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.
You can calculate the amount of electrical energy that the inverter produces. 160 A*25 V / 0.90 – 4445 Watt. Approximately we are talking about 4.4 kW. We are talking only about the power of the device, which is used during operation.
But welding work does not always take place without pauses. Sometimes it happens that you need to change the electrodes, the current strength, or prepare accessories. And our calculation becomes not entirely accurate.
We mentioned earlier that this problem is solved by calculating the operating period of the machine. Defined, let's say it is 60%. Multiply 4.4 by 0.6 and you will get the exact result.
For our device it is 2.7 kW. The final figure indicates the average power of the welding unit, which it uses during the work period, taking into account rest.
Let's make a reservation that we offered our own calculations. You need to substitute the numbers that correspond to your device.
At this point the process can be considered complete. A minute calculation allows you to easily find out what volume of kilowatts is needed for welding work.
You will be able to create comfortable conditions for yourself. Note that with a semi-automatic machine, all figures when calculated will be approximately 20% higher than those described by us. But this is a matter of chance and apparatus.
Let's sum it up
This is all the information that will be relevant for calculations. You know about all processes and stages of work. We suggest you calculate for yourself whether you can cook at home without damaging your wallet.
It happens that you are not sure of the numbers - then buy a low-power unit. It will become a companion in carrying out simple household work and at the same time save energy. You will be able to build a greenhouse or repair small metal.
Maybe you know other methods of calculations - please leave them in our article. Let's share our experiences with each other!
Source: https://prosvarku.info/tehnika-svarki/raschet-moshchnosti-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/
Inverter welding machine Resanta SAI 220
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://www.rosprokat23.ru/instrumenty-i-oborudovanie/svarochnye-apparty/57/%D1%81%D0%B2%D0%B0%D1%80%D0%BE%D1%87%D0 %BD%D1%8B%D0%B9-%D0%B0%D0%BF%D0%BF%D0%B0%D1%80%D0%B0%D1%82-%D0%B8%D0%BD%D0 %B2%D0%B5%D1%80%D1%82%D0%BE%D1%80%D0%BD%D1%8B%D0%B9-%D1%80%D0%B5%D1%81%D0% B0%D0%BD%D1%82%D0%B0-%D1%81%D0%B0%D0%B8-220-%D0%BC%D0%B0%D1%81%D0%BA%D0%B0- %D1%81%D0%B2%D0%B0%D1%80%D0%BE%D1%87%D0%BD%D0%B0%D1%8F-welding-mask-detail
How much power does a generator need for inverter welding?
How much power does a generator need for inverter welding?
Inverter welding is becoming popular day by day. The ability to weld at reduced voltage in the mains and from a generator has made welding inverters an indispensable tool for welding in everyday life.
To figure out which generator to choose for inverter welding, you need to take into account not only the power of the inverter. The choice is strongly influenced by the welding current, which is selected taking into account the use of various electrodes.
Welding is inherently a short circuit, so most generators react accordingly to the connected welding machine. If the generator is of insufficient power, then when welding with an inverter it will always go into protection, in simple words, turn off. To prevent this from happening, you need to correctly calculate the power of the generator to connect the welding inverter.
A generator for welding must be powerful and reliable, otherwise it will quickly fail. Today, there are various types of generators, synchronous and asynchronous, as well as inverter ones (see the website mmasvarka.ru). To connect a welding inverter, you need to purchase only an asynchronous generator running on gasoline or diesel fuel.
Now, as for the power of the generator, it, as mentioned above, should be selected with a small margin ( 20-25% ) so that the generator does not go into protection when connecting welding. The power of the generator should be selected based on the power of the welding inverter connected to it. You can find out the power of the inverter in its documentation. However, one should not confuse kW and kVA , since these are completely different values.
How to convert kVA to kW
- kVA is the rated power of an electrical appliance;
- kW - active power.
Very often, in the passport for a welding inverter, the power is indicated not in kW, but in kVA, so you need to be able to convert kVA to kW. To do this, just use the following example, where 10 kVA * 0.8 = 8 kW . Thus, after the necessary calculations, it becomes clear exactly how much the welding inverter consumes in the load.
In this case, you need to take into account the welding current that the inverter produces. The higher the welding current, the more the inverter will create a load on the power grid or work at the limit of its capabilities. Therefore, if you need to cook with 3 or 4 mm electrodes from a generator, then you need to be prepared for the fact that a 2.5-3 kW generator will be absolutely unsuitable for these purposes.
Inverter current and generator power: what do you need to know?
Therefore, when choosing a generator for a welding inverter, you should also take into account the maximum current strength. So, for example, if the maximum current strength of the welding inverter is 180A, then you need to multiply them by 25V, not forgetting about the efficiency. Most often, the efficiency of an inverter for welding is 85%, so you can safely take a value of 0.85.
Using this calculation: 180A*25V/0.85=5294 W , it becomes clear that the generator power for a 180A inverter must be at least 5.5 kW. However, ideally, you need to take a generator with at least a 25% power reserve if you have to cook with inverter welding quite often. Therefore, the figure regarding the generator power automatically increases to 6.6 kW and is optimal in this case.
Many people wonder whether it is possible to weld using inverter welding from a 2.5 kW generator . The answer is yes, it is possible, but only for a short time and using for this purpose electrodes no more than 2 mm in diameter, with a current strength on the welding inverter of 30-40A, maximum.
