How to choose a generator for repair and welding work?

Popular models

For the correct choice of a gas generator, one must not only look at the operating parameters, but also take into account the manufacturer, of which there are enough on the market today.

Characteristics of the FUBAG WS 230DC ES station

If you are looking for a gas generator for welding, then we advise you to consider the following model as a possible option. With the FUBAG WS 230DC ES generator, you can solve a wide range of tasks, including those that arise for assembly and construction crews. Thanks to the spacious fuel tank, it will be able to operate continuously for 9 hours at a maximum load of 75%.

To start the station, an electric starter is provided, which allows you to quickly start work. There is a choice of operating current in range from 50 to 230 A. With this device, you can weld metal products by arc welding using stick electrodes, which can have a cross section of 1.6 to 5 mm.

In this model of the generator, control automation is not provided. Weighing 112 kg, it is equipped with a 25 liter fuel tank. The model is easy to use and has an oil sensor for this. The power drive used has a power rating of 14 liters. with. During operation, the generator generates a noise level of 77 dB. With dimensions of 722 × 530 × 582 mm, the installed 439 cm3 engine can be assessed as the correct decision of the manufacturer. The operation of the device is provided by a four-stroke motor. The model is not equipped with a handle or wheels.

Power plant FUBAG WS 190 DC ES

This model can be use to connect metal products by arc welding. It supports generators up to 4 kW. For welding work, it is allowed to use only electrodes with a diameter in the range from 1.6 to 4 mm.

This generator has a reinforced painted metal frame that protects the housing from corrosion. The latter is equipped with special damping pads to reduce vibration during operation. The weight of the device is 97 kg, and the volume of the fuel tank is 25 liters.

The device has a rather compact size - 722 × 530 × 582 mm. The working noise index does not exceed 77 dB. The power drive used in this model has a power of 13 liters. with. The generator is powered by a four-stroke engine. Additionally, the design provides a fuel level indicator. Both an electric and a manual starter can be used to start the power plant.

Characteristics of the Caliber BSEG-5511

To choose the most suitable gas generator model, you should first look at several models. Among the devices on the market, the "Caliber" generator deserves special attention. This is a universal device that will be indispensable at a car service and construction site.

This unit uses an engine with an increased service life, which is explained by the presence of a forced cooling system. The operation of the device at a load of no more than 75% without refueling is possible for 9 hours. The model is supplied with control automatics. The permissible power of the device is 5.5 kW. The fuel tank is quite spacious and has a volume of 25 liters. The weight of the device is 86.1 kg. For this model, the minimum and maximum currents are 50 and 190 A, respectively.

Gas generators with welding function

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

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

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

• Welding of pipes;
• Installation of metal structures;
• Connecting autonomous objects to power supply, etc.

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

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

• Manual or electric starting actuator;
• Wide range of battery life;
• A certain consumption of a fuel resource;
• Noise level and other parameters.

Welding generators dominate over simple power plants, as their performance under load is several times higher, and in conditions of instantaneous overload, they feel better. In general, the functionality of these installations is more flexible in comparison with simple "household" counterparts.

Model examples

Welding generator Eisemann S6401:

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

Excellent for welding in locations away from the mains. Differs in optimal dimensions, operational reliability and unpretentiousness in terms of service. The systems of this unit are perfectly protected from possible failures, which ensures an extremely long and stable operating period, even at facilities with increased pollution and high labor intensity (construction sites).

Power plant Eisemann S6400:

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

It can work in two formats:

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

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

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 more than one year.

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

HUTER DY6500L

This device will show itself well on the farm, 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 is just combined with the calculations. It is best to use 92nd gasoline as fuel, then the device will work fully. But propane can also be used.

It is started manually with a starter. A rapid air cooling system is built into the Hunter. It weighs a little more than eighty kilograms, so one person will not be able to transfer 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 more - 6.5.

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

LT 8000B is also gasoline. Its tank holds twenty-five liters of fuel. Four-stroke engine, also has forced air cooling function streams. The launch is electronic, unlike the previous model.

He can work continuously for a third of the day, but it is better to let him cool down as often as possible so as not to let him overheat.

It is oversized, of rather high power, like all models of this type, weighs 83 kilograms. But even one person can move it, since special wheels are screwed to it.

