Inverter welding at home is a universal tool for which practically nothing is impossible. You need to weld a wicket, gate, greenhouse frame or foundation piping - no problem. A compact, easy-to-use inverter will cope with all tasks. It can be used by both an experienced welder and a beginner in this matter.
To do this, it is enough to provide the equipment with a power supply of 220 Volts. It is good when a single-phase network is connected to the site. What to do when there is no electricity? How to perform work on a new building or in the field? A generator designed for welding equipment will help out.
Description
Currently, stores offer two types of generators, which are designed to work in conjunction with welding machines . It is customary to highlight:
- synchronous;
- welding
The first type is conventional voltage sources that support operation with household appliances and welding inverters.
If we talk about welding generators, then these are small devices, additionally equipped with a built-in welding machine. Due to the fact that they require very little space, they are very convenient to take with you . It is important to take into account that gas generators with a welding machine differ in power indicators. Therefore, consumers need to choose a suitable model with an emphasis on this characteristic.
Types of Gasoline Generators
There are two types of gasoline generators: generators for powering a third-party welding machine and generators with a built-in welding function. Don't confuse them.
Generators for powering a third-party device are used only as a source of electricity. Their task is to generate electricity. A welding machine is additionally connected to such generators, with the help of which welding is carried out. It is this type of generators that we are talking about in this article.
A gas generator with a welding function is a completely different device. Such generators do not need to connect a welding machine; they are a machine + a generator in one housing. The thing is extremely convenient, but it is rarely used in everyday life, since such generators are designed for welding in hard-to-reach places and are often very bulky. A striking example is the so-called SAK (wheeled welding machine), which has large dimensions and is equipped with wheels and a trailer.
To summarize, a gas generator and a gas generator with a welding function are not the same thing. In everyday life, it is recommended to use a gas generator paired with an inverter, and leave gas generators with a welding function to professionals. These are very highly specialized devices that are used in certain cases.
Design features and operating principle
Some experts distinguish gasoline generators for welding into a separate type of generators that operate on the same principle as conventional devices.
At the moment the arc is ignited, a welding current is supplied to the armature winding, which ensures the stability of the welding arc. The current is generated due to the transformation of energy resulting from the rotation of the crankshaft in an internal combustion engine, which makes it possible to obtain electrical energy from mechanical energy.
Power calculation
To calculate power, you will need to take into account the following parameters:
- welding current I
- arc voltage U
- Efficiency taken as 0.85
- safety factor, recommended value is 1.2.
If a welding current of 200A is required at a discharge voltage of 25V,
then 200A*25V/0.85 = 5882 W
When adding headroom, the result is 5882*1.2=7058W
This calculation is relevant for constant work during a shift . If you plan only minor repairs to a fence or wheelbarrow on your property, the power can be halved.
Selecting a generator for a welding machine
The main characteristic that you should pay attention to when choosing a generator for welding is its power. It is very important that its indicator for the generator is higher than that of the inverter. Thanks to the presence of a power reserve, the device will be able to operate in normal mode and maintain stable performance, provided that the load is correctly selected.
In order to select the optimal power of a gas generator for a welding inverter, you should first find out the maximum current consumption . You can get this information by looking at the device case, where the parameter you need is designated as Imax.
To make it clearer, let's consider this parameter using the example of a generator with an Imax 23A indicator. Power calculation is performed according to Ohm's law.
- You need to multiply the above value by 220, the result is 5060 W.
- You need to additionally add 30% to it, then the final figure will be 6600 W.
- This will be the approximate power of the generator.
When choosing a generator for an inverter, you must also pay attention to the diameter of the electrodes, which must correspond to the power of the device. For example, for a 2.5 kW generator, electrodes with a cross section of 2 mm are perfect. If the diameter of the electrodes is 3 mm, then the generator power should be 3.5 kW. Depending on the generator model you select, power requirements will vary.
It is also necessary to mention another important characteristic that consumers need to take into account - the voltage of the outlets, which must correspond to the type of inverter. If you choose a device for domestic use, then you can limit yourself to a 220 V outlet. For three-phase powerful inverters, you will need a 380 V outlet.
In addition to the above characteristics, there is one more that must be taken into account. We are talking about the body. If you are going to often take the station with you, then it is best to choose a compact model with wheels. One of the main reasons for the popularity of gasoline units compared to diesel ones is their lighter weight and size.
Can it be used as usual?
Such use is quite acceptable if the device is equipped with a separate 220 volt output . Working for home consumers will not overload the unit, which is accustomed to possible peak loads.
Cheap models of welding generators can tolerate voltage surges, pulsed high-frequency interference, etc. They do not interfere with the welding process, but can damage sensitive household, media and medical equipment. Therefore, it is better to connect such a device through a voltage stabilizer with a built-in surge filter.
An inverter generator usually produces high-quality voltage without impulse noise.
Selecting a generator with welding function
To ensure that the welding gas generator lasts a long time, make sure that cast iron sleeves are used in its design. Such devices can easily withstand operation for 1500 hours. But their aluminum counterparts are less reliable and can fail three times faster.
In stores today you can purchase inverters with the function of adjusting the power percentage. This is an excellent option for use in conjunction with generators, as they support operation at reduced voltage. If you are interested in just such a model, we advise you to carefully study the markings before purchasing - it must contain the PFC prefix.