In any case, you must understand that by connecting your inverter to a generator, you can easily cause it to fail, since welding requires high power and loads.
Source: https://mmasvarka.ru/kakoj-moshhnosti-nuzhen-generator-dlya-invertornoj-svarki.html
How to choose the right generator for a welding inverter | Tiberis
“Which generator is suitable for welding” is a question that often arises among people who have decided to seriously engage in welding on their own and at the same time do not have the opportunity to connect the welding machine to the network. It’s easy to get confused, especially after we see a huge list of available models on the online store page.
It would seem that it is very difficult to understand this diversity, especially if you have a liberal arts education behind you. In fact, any of us can choose the right generator for a welding inverter; to do this, you just need to know a few small but very important nuances. They will be discussed in this article.
What points must be taken into account when choosing a generator?
As befits a serious unit, each generator for inverter welding has a huge number of different technical characteristics, among which it is very easy for a beginner to get confused. But for the right choice, only five of them are most important:
It is these parameters that you should pay special attention to in order to use the generator for a long time and safely.
Generators differ by type into synchronous, inverter and asynchronous, as well as a symbiosis of asynchronous and synchronous Duplex series (manufactured by Endress); synchronous or Duplex series generators are suitable for welding . Inverter engines, as a rule, have insufficient power and are not designed for high starting loads. You can find out more about the types of generators in a separate article here.
Generator power for welding - what is the reserve for?
In most cases, the power of the welding inverter and generator is indicated by the manufacturer in the technical data sheet. Therefore, even a child can easily find these values and compare them. The main thing is not to confuse the power units kVA and kW, as well as the declared rated and maximum power of the generator.
It should be remembered that when buying a generator, you need to choose a model that has 25-50% more power than the inverter you have. This is explained quite simply - constant operation of the generator at the limit of its capabilities will very quickly disable it and will not make it possible to use the full potential of the welding machine.
If for some reason you do not have information about the power of your welding inverter, you can calculate it yourself using a simple formula:
Maximum current * arc voltage / efficiency of the welding inverter - maximum power.
In this case, you only need to know the value of the maximum current, since the other two components are almost always constant (the arc voltage is 25V, and the inverter efficiency is 0.85).
For example, if your welding machine has a maximum current of 180 Amps, then approximately its power is:
180A*25V/0.85=5294 W, which means that in this case, the optimal value for the generator will be a power of 5294 W + 25% reserve = 6617.5 W, or if converted to kW - 6.6 kW. In this case, the Huter DY8000LX gasoline generator model will be one of the best options.
Welding current - it must be taken into account
Another good news is that you can very well use a generator for inverter welding, which has less power than your inverter. However, in this case, you will have to use it with some restrictions, namely, reduce the current strength to an acceptable value.
Take, for example, the case if you decide to purchase a 4 kW generator model.
We use the same formula as when determining power, but in reverse order:
Power*Efficiency/Arc Voltage = Current or 4000*0.85/25 = 136 A
Thus, on a 4 kW generator you will be able to weld on your welding inverter without any noticeable loss of quality with a current of up to 130A.
Electrode diameter - a label that is easy to remember
Another important nuance that should be taken into account is the correspondence of the electrode diameter to the minimum power of the generator. These data are approximate and fit into a simple table:
Electrode diameter (mm) Minimum generator power (kW)| 2 | 2,5 |
| 3 | 3,5 |
| 4 | 4,5 |
That is, if you plan to carry out welding work with a 4 mm electrode, then the minimum power of the generator for welding should be at least 4.5 kW and higher.
Which generators are suitable for working with a specific welding machine?
You have read the main rules for choosing a generator for welding in the previous sections. Using them, you can safely start purchasing a power plant. But to make it easier for you to navigate the assortment, let’s take a closer look at the most popular inverters for household tasks and determine which generators are most suitable for them.
For inverters Svarog
Unpretentious and inexpensive Svarog inverters stand out among other brands with a long five-year warranty. Buyers also often prefer them due to their low price, so purchasing budget options for Huter and Fubag generators seems like a completely reasonable decision.
The welding inverter Svarog REAL ARC 200 (Z238N) will work perfectly in tandem with the Huter DY6500L generator. This high-quality and useful unit can successfully operate on natural gas, which significantly increases the efficiency of the generator.
For Resanta inverters
The popular inverter manufacturer Resanta also produces products intended for the mass consumer. A distinctive feature of this brand is the compact size and light weight of welding machines.
For the household welding inverter Resanta SAI-190, you can use the BRIMA LT 8000 B gasoline generator, which, in addition to this purpose, will, if necessary, serve you as a backup power source at the dacha or in a country house.
For Kemppi inverters
Finnish Kemppi inverters have proven themselves worthy when working in harsh natural conditions and in production. They are rightfully the leader in sales among imported premium models. They are bought by people who know how to value real quality and reliability.
In addition to the popular model of the Kemppi Minarc 150 welding inverter, you can safely purchase the Fubag BS 5500 generator, which is characterized by very low fuel consumption, a durable frame and reliable overload protection.
For EWM inverters
Products of the famous German brand EWM appeared on our market back in Soviet times. From then until now, EWM inverters have brought real pleasure to the people who work with them. Such a device needs an excellent generator.
Therefore, for the EWM Pico 160 welding inverter, the Fubag BS 7500 A ES generator seems to be a worthy partner, which is equipped with a powerful engine, an AVR unit and is equipped with a spacious fuel tank for long-term operation without refueling.