Coordination of the gas generator and inverter

To ensure operation with optimal welding modes, it is necessary, first of all, to coordinate the gas generator and the welding inverter in terms of parameters. This is achieved in several ways, and one of them is to simply add the inverter power and 30% -40% headroom. This method allows you to ensure uninterrupted welding, but it is an expensive solution because in this case you will have to buy a notoriously expensive and heavy gasoline unit. In order not to overpay and ensure greater mobility, several factors should be taken into account, namely:

the length of the cable connecting the inverter and the generator should not exceed 10-15 meters, which will avoid losses;
to select a generator, the average power consumption of the inverter should be taken into account;
modern inverters have hot start functions and current regulation, therefore, in the calculations, it is necessary to correlate the current consumption at the moment of peak load and the maximum power of the gas generator.

For example, we considered a generator whose power is 4 kVA, we multiply this value by the efficiency of the welding machine, for inverters 0.8 and divide by the arc voltage, let 25 V. We get a current of 128 A, which allows reliable welding with a 3 mm electrode. There is a simplified method for matching the maximum load on the generator and the thickness of the electrodes, and hence the workpieces to be welded. It consists of the following:

• electrode diameter up to 2 mm, requires a maximum generator power of 3 kVA;
• with a diameter of 3 mm, a 4.5 kVA generator is required;
• for a 4 mm electrode, a gasoline unit with a maximum indicator of 5.6 kVA is needed;
• using a 5mm electrode implies a power of 6.9 kVA.

This figure is too high as it is calculated for peak generator loads at maximum inverter demand.

Generator selection

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

Look at the power that the device consumes, the maximum possible current of the inverter, 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 generator power are related, then compatibility is more questionable. The generator can be inverter, synchronous and asynchronous, there are also hybrid types in which the properties of the latter two are combined.

It may seem to a beginner that in this situation you need an inverter generator, but this is a common mistake. Here either the synchronous or the hybrid version is suitable, since they have a fairly high power.

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

In addition, it is much easier to find the right version of a device with a suitable power on gasoline, 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 if your device will be able to run on a generator, talk to a store consultant about it.

Selection of a generator for welding

When the design of a petrol welding generator is equipped with cast iron sleeves, its service life increases dramatically. These devices can use approximately 1500 engine hours. Aluminum counterparts have a shorter lifespan.

Today it is possible to purchase inverter units with power factor control. These systems can work with a variety of generator models as they can be configured for low voltage.

Diesel models are suitable for daily, many hours of work. An apparatus with a power of 0.7-5 kW is suitable for working on a personal plot. These products are lightweight. Therefore, they are easy to carry from place to place. The power of 10 kW allows you to carry out daily work for 8 hours.

The most important details, especially their dimensions, in a welding gasoline generator are:

• Fuel tank.
• Soundproofing casing.

For construction sites, it will be better to use equipment with valves on top. The advantage of such devices is:

• High performance.
• Silence.
• Durability.
• Compactness.

Most popular models

Depending on the principle of operation of the engine, almost all gasoline welding machines are divided into several types:

• Two-stroke.
• Four-stroke.

To work in a domestic environment, the HUTER DY6500L model is considered the most efficient and productive. The device is not designed for long-term operation, but it differs from other products in its good characteristics. Such a compact station works perfectly in conjunction with an inverter of the Svarog type.

Target system Brima LT 8000B shows excellent performance with most inverters manufactured by Resanta. Sometimes Brima can become a backup power supply for a country house.

Very large fuel tank for the Endress ESE 606 system. The model is distinguished by its high cost. However, it works much longer than a conventional generator. The product is equipped with a Honda engine, which significantly reduces fuel consumption. The device shows excellent results when working in conjunction with an inverter type EWM.

How to care for your generator

Maintenance of a gasoline generator is not associated with serious technological operations. It is enough to monitor the oil level. Refill it if necessary. Sometimes it will be necessary to recharge the battery.

Originally posted 2018-07-04 07:14:50.

Video. Welding from a generator.

From the above information, it is clear that for short-term household work, it is enough to take a gasoline inverter generator slightly higher than the estimated average power consumption inverter welding machine... By setting the welding current on the panel to an average or slightly higher power, you can carry out high-quality welding with electrodes Ø up to 3mm. This will save money on buying a generator. In other cases, it is better to choose an industrial or professional inverter gas generator.

When choosing generators of this group, the powers are calculated based on the maximum power consumed by the welding machine plus 30-40%.

Only such conditions will ensure high-quality welding and long-term operation of the equipment.

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A gasoline generator is an irreplaceable technical tool used for autonomous operation of electrical appliances and other equipment, when there is simply no possibility of power supply from the central power grid. Naturally, the use of a gasoline generator for welding is not limited to electric welding alone - it is possible to connect any electrical appliances in the conditions of production and construction sites, in suburban areas, etc. Next, we will talk about the key operational features, characteristics and nuances of choosing this equipment.