Remember that gasoline welding generators are not designed for continuous use. It is necessary to take breaks while working. If you are going to use this device for 5-8 hours a day, then it is best for you to choose a diesel model. A model with a power rating from 0.7 to 5 kW is ideal for relaxation and gardening. They are lightweight, so you won't have any problems with carrying and transporting them.
A generator with a power rating of 10 kW can easily cope with intensive work for 8 hours every day. Features that also need to be taken into account include the size of the fuel tank, as well as the presence of a soundproofing casing. Many experts consider the function that allows you to start a gas generator from an electric starter to be important.
An interesting solution are models with overhead valves. If you have experience working with diesel analogues, then be sure to pay attention to the quality of the energy released. These units have such advantages as compactness, long service life, high performance and low noise level.
You should consider such a generator model only if you are going to use it to perform work on a construction site, where you will need to supply a powerful flow of energy from time to time. If you are looking for a unit for a cottage or enterprise, we advise you to choose from generators with a capacity ranging from 10 to 20 kW. Many devices of this type have the ability to start automatically, and, in addition, they can be used as a permanent installation.
How to choose and what to pay attention to?
- Pay attention to the value of the welding current . Usually specified in a specific range. The higher the indicator, the larger the diameter of the electrodes you can use.
- Type of welding current . It can be constant or variable. It is better to give preference to models with direct current. They allow you to achieve smooth ignition of the electric arc and its stable combustion.
- For power and output voltage . The higher the power, the more efficient the welding work. If we consider the issue of phasing, then three-phase welding generators allow you to connect a large number of single-phase and three-phase users.
- Decide on the type of fuel . The stations run on gasoline or diesel. The second type of fuel is considered economical. But when choosing, the buyer should rely on personal preferences.
- Explore additional options . A good indicator for the model is the presence of a protection system, autostart, and fuel efficiency at minimal loads.
Popular models
To choose the right gas generator, you need to not only look at the operating parameters, but also take into account the manufacturer, of which there are plenty 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 help of the FUBAG WS 230DC ES generator you can solve a wide range of problems, including those that arise for installation and construction teams. Thanks to the spacious fuel tank, it can 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 working. It is possible to select the operating current in the range from 50 to 230 A. Using this device, you can weld metal products using arc welding using stick electrodes, which can have a cross-section from 1.6 to 5 mm.
In this generator model, automatic control 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 purpose. The power drive used has a power rating of 14 hp. With. During operation, the generator creates noise at a level of 77 dB. With dimensions of 722x530x582 mm, the installed engine with a volume of 439 cm3 can be assessed as the correct decision of the manufacturer. The operation of the device is ensured by a four-stroke motor. The model is not equipped with either a handle or wheels .
Power station FUBAG WS 190 DC ES
This model can be used to connect metal products using arc welding. It supports generators up to 4 kW. For welding work, it is allowed to use only electrodes whose diameter is in the range from 1.6 to 4 mm.
This generator has a reinforced metal frame coated with paint that protects the housing from corrosion. The latter is equipped with special damping pads that reduce vibration during operation. The weight of the device is 97 kg, and the fuel tank volume is 25 liters.
The device has quite compact dimensions - 722x530x582 mm. The operating noise indicator does not exceed 77 dB. The power drive used in this model has a power of 13 hp. With. The generator is powered by a four-stroke engine. Additionally, the design includes a fuel level indicator. To turn on the power plant, you can use either an electric or a manual starter.
Characteristics of 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-purpose device that will be indispensable at car service centers and construction sites.
This unit uses an engine with an increased operating life, which is explained by the presence of a forced cooling system. Operation of the device at a load of no more than 75% without refueling is possible for 9 hours. The model comes with automatic control. 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 current are 50 and 190 A, respectively.
Is it possible to combine them in one device?
Such a merger is possible and profitable . If you have to use such a unit often or it must be constantly ready (like repairmen or rescuers), then both money and time are saved. Using a single design provides the following advantages:
- compactness, use of a single frame and control unit;
- ease of transportation and carrying;
- low energy losses and energy efficiency;
- high degree of device availability;
- saving time on connecting and adjusting individual devices.
Amangeldy Kurbanaliev, foreman of the repair team at Tatneft-Transservice: “Without a welding gas generator in a repair workshop it’s like being without hands. We arrived on site to fix the problem - no need to unwind the wires and connect the welding to the generator, saving both time and space.”
The most significant argument in favor is the price. A single unit will, in principle, cost less than two separate devices.
Can I do it myself?
Many home craftsmen make their own welding generators.
To create the unit, several horsepower engines at hand and a generator (or starter) from a powerful truck or tractor are adapted. How to make a welding machine from a car starter or generator? The frame is made from a corner; a belt or gear drive is usually used for the gearbox. The engine and generator are positioned so that their axes are parallel. An ordinary powerful transformer is used as a current source. Due to the fact that a home master cannot carry out a full-fledged engineering calculation, the efficiency of such devices rarely exceeds 40-50%. However, at low initial costs, such units make it possible to weld structures with acceptable quality.
Combining a generator and a welding machine in one unit is justified in the case of a large volume of work far from a constant power supply. Such devices are necessary for services for which constant high availability of the welding complex is important . The universal welding generator can also be used to power construction tools and household needs.