Useful tips for choosing a generator
There are several other useful tips based on the recommendations of welding professionals that will be useful to you when purchasing a generator for an inverter welding machine.
- generators with a power of up to 10 kW on a gasoline basis . They are most widely represented in this segment. And more powerful power plants run on diesel fuel.
- The power reserve of a gasoline generator, at least 15-25%, greatly facilitates ignition of the arc. For power plants running on diesel fuel, it is desirable to have a larger reserve - up to 50%.
- The most functional are power plants equipped with cast iron sleeves. Their minimum service life is 1500 hours . Aluminum blocks can withstand significantly less load - up to 500 operating hours.
- Inverters with the abbreviation PFC in the name have a built-in power factor corrector in their circuit design, so they can operate at reduced voltage and are excellent for operation from a generator, for example the Svarog ARC 160 PFC model.
The information provided in the article is intended for conventional welding inverters, which are often used in domestic conditions.
For professional equipment (semiautomatic welding machines and inverters designed for argon-arc welding), certain problems may arise when operating from a generator. Many manufacturers explicitly state this in the user manual. Therefore, it is highly advisable to consult with specialists before purchasing in order to avoid serious consequences.
It is quite possible to select a generator for a welding inverter yourself, using common sense and our advice. And for complete confidence, contact the consultants and managers of our welding hypermarket, who will tell you which generator is suitable for welding in each specific case. Our specialists have the right answers to the most tricky and difficult customer questions!
Source: https://www.tiberis.ru/stati/vybor-generatora-dlya-svarochnogo-invertora
Main characteristics of the welding inverter
Essentially the same characteristic of the operating current range. Sometimes, due to illiteracy or malicious intent, the diameter of the electrode is indicated, which will not be able to cook with the stated maximum current. Sometimes it’s the other way around: the maximum diameter of the electrode is indicated, which clearly does not reach the value of the declared welding current.
The latter option is occasionally a glimpse into the conscience of deceptive suppliers. They indicate the short-circuit current as the maximum current. But the maximum working diameter of the electrode is still indicated honestly.
Welding current type: direct (DC) or alternating (AC)
Cooking with constant (or direct, in English - DC) current is simpler: it is easier to hold the arc. Therefore, 99.9% of modern MMA inverter machines produce constant welding current.
But among transformers, previously the majority were AC devices.
Alternating current (in English - AC) is used for welding non-ferrous metals. But not with MMA devices, but with TIG devices. Therefore, an MMA welding inverter that produces alternating current is a rarity.
No load voltage
After turning on the device, until the arc is ignited, the voltage at the tip of the electrode is significantly higher than during operation. And the higher it is, the easier it is to ignite the arc. But standards prohibit open-circuit voltage levels on devices delivering direct current above 100V.
To further reduce risks, the so-called VRD blocks. A device equipped with a VRD has only a few volts at the tip of the electrode before the arc starts. And only when you touch the metal, the no-load voltage is restored to the level necessary to ignite the arc.
All electrodes always indicate the polarity of the connection, the type of welding current (direct or alternating) and the minimum level of open circuit voltage required for ignition. For the vast majority of widely used electrodes, it does not exceed 60V.
The open circuit voltage, as well as the welding current, depends on the input voltage level. The lower the voltage in the power supply, the lower the open circuit voltage. Therefore, as the supply voltage decreases, ignition of the electrode becomes more and more difficult.
Duty cycle, also known as PV (on period), also known as PN (payload)
PV is indicated by two numbers. The first is current strength. The second is the percentage of time. For example, “130A-50%” means that this device with a current of 130A can cook half the time. And the same amount of time will remain idle, waiting for cooling to operating temperature.
If measurements are carried out at the maximum current of the device, the first digit is omitted, leaving only the percentage indicator.
For example, if a device with a rating of 160A has the entry “30%” opposite “PV”, this means that with a current of 160 amperes it can operate 30% of the time, and 70% will cool down.
That's right. It only remains to add that the domestic GOST R IEC 60974-1-2004 does not establish a single mandatory method for measuring the PN indicator for MMA devices. “The standard does not apply to limited-duty manual arc welding power supplies that are designed primarily for non-professional use.”
The European methodology, set out in the EN60974-1 standard, suggests measuring on a load stand at an ambient temperature of 40C only until the first shutdown due to overheating. The result obtained is referred to a 10-minute period. It turns out that the thermal protection worked after 3 minutes, the cycle of the device at this current is 30%.
Methodology of the TELWIN concern. To date, it is used by most Chinese manufacturers (those that generally conduct such tests on their cars). The Italian concern itself, when measuring the PV of its devices using its own method, modestly indicates “TELWIN” after the indicator. The vast majority of Chinese manufacturers do not do this.
Finally, there is a Russian, also known as Soviet, methodology. In essence, it is closer to the TELWIN method: all intervals during the control period when the device was working are summed up. But the segment is taken not 10, but 5 minutes. And - most importantly - the device is first put into overheating protection mode, after which measurements begin.
As a result, the same device produces completely different percentages using all 3 methods! Naturally, the most modest “numbers” are obtained using the European method, and the most impressive ones – up to 2 times or more – using the Telwin method.
Version: IP protection class
The IP protection class indicates the performance of electrical devices in relation to solid objects (first digit) and liquids (second digit).
You can determine the degree of protection of the device visually. If a device with IP21 has all the ventilation slots completely open, then with IP22 they are already covered on top with protruding visors. And on a device with IP23, these visors almost completely cover the cracks.
