Which diesel welder generator do I need?

Choosing a diesel welder generator involves considering several key factors to ensure you select the right equipment for your needs:

1. Power Output: Match the generator’s power rating (kVA) with the requirements of your welding tasks.

2. Duty Cycle: Determine the generator's duty cycle to ensure it can handle prolonged use without overheating.

3. Fuel Efficiency: Assess fuel consumption rates for cost-effectiveness during long operations.

4. Portability: Consider the size and weight if you need to move the generator frequently.

5. Brand and Warranty: Opt for reputable brands that offer solid warranties and reliable customer support.

6. Budget: Balance the cost with the features you need, considering both purchase and hire options.

 

What size generator do I need for a welder?

When selecting the appropriate generator size for a welder the primary consideration is the welder's input power requirements, which are determined by the type of welder, its output range, and the duty cycle.

1. Welder Type and Power Requirements:

• MIG Welders: Typically, a MIG welder requires a generator with at least 3-5 kVA (kilovolt-amperes) for light to medium welding tasks, but for heavier jobs, a generator in the range of 6-8 kVA is often needed.
• TIG Welders: A TIG welder usually requires a generator with a similar range, depending on whether you're welding thin materials or engaging in more demanding tasks. A generator between 5-8 kVA is generally suitable.
• Stick Welders: Stick welders often require a higher power output due to their versatility in welding thicker materials. For these, you may need a generator with a power rating of 6-10 kVA or more, depending on the amperage.
• Multi-Process Welders: These welders, capable of performing multiple types of welding, will require a more powerful generator, typically between 7-12 kVA.

2. Duty Cycle:

• The duty cycle of your welder directly impacts the generator size. For instance, a welder with a 60% duty cycle at 200 amps will need more power compared to one with a 30% duty cycle at the same amperage. This is because a higher duty cycle demands more consistent power delivery over a longer period.

3. Surge Capacity:

• Generators must also handle the initial surge of power when the welder starts. This surge can be significantly higher than the running power requirement, sometimes by 2-3 times. Therefore, ensuring the generator can handle this surge without tripping or causing voltage drops is crucial.

4. Power Quality and Stability:

• Welding requires stable power to avoid issues like inconsistent arcs or poor weld quality. Generators with Automatic Voltage Regulation (AVR) or inverter technology are preferred because they provide the stable voltage and frequency necessary for high-quality welds.

5. Considerations for 3-Phase Welders:

• If you're using a 3-phase welder, your generator must also support 3-phase output. This typically requires a larger generator, often in the range of 15-20 kVA or more, depending on the specific welder's requirements.

Example Weld Power Calculation:

• Suppose you have a MIG welder with a peak requirement of 200 amps and a 60% duty cycle, running on 240V single-phase power. The general calculation for the required generator size is:
  • Amps x Volts = Watts,
  • Then divide by 1000 to convert to kVA and consider the duty cycle and surge capacity.
  • In this case: 200 Amps×240 Volts=48,000 Watts=48kw. Considering a surge and duty cycle, a generator around 8-10 kVA would likely be sufficient.

Help to Hire a Diesel Welder Generator

For most professional applications, particularly those requiring mobility or work in remote locations, a generator in the range of 6-12 kVA should cover the needs of various types of welders.

Note that it is prudent to choose a generator with a slightly higher capacity to ensure reliable performance under all conditions.

However, you can always consult the experts at Spectrum to pick the right diesel welder generator to hire!

Call: 01246 205 267