What it is?

Gasoline generators for domestic use have been known for a long time and are widespread - but they are not very suitable for welding. A gasoline welding generator suitable for the operation of an inverter-type apparatus must have a power significantly higher than the usual household unit. In addition, simple gas generators are designed only to power the "active" load: electric heaters, lighting devices, low-power household appliances.

The welding inverter is distinguished not only by its high power, but also by a sharp uneven current consumption. Automation of the generator apparatus for powering the welding inverter must be resistant to work on a powerful "reactive" load. All this determines the design features and subtleties of the operation of such devices.

Gas generators with welding function

Welding gas generators give a full guarantee of coincidence of characteristics. In one housing are connected: an inverter type welder and a generator, with an engine running on gasoline.

Amateur models deliver currents up to 170 A, professional 220 A and more.

Models

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

Models from Germany are most in demand in stores:

• RID RH5221 S - gasoline power plant has a built-in welding machine;
• RID RH7220 S - continuous welding current up to 220 Amperes.

The equipment of the Russian Federation from Svarog is popular among professionals and amateurs.

Operating rules

The generator must always be clean. Dust and dirt settling on the electrical terminals and windings lead to overheating and malfunction. To excite the current in the winding on gasoline generators, a battery is installed. It should be charged periodically. In addition, there is an oil level indicator on the panel. A red light indicates that the coolant and lubricant level is low and must be replenished.

Like all electrical equipment, the generator should be periodically checked for insulation integrity, the terminals should be cleaned of oxides and the contacts should be tightened.

Criterias of choice

The answer to the question of which one is better to choose a gas generator for inverter welding depends on the purpose of the latter. Here are the main criteria:

• power;
• fuel type;
• engine's type;
• versatility;
• generator type.

Power

It is selected based on the required value of the welding current (depending on the thickness of the parts to be welded) and voltage. In the characteristics of welding gas generators, two powers are indicated - nominal and maximum. You need to focus on the nominal value, since in the maximum power mode the device works only for a short time.

The power is calculated by simply multiplying the welding current and voltage.

So, to generate a welding current of 120 A with a voltage of 25 V, a generator with a rated power Wн = 120 * 25 = 3000 W = 3 kW is required.

Fuel type

Along with gasoline welding generators, diesel ones are produced. The first ones have the following advantages:

• low noise level (54-73 dB versus 71-110 dB for diesel);
• low cost (1.5-2 times cheaper than diesel ones);
• ability to run on cheaper gas fuel (re-equipment will be required).

But gasoline models have a limited continuous operation time: for most, it is less than 2 hours. Therefore, they are more suitable for work with moderate intensity: installation of light metal structures, small-scale production in a small workshop, non-urgent repairs.

Diesel welding machines, on the other hand, are noisy, roads and gas are not converted. But they also have strengths:

• low fuel consumption (efficiency of gasoline devices is 20-40% lower);
• great resource;
• the ability to work continuously for a long time;
• reliability.

Therefore, for constant construction work, when installing pipelines and for emergency repairs, diesel generators for inverter welding are more preferable.

Gasoline-fueled engines have another advantage: severe frosts are less of a barrier to starting. But taking into account the fact that welding inverters are mainly designed for temperatures not lower than -100C, this feature of the welding gas generator does not play any role.

engine's type

Inverter type welding gas generators are equipped with two types of motors:

• two-stroke;
• four-stroke.

The former have a simpler design, and therefore they are cheaper. But they have a number of disadvantages:

• high noise level;
• increased fuel consumption;
• the need to prepare a fuel mixture by mixing gasoline and oil;
• toxic exhaust.

Versatility

Some models of inverter-type gas generators are capable of working with ordinary electrical consumers. Such a model is chosen if, in addition to welding, it is supposed to be used as a backup source of power supply at home.

As a rule, professional models are focused exclusively on welding.

Generator type

Autonomous power plants use generators of two types:

• synchronous;
• asynchronous.

An asynchronous generator for a welding machine is more preferable because it is simpler in structure and more easily tolerates short circuits. Its rotor, unlike its synchronous counterpart, is closed, therefore it is less prone to breakdowns due to moisture and dust entering the mechanism.

The structure of the apparatus

The design of the inverter welding machine is much lighter and more compact.