The degree of protection IP24 and higher is technically difficult and makes no sense.
Version: insulation class (heat resistance)
Many materials lose their working properties when heated above a certain temperature. To standardize materials according to this criterion, a classification of insulation based on heat resistance has been introduced. Almost all welding inverters using IGBT transistors have insulation class H, which corresponds to a maximum heating temperature of 180C. The previous “step” - class F - means a heating limit of 155C. Above class F is only class C, indicating a possible heating temperature of over 180C.
Operating temperature
Like internal heating, external heating and especially cooling impose certain operating limitations. Most inverter welding machines are suitable for operation in the range from 0C to +40C. If the device is suitable for use in cold weather, its limit value must be indicated: minus 20C or minus 40C.
Author of the text: Yu. Shklyarevsky.
Source: https://www.kuvalda.ru/blog/articles/raznoe/osnovnye-harakteristiki-svarochnogo-apparata-mma_2.html
160 Amps: which welding inverters are best for home
The happy owner of a country property, in addition to a green lawn and clean air, receives a very wide scope of work, many of which are related to metal. But, unfortunately, they cannot always be done using hardware products and tools. For example, you can quickly assemble a fence or metal structure for a gazebo only using electric welding. Therefore, over time, every owner tries to purchase a reliable welding machine.
Criteria for choosing a welding inverter for home
Transformer current sources are still popular among developers because they are reliable, cheap and quite suitable for home use. However, such a tool also has many negative aspects, including impressive weight and large dimensions. Moreover, a device based on a transformer consumes a lot of electricity and drains the network during operation.
Inverter units are another matter - they are small in size and weight, and easy to operate. Almost all welding inverters comply with 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
Usually, summer residents with practical experience already know exactly which inverter device is best to buy for the job. Based on their opinion, you can make a list of parameters that should be taken into account when purchasing.
Welding power or rated current
When buying a new welding machine, it doesn’t hurt to find out what reviews say about a particular model of the unit. When purchasing, most home craftsmen take into account the value of the rated current - this 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
Many samples of welding equipment have additional functions that are designed to make the process easier for a novice welder:
- 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.
Service and warranty
According to the experts, a decent unit should have a long service life. Therefore, when choosing a welding inverter for work in a private home, be sure to find out the warranty period. Practice shows that the best manufacturer is the one that carries out repairs quickly and efficiently, has its own service centers and a spare parts database.
If there is no service, then you need to take into account the availability of repair kits in tool stores. Reliable brands today set warranty periods from one to two years.
Which welding inverter is best for home use: review of models
Choosing a unit for welding on the modern market is problematic - the number of models on the market clearly exceeds demand. Experienced welders do not like various experiments and prefer to buy only work-tested specimens.
A serious manufacturer will never sacrifice its reputation and the quality of such a product will always be at its best. Therefore, when thinking about which company to choose a device with an operating current of 160 Amperes, first of all, inverter units with “authority” are considered.
Fast and Furious-161
The Ryazan Instrument Plant has developed the most compact manual welding machine in its line. Any household outlet can handle a power of 5.5 kW. The unit belongs to the “intelligent” class, it is universal and structurally thought out. Its cost is 11,900 rubles. The main parameters speak only about the advantages of the device:
- Mobility and portability, the ability to increase the standard network cable up to 50 meters.
- Low power consumption and the ability to operate from an autonomous voltage source.
- If additional equipment is available, it is possible to organize argon arc welding.
- Wide functionality and extended warranty period up to 3 years.
A real review about this household inverter will describe it better than any instruction:
“The maximum current of 160 A is set using a “twist” from the 15 A mark. This is enough to cook with electrodes with a diameter of up to 4 mm, and with any coating. I also took a TIG torch in the kit, now I can work with argon arc welding with cast iron and stainless steel.”
In terms of equipment, the unit is not the simplest - there are Arc Force, Hot Start and Antistick systems. All this allows it to function in the range from 188 to 245 Volts, and the “troika” can be cooked even at 140 Volts. Many craftsmen note a technological feature - “standby mode”, into which the device goes when the voltage is 100 V.
Forsazh-161 is a good inexpensive welding machine, weighing only 4 kg. It has a squat design, which makes it stable, but this is not liked by craftsmen who are used to working with a welder on their shoulder. Another negative can be heard from Alexey D. from Pushkino:
“The kit does not include a mask, gloves or brush. I also had to buy a cable separately. In principle, these problems are not so serious if you consider its functionality. Another feature is that the device can operate from a generator with a power of 9 kW or more.”
ARC 160 PFC
The arc welding unit from the Svarog company tops the rating of welding inverters in some tests, it must be said that it is not in vain - it is capable of working with electrodes up to 4 mm. Tig welding and TIG welding are available as an option. The last mode is ignited by touch. A potential buyer may be confused by the cost of the structure - 20,750 rubles, but Alexander Sh. claims that it is worth it:
“At idle, the device takes only 70 Volts, the network needs a single-phase network, it can operate from a generator. The design has a fan and an overheating protection system. There are few additional functions, but Hot Start is available. The current strength is adjustable from 10 to 160 A.”
The main advantage of the ARC 160 PFC is its ability to operate at a voltage of 90 Volts. This was made possible thanks to the PFC system, which is an additional step-up power supply. The welding inverter from Svarog is quite suitable for home use, and the plant provides a five-year warranty period.
