. It is best to use 92-grade gasoline as fuel, then the device will work properly. But you can also use propane.

It starts manually using a starter. A rapid cooling system using air is built inside the Hunter. It weighs a little more than eighty kilograms, so one person will not be able to carry it - at least three will be needed.

BRIMA LT 8000 B

BRIMA is a manufacturer from Germany. The LT 8000B model of this brand fits well into the inverter welding process. It is more powerful than the previous model by one kilowatt, but the maximum power is higher - 6.5.

However, we do not recommend constantly using the generator at maximum, so for an inverter with a current strength of more than 180 amperes, it is better to choose a more powerful power source.

The LT 8000B is also petrol. Its tank holds twenty-five liters of fuel. The engine is four-stroke and also has a forced air cooling function. The start is electronic, unlike the previous model.

It can work continuously for a third of the day, but it is better to let it cool down as often as possible to prevent it from overheating.

It is large in size, quite powerful, like all models of this type, weighs 83 kilograms. But even one person can move it, since special wheels are screwed to it.

ERGOMAX ER 5400

This model cannot boast of high power, so it is used for devices that support a current of 120-140 amperes. ERGOMAX ER 5400 runs on gasoline, best of all - 92 and higher grades.

The quality of gasoline directly determines how long your generator will operate. The big advantage of this model is its economy: the engine consumes only two liters of fuel per hour.

There is no electric start, so you will need to start the engine using a hand lever.

The model is quite compact: it weighs seventy kilograms and the volume is only two cubic meters. It will not be difficult to deliver it from one point to another. The device is also water-repellent, resistant to dirt and cold.

So you can safely store it in the basement or garage.

ENDRESS ESE 606 HS-GT

For most low-power inverter devices, the Endress ESE 606 HS-GT generator is suitable. Its power is 6.4 kilowatts. This is a synchronous gasoline machine.

As with other generators, it is recommended to use fuel no lower than 92. The tank of the ESE 606 HS-GT is relatively small - 18 liters, but has high consumption: a full tank lasts for a couple of hours of operation.

By adding gasoline, you can work for five hours without a break, but after that, the device needs a rest.

The engine of the device is started manually - reversely. In order for the process to begin, the start handle will need to be pulled sharply several times.

This model will be useful for a master who often moves between workstations, since its weight is only 70 kilograms, and special handles are screwed on for movement.