The structure of a large-sized welding transformer

Appointment of elements of the transformer apparatus for welding:

• A closed magnetic circuit is a core folded from sheet steel, the sheets are varnished before assembly.
• The handle is used to rotate a vertical screw with a tape thread.
• The eyebolt fixes the set position of the handle.
• The cover protects against rain, snow, and accidental objects entering the transformer structure.
• A vertical screw with a tape thread, when the handle is rotated, adjusts the magnitude of the magnetic flux through the core of the magnetic circuit.
• The running nut is the bottom base through which the vertical screw is twisted.
• The primary winding is designed to supply voltage to it from a 220V or 380V power source.
• The secondary winding, when connected to the load (electrode to the place of welding), ensures the passage of current from the primary winding, through the magnetic circuit to the secondary, then to the load. The system works as a step-down transformer with 380 / 220V input and 60V output, while the current reaches up to 500A.
• Louvers for air cooling of the windings and the rod are made in the transformer housing.
• Special clamps are provided for connecting welding wires.
• A handle on the body makes it easy to move the heavy transformer on wheels.

The inverter device consists of three main small-sized elements:

• low-power, step-down voltage, transformer;
• an electronic circuit board that converts and stabilizes the output welding current;
• control panel with elements for monitoring and adjusting the current strength.

Inverter welding machine device

On the outside of the case and the control panel there are:

• indicator LED, when the temperature reaches 90̊C on radiators with transistors and inverter diodes, it starts to glow, warning of overheating of the device;
• the indicator diode of connection to the mains indicates the presence of an input voltage;
• on the bottom of the control panel there are terminals for connecting welding wires;
• the current adjustment knob allows you to smoothly change the welding current in the range from 10A to 180A;
• a shoulder strap is provided for transporting the device, its length is adjustable;
• louvers are made in a metal case for air cooling of the electronic circuit.

With the development of modern welding technologies, inverter machines are gradually replacing transformer ones. This topic is well disclosed by the forum on the Internet, where the advantages and disadvantages of inverter devices are considered. They are better than transformer welding, have low weight and dimensions, are more functional, easy to operate, and easily carried by hand.

An example of transporting an inverter device

What power is needed for a generator for inverter welding

The selected generator for welding must have a power not lower than that of the inverter, but, on the contrary, slightly higher, taking into account the required margin of 25%. Usually, the power of the generator and the welding inverter can be found in the technical data sheet. In this case, you should not be mistaken in the units of measurement, since very often the power of electrical appliances is indicated not in kW, but in kVA.

kW is the active power and kVA is the apparent power of the 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 the calculation: where 10 kVA * 0.8 = 8 kW. At the same time, you need to understand that the welding inverter will not always work 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 are always constant, it is not so difficult to calculate the power of the generator for welding. 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 just such a current for welding, then the power of the inverter will be: 160A * 25V / 0.85 = 4705 W. Taking into account the required power reserve for the generator, and this is not less than 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. Therefore, 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. It all depends on the diameter of the welding electrodes and the thickness of the welded metal. For example, using electrodes up to 2 mm, you can cook 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.

Types of gasoline generators and their characteristics

Manufacturers present to your attention a huge number of gasoline generators for domestic use, they are equipped with both two-stroke and four-stroke internal combustion engines. The two-stroke configuration is somewhat cheaper, but such engines need to be refueled with gasoline with the addition of oil. Four-stroke engines are more durable, more stable in operation and are fueled with pure gasoline. The capacity of the gas tank, as a rule, allows uninterrupted operation from 8 to 12 hours.

It is important to know that at the time of peak loads, the inverter can consume a current of 20 A or more, therefore the generator must be equipped with a power outlet and an automatic fuse designed for this current strength.To organize the electric power supply of the welding inverter from the gas generator, you need to know the parameters of the generated current and voltage.

We will consider them using the example of the Daewoo GDA 3500 power plant, namely:

To organize the electric power supply of the welding inverter from the gas generator, it is necessary to know the parameters of the generated current and voltage. We will consider them using the example of the Daewoo GDA 3500 power plant, namely:

• a gas generator, using a four-stroke engine, outputs a voltage of 220 V to two sockets with a maximum current of 14.54 A;
• rated power 2.8 kW, maximum 3.2 kW and apparent power 4 kVA;
• engine power 7.5 hp, AI-92 gasoline, tank capacity 18 liters, which allows the gas generator to work from 12 to 18 hours, depending on the load.

All generators in this price group produce about 4-5 kVA and allow welding with electrodes with a diameter of 1.6 mm to 3 mm. In the event that it is necessary to work with large-diameter electrodes, stations with higher parameters are needed. This greatly increases their cost, but also significantly expands the possibilities of welding. It is also worth noting the increase in the weight of the gas generator with increasing power, which affects its mobility.