Let no one be confused by the country of origin - yes, it is China, but the quality of workmanship is excellent. The practice and opinions of real homeowners confirm the reliability and functionality of the device.
Fubag IR 160 – reliable and cheap welding inverter for households
Fubag presents itself as a German manufacturer of professional tools, but it seems that units for home use from the IR series are produced in China. But this is not so important for those who want to weld a metal structure with high quality, especially since the price of the device is only 7,300 rubles. With all this, the welder welds with “four” without any questions, for which it consumes only 5 kW.
The unit is assembled on the basis of IGBT technology, which helps to make a high-quality seam. Despite the lack of additional options, a novice welder will immediately get to work without any problems, which is confirmed by numerous assessments from homeowners:
“Despite the fact that Fubag IR 160 is the cheapest welding inverter, the device has on-board protection against overvoltage and overheating. Ventilation turns on immediately after pressing the “Network” button. For a budget car, Fubag operates in the range of 150-240 Volts, which is quite good. Some inconveniences arise when welding with 4 mm electrodes, because this requires maximum current.”
The following factors may cause some complaints:
- The device is not intended for operation in argon arc welding mode.
- It is impossible to power the unit from any generator.
If you are looking for an inexpensive and reliable welding inverter, then you should pay attention to the Fubag IR 160. The ergonomics of the device do not cause a negative reaction, the housing itself has a degree of protection IP21S. The weight of the unit is somewhat overestimated, but quite adequate - 4.6 kg.
The kit includes 13 mm2 cables: 2 meters for ground and 3 meters with an electrical holder. If you need an understandable welding device, but your budget is tight, then Fubag IR 160 is the most suitable option. Its price is about 7,000 rubles, and the warranty is 24 months. In the case when you need more advanced capabilities, and the funds allow, then look towards the IN series.
Source: https://stroimass.com/kakoj-svarochnyj-invertor-vybrat-dlya-doma.html
Welding machine power consumption
Energy consumption for the operation of a welding unit may vary depending on various reasons. Firstly, this is the power of the device itself, secondly, the limits of the incoming voltage, etc.
But using a certain formula, the final power of the device is calculated; it has minor discrepancies with the real numbers, but this is not significant. Therefore, for those who monitor the revolutions of the electric meter, this article will be useful.
We will talk in detail about all the points that affect the power consumption of an inverter welder and how its total power is calculated.
Factors affecting energy consumption
Before making calculations, you must clearly understand what quantities make up the total electricity consumption. The power indicated on the box is also taken into account in the calculation; this is an important component, but it is not the only one. You also need to know several quantities in order to more accurately create a formula.
The main factors influencing voltage include:
- device power;
- input voltage range;
- the maximum welding current that the inverter is capable of;
- electric arc voltage parameters;
- efficiency of a specific model;
- duration of work.
The totality of all values will determine the total power of the unit.
Additional components of power consumption include:
- the condition of your wiring;
- welding conditions and modes;
- reliability of wires.
You also need to pay attention that the household electrical network does not always produce the generally accepted voltage of 220 volts. At best, you will get 200. When you turn on the welding machine, the range of welding current required during operation is reduced.
This makes it difficult to make an accurate calculation. First of all, this applies to low-power inverters. If the device is designed to operate within 150-250 volts, then calculations are made with more accurate indicators.
Since the arithmetic average is approximately equal to the mains voltage.
Now let's talk about the operating time of the device. It refers to the basic conditions for calculating power. This important characteristic shows how long the inverter can operate continuously. Each model has different meanings for work and rest.
For example, a welder works for four minutes, but it will take the same amount of time to cool down. But there are welding inverters that work for 5 minutes and rest for 2 minutes. In this case, consumption will be higher.
This fact must be remembered in subsequent calculations.
Calculation formula
To make the calculation correctly, first of all, you need to familiarize yourself with the technical parameters of your welding machine from the instructions included with the product or information on the Internet that applies specifically to this model.
The data you will find in the technical specifications is as follows:
- Power efficiency;
- current strength at maximum value;
- highest arc voltage;
- apparatus efficiency coefficient;
- duration of work.
The formula is:
Max current value* Max voltage value / efficiency = device power consumption
We will make your work easier and say that the power factor is always set to 0.6. Almost all modern inverters have this value. Now substitute the numbers from the data about your welder into the formula, and you will get the power of the device in working condition.
But let’s highlight such moments as replacing electrodes, adjusting power, easy selection of the next surfaces to be welded, and other moments when you do not make the seam itself. For these purposes, the device operation duration parameter, which we discussed above, will be useful.
The resulting result of the device’s power must be multiplied by this figure. Then you will bring the result closer to more accurate values. For example, your first figure was 5 kW.
We multiply by the lower value of the work time (for example, 60%) and get 3 kW, which is the average power of all welding work, including downtime.
This simple calculation procedure will provide you with knowledge of how much electricity your inverter consumes. Let us remind you that this formula is applicable only to welding inverters, and does not work with semi-automatic calculations. But we'll talk about them next time. Let's just say that their power consumption will be higher.
conclusions
Now you can accurately calculate how much electricity is spent on welding work. To save money on your electrical bills, purchase a unit with a lower wattage. Any welding inverter is suitable for small country work, and low electricity consumption will be a pleasant bonus for you.
What calculations do you make to calculate the power of your device? Maybe you have a different approach? We would appreciate your comments.
Source: https://svarka-weld.ru/potreblyaemaya-moshchnost-svarochnogo-apparata
What power generator is needed for a welding inverter?
What kind of generator is needed for a welding inverter?
“Which generator to buy for inverter welding” is the question asked by most people who dream of mastering electric welding if they do not have the opportunity to connect a welding inverter to a household power supply. At the same time, if you buy any generator you come across, it won’t work, since it must meet a number of requirements, including being suitable in terms of power.
Welding is essentially a short circuit. Therefore, the generator will react accordingly to a short circuit. Not only will it constantly turn off when welding, but there is also a risk of the inverter failing. Therefore, you need to approach the choice of generator consciously. And if we don’t go into the types of existing generators, we can only say that only a synchronous type generator is suitable for welding with an inverter.
In addition, it is better to give preference to a generator with a copper alternator winding than one with aluminum. Generators with copper winding are more reliable in operation, they are able to carry loads much better. Well, we’ll talk about other parameters that influence the choice of a generator for welding with an inverter below, in this article from the construction magazine samastroyka.ru.
What kind of generator is needed for a welding inverter?
A generator for inverter welding must meet a number of the following requirements:
- Have a sufficient power reserve (about 20%);
- Be a synchronous type;
- Be compatible with inverter equipment.
When choosing a generator for welding, you must be guided by the following points:
- Inverter power consumption;
- The current required for welding;
- The diameter of the electrodes (depending on the thickness of the metal being welded).
It is precisely these nuances that you need to be guided by when choosing a generator for a welding inverter. At the same time, the power of the generator comes first, so that’s where we’ll start.
How much power does a generator need for inverter welding?
The selected generator for welding must have a power no lower than that of the inverter, but on the contrary, slightly higher, taking into account the required margin of 25%. Typically, the power of the generator and welding inverter can be found in the technical data sheet. At the same time, you should not make mistakes in the units of measurement, since very often the power of electrical appliances is indicated not in kW, but in kVA.
kW is active power, and kVA is the apparent power of an electrical appliance. If the power of the welding inverter is indicated in kVA, and you need to convert it to kW, then it is enough to use the following formula for calculation: where 10 kVA * 0.8 = 8 kW.
At the same time, you need to understand that the welding inverter will not always operate at full power, and here everything largely depends on the required current strength. And since the efficiency of the inverter for welding and the arc voltage always have a constant value, then calculating the power of the generator for welding is not so difficult.
The efficiency of the welding inverter is 85%, and the arc voltage is 25V.
Knowing these parameters, you can independently calculate how much power a generator is needed for inverter welding, based on the strength of the welding current. If the inverter for welding has a maximum current of 160 Amperes, and you need exactly this current for welding, then the power of the inverter will be equal to: 160A * 25V / 0.85 = 4705 W. Considering the required power reserve for the generator, which is at least 25%, you can easily calculate its optimal power: 4705 W + 25% = 5881 W, which is almost exactly 6 kW.
From all of the above, it becomes clear how exactly the current strength of the welding inverter affects the required power of the generator. Consequently, by reducing the current on the inverter, it will be possible to use a generator of much lower power, for example, 2.5 or 3 kW.
Here everything depends on the diameter of the welding electrodes and the thickness of the metal being welded.
For example, using electrodes up to 2 mm, you can weld from a 2.5 kW generator, the power of which will be quite enough for the welding inverter to produce the required current for welding.
Source: https://samastroyka.ru/kakoj-nuzhen-generator-dlya-svarochnogo-invertora.html
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.
Power as an important characteristic of a welding machine
When purchasing equipment for electric arc welding, the power of the welding machine in most cases is the determining factor in choosing the appropriate model. The value of this parameter determines the operating current of the device, as well as the thickness of the metal workpieces with which it is capable of working.
- 1 Selection order
- 2 Rectifier
- 3 Inverter
- 4 Semi-automatic
Selection order
In the accompanying document (passport) for each specific welding machine, the manufacturer indicates the maximum power that ensures its operation under peak loads. That is why, when assessing it, you should focus on the quality of the voltage in the electrical network to which this device is connected.
Page with technical characteristics in the passport of the welding machine
At the same time, one should not lose sight of the fact that even a relatively powerful inverter, with significant fluctuations in voltage in the network, will not be able to guarantee the required operating performance and maximum output.
The procedure for choosing an inverter welding machine, a semi-automatic device or a conventional transformer rectifier that is suitable for its energy intensity has many similar features. Therefore, let us first familiarize ourselves with the general rules for choosing working units, when assessing the power of which we are usually guided by the following considerations:
- For certain models of welding machines, the manufacturer’s passport data is often overestimated by 10-15%. It follows from this that when purchasing, you should choose a device with some power reserve;
- in the absence of a “power” column in the passport, you need to focus on the amount of current that the device consumes in maximum load mode (to estimate its power, this value is multiplied by the current voltage in the network - 220 or 380 Volts);
- when purchasing a welding machine that is not designed for significant overloads (for long-term operation in “heavy” modes), high power is not required; under normal welding conditions, a device with a working load of about 120-130 Amps is sufficient.
When choosing transformer machines for manual welding, you should remember that over time this equipment wears out. Moreover, the greater the power and operating current, the greater the heating of the welding machine and its wear. .
Rectifier
This device is a transformer type device that operates on the principle of converting alternating voltage into a constant value required for welding.
Unlike a standard converter device, when working with a rectifier, it is possible to obtain a more stable arc with good quality indicators and better characteristics.
Thanks to this, it is possible to weld not only ordinary steel products, but also non-ferrous metals, including workpieces of small thickness. When working with a rectifier, no special welding experience is required.
When determining the required power indicator of this device, they usually proceed from the value of the electric arc voltage (for a rectifier it is 24 Volts). This value is then multiplied by the operating current (usually 160 Amps), which results in the so-called “arc power”.
If it is necessary to accurately estimate the energy consumption of the purchased device, an adjustment is introduced into the calculations for unproductive heating of the equipment (efficiency indicator equal to approximately 0.65-0.7). For devices with transformerless output, the power factor must also be taken into account (usually 0.951).
Inverter
When purchasing and choosing such a well-known type of welding equipment as an inverter machine, you should also pay attention to its power indicator. In this case, it is necessary to take into account the rated current value at which the electronic device can work intensively for a long time and not overheat.
To justify the correct choice of an inverter, let’s consider an example of working with a three-millimeter electrode and a working load equal to 120 Amperes. In this mode, it is possible to weld metal workpieces with a thickness of about 3-4 mm.
It follows from this that to expand the functionality and power of welding with an inverter, it is desirable to provide a small margin in the current parameter (up to 160-180 Amperes).
This will allow you to work not in the maximum (critical) mode, but in a gentle mode, which significantly reduces the likelihood of the welding machine failing and will prolong its service life.
When choosing the size of the current reserve, it is important to calculate not only the amount of workload on the welding machine, but also possible deviations of the supply voltage from the nominal value.
A power reserve may also be required in cases where the length of the cables used for power supply exceeds 5 meters. At the same time, their length, reaching a 15-meter mark, is considered critical.
Semi-automatic
Such a common type of equipment as a semi-automatic welding machine allows you to work in a wide range of currents and perform difficult operations on welding sheet blanks and non-ferrous metals.
With the help of semi-automatic welding equipment, it is possible to fuse difficult-to-process products from thin-sheet material, which are usually worked with in auto repair shops.
This type of welding machine allows you to weld in a protective atmosphere of argon or carbon dioxide, which increases the efficiency and quality of welding by blocking the oxygen contained in the air.
Sometimes, for these purposes, a special flux-cored wire is used, which acts as a filler material and also improves the quality of the weld.
The operating power of the semi-automatic device is selected taking into account all the previously discussed factors, to which should be added the peculiarity of this device.
The fact is that at the moment the semi-automatic device is turned on, a pulse jump in current consumption is observed, which must be taken into account when evaluating the purchased equipment.
It is also important to navigate the cost of the welding machine you choose, which is directly related to its power rating. However, in the case when it is necessary to work with thin-sheet workpieces and non-ferrous metals, you can quite accept the additional costs when purchasing a semi-automatic machine.
When assessing the parameter of the current consumed by the unit (regardless of the model and class), specialists also take into account such a parameter little known to amateurs as the power factor of a welding inverter or any other welding device. This value takes into account the reactive nature of the load on the network when one or another welding machine is connected to it.
For some of them (inverter, in particular), capacitive indicators of reactive losses predominate, and for transformer circuits, inductive components are more noticeable.
As a result, it should be noted once again that the power of any welding unit is the most important indicator of its operating efficiency in various operating modes . That is why special attention should be paid to the choice of this parameter.
Source: https://svaring.com/welding/apparaty/moshhnost-svarochnogo-apparata
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/
Power of the welding machine and arc: how is it determined and how much does the inverter consume?
The power of the welding machine is one of the main characteristics that you need to pay attention to when choosing it.
In order to better understand all the intricacies associated with welding devices and understand the main points for calculating this parameter, it is necessary to clarify several important aspects. The information will be useful to know for all those involved in welding.
Main types of welding machines
Inverter device for welding.
Inverter welding machines are divided into three categories:
- household;
- semi-professional;
- professional.
The noted division is made primarily based on the area and frequency of use of the device. To understand what kind of welding machine you need, you need to determine the conditions of its use.
Household ones are designed for short operating times. It is not possible to use such devices for constant and long-term welding. After only 5-10 minutes of use, the device must be allowed to “rest” for the same, and sometimes longer, period of time.
At the same time, the ability to connect such an inverter to a single-phase household network makes it very convenient for use at home. For quick welding of metal structures in the country or for home work, it is not so critical how many breaks the welding inverter takes.
Semi-professional class inverters are able to operate longer, which is achieved due to the features of their design. Such devices are used in the repair of pipes, the manufacture of frames and metal structures. They are usually powered from a three-phase network.
Professional-grade devices are capable of working without interruption throughout the day. Their welding current can reach 500 amperes. This means that the power consumption of a welding inverter of this type will be the greatest.
All household, some semi-professional and professional devices can be powered from a 220 volt network. At the same time, do not forget that the mains current cannot exceed 160 amperes.
When purchasing an inverter, you must calculate in advance how much power it needs and how much current it will consume.
Connecting a device with higher ratings may lead to the machine turning off or to burnout of the socket contacts, since the equipment is designed for a larger number of kilowatts.
So, what should you pay attention to when choosing a household inverter? First of all, on the welding current, the characteristics of which are indicated by the manufacturer in the passport or manual for the device.
This criterion shows at what current the normal operation of the inverter will be ensured without overload, taking into account the continuous load. Of course, it is better to give preference to devices with a power reserve of 30-50% to the operating current.
Dependence of welding current on metal thickness and electrode diameter.
In a regular city power grid, there are often power surges. As a rule, such changes occur in both directions by 15-20% of the nominal value of 220 volts.
Typically, household and professional inverters are not so sensitive to such surges. Even with them, they are able to work effectively.
However, when connected to a generator, fluctuations can be significantly greater. In this regard, it is better to choose a welding machine with protection against voltage surges.
It is quite difficult to check all the parameters of devices directly upon purchase, even if the devices have digital displays. Even they can display incorrect information and mislead the buyer.
Calculation of device power
Before you begin calculating the power of the device, you need to know the following parameters:
- range of input voltage and welding current;
- welding arc voltage;
- Efficiency of a specific device;
- duration of switching on;
- Power factor.
The welding current interval shows at what network parameters you can work. This is due to the fact that in reality the declared 220 volts are not observed in household electrical networks. Sometimes the voltage can be less than 200 V, and sometimes it can significantly exceed 220 V.
When connecting the welding machine to the mains, a voltage drop of 5-10 percent from the nominal value may be observed.
Schematic diagram of the current regulator.
In this regard, it is advisable to pay attention to models for which the operating range is stated to be from 150-170 to 220-250 volts. It is these devices that are able to provide the best power performance.
The welding current range determines its highest and lowest values. The power of the inverter directly depends on this characteristic. For household models, the minimum values can vary from 10 to 50 A, and the maximum - from 100 to 160 A.
One of the important characteristics of the inverter is the on-time. This parameter actually indicates how high quality a particular device is. The meaning of the criterion comes down to the ratio of work time to “rest”.
For example, if this indicator is 50%, then for every five minutes of operation the device should cool for the same period of time. Thus, the lower this parameter, the longer the breaks will be.
A high percentage, on the contrary, indicates that the device can be used for an extended period of time without interruption.
The power factor of a welding inverter directly depends on the duration of switching on. The calculation to determine this characteristic is determined from the ratio of continuous operation time to total time.
Let's look at everything using a simple example. Let's calculate the power of an inverter welding machine that worked for 4 minutes before the protection tripped. It then needed to cool for two minutes before it was ready to go.
So, to find out what coefficient this device has, you need to divide three by five - the total operating time, and multiply by one hundred. We get the desired value. For household mini versions and semi-professional equipment, the coefficient does not exceed 0.6-0.7.
Welding machine characteristics table.
Let's say there is a device that requires a power supply of 160-220 V, and its maximum current is 160 amperes with an arc voltage of 23 volts. Let the efficiency of such a device be 0.89, and the duty cycle 60%.
The parameters listed above are quite sufficient to calculate power consumption. It is necessary to multiply the current by the arc voltage and divide it all by the efficiency. The result is 4135 watts.
This value shows the power consumed directly during operation. However, as mentioned earlier, it is also necessary to take into account the duration of activation. To do this, you need to multiply 4135 by 0.6. The result is 2481.
This value is the average power. It is considered the most relevant and correct when determining energy consumption.
This approach is closest to reality. After all, it is very rare to encounter a situation where the inverter would work for days on end without interruptions. Pauses and delays always happen; you simply cannot do without them.
It is worth at least taking into account the time required to change electrodes or to prepare parts for welding.
Power table
When choosing a welding inverter, it is necessary to take into account other factors besides the kW consumed. This is especially true for professional models. They are subject to higher demands than household versions.
Required inverter power for welding different metals.
It is necessary to take into account the thickness of the materials being welded. The power of the inverter welding machine and the thickness of the electrodes will also depend on this criterion. The required parameters are shown in the table below.
It greatly simplifies the calculation of power consumption depending on operating conditions. In addition, this table will be useful for beginners who often wonder about choosing an electrode of the correct diameter.
| Metal thickness, mm | Welding current, A | Electrode diameter, mm |
| 1,5 | 30-50 | 2 |
| 2 | 45-80 | 2,5 |
| 3 | 90-130 | 3 |
| 4 | 120-160 | 3 |
| 5 | 130-180 | 4 |
| 8 | 140-200 | 4 |
| 10 | 150-220 | 4-5 |
| 15 or more | 160-320 | 4-6 |
The intensity and volume of work is the criterion by which a device with a certain duration of operation is selected. As already described above, this parameter shows how long the device can work with wire of a certain thickness under given conditions.
The operating conditions of the inverter determine its protection class. If the device is to be used indoors, then IP21 certification will be sufficient, but if used outdoors, when the temperature is low or there is high humidity, IP21 protection will be required.
Schematic diagram of a welding inverter.
As for the power supply, household appliances can also be plugged into a regular outlet. Professional inverters usually operate from a three-phase network with a voltage of 380 volts.
In addition to the above criteria, you must also pay attention to additional parameters. The functionality of an inverter can greatly simplify certain operations.
For example, arc forcing by optimizing the current strength will prevent sticking. Hot start allows you to quickly ignite the arc. Anti-stick switches off the inverter if the electrode gets stuck.
The presence of a display on the device will never be superfluous. It can display operating modes, which greatly simplifies the operation of the device.
Bottom line
This article describes what parameters of the inverter operating mode determine the power; it is shown that it is influenced by the welding arc voltage, current strength, duration of activation, etc.
In addition, various classes of welding machines are considered, as well as their features and differences. This material will definitely be useful to novice welders who are still thinking about purchasing a welding machine.
Source: https://tutsvarka.ru/oborudovanie/moshhnost-svarochnogo-apparata
