6300 watt generator for 50 amp welder?

[gerard]

Originally Posted by Iron Horse

My WIA 240 volt AC 160amp (output) stick welder is 15 amp input . I burnt out a new 5500watt generator trying to weld 1.5mm shed purlins together . I had to buy a new 8000watt generator to run it . I have since bought a 12000watt generator which powers it just right . Buy the time ive finished a 3.2mm rod it is (the rod) starting to glow red hot and the penetration is very good . The caracteristics must all be different with our 240 volt Ac compared with your 110? volt Ac .

We have 110 AND 240 volt in most residences. Small migs can run on 110, larger ones need 240. I don't know of ANY that will do much with a 15 amp, 110 volt input. You could weld really light stuff without tripping the breaker but most 110 migs get put on a 20 amp circuit. My stick welder, which runs off 240 volt is on a 50 amp circuit (50 amp input needed for the MAX output capacity. This is the same capacity as an electric stove. Now I've never welded anything at max capacity becuase I haven't had anything that thick or rod that heavy but that IS what the plug and circuit are rated for)

[Treemonkey1000]

The efficiency of the unit has something to do with it. I am guessing all of these are single phase welders. Just running the numbers here
240 volts x 15 amps= 3840 watts
220 volts x 50 amps= 11000 watts
220 volts x 20 amps= 4400 watts
Those were some of the input currents and voltages in the postings. That would be maximum input currents to the welder. I doubt if they are drawing that much current as we don't weld at full current all of the time. When you strike your arc current there is a very large spike to the primary side. That can pull down the generator or source voltage and trip breakers. Then while your arc is running it will settle down to what ever your welder is set for. I would think Iron horse is still running single phase? If you go 3 phase it is more efficient to pull current out of 3 phases. So I am probably preaching to the Choir here...

[Iron Horse]

Yes i am running single phase . As for starting load , maybe thats what happened as i was stitch welding thin gauge metal at the time of the failure .

[cdhd2001]

As for 110 v. I have a Sears (Century) 100 amp stick welder that is 110v 20 amp. I burn 3/32" rods at 90 amps at a 50-60% duty cycle. Great "little" welder.

However, my next welding machine will be gas/diesel powered unit AC/DC that is 200-300 amp and has a 10,000 watt generator. ($2,500-$10,000)

[SPYDERLK]

Originally Posted by Iron Horse

My WIA 240 volt AC 160amp (output) stick welder is 15 amp input . I burnt out a new 5500watt generator trying to weld 1.5mm shed purlins together . I had to buy a new 8000watt generator to run it . I have since bought a 12000watt generator which powers it just right . Buy the time ive finished a 3.2mm rod it is (the rod) starting to glow red hot and the penetration is very good . The caracteristics must all be different with our 240 volt Ac compared with your 110? volt Ac .

Lets see- P=IE=15x240=3840W input. If you burnt out a 5500W it makes me wonder about the welder spec. Looked at another way, with a [rather low] 20V arc it would be putting out 3200W at 160A welding. I wouldnt expect the efficiency to be that high [3200/3840=83%] It just doesnt add up. I think the 15A # is wrong.
larry

[gerard]

Originally Posted by Treemonkey1000

........... If you go 3 phase it is more efficient to pull current out of 3 phases. So I am probably preaching to the Choir here...

I don't know of anyplace you can get three phase power in a residential setting. Usually you can only get this in area's zones for commercial use. It is a lot more efficient but don't think it will be available to most people in a residential setting. (though I guess some large farms might have three phase?)

[Treemonkey1000]

I wasn't sure about Ironhorse if his 240 volts was single phase. I guessed that it was. And yes 3 phase isn't common in homes at all. Here where I work we use 3 phase a lot for power supplies and motors. Maybe as someone else said burning out a 5500 watt generator would make you wonder. It would be interesting to put a analyzer on the power line to see what the power spikes looked like when you struck an arc with the welder. I am sure they are pretty large spikes. Another thing I have learned is that some generators have kind of noisy outputs. Meaning that the AC waveform is not very clean. Slip-ring generator versus brushes maybe? I think the slip-rings would take the abuse better.. Just my opinion.

[Highbeam]

Yes, the welder has a sticker that says to provide a 50 amp 220 volt input to the AC225. Lincoln also "suggests" a 15,000 watt generator or some other ridiculous genset which they just happen to sell mated with a welder.

The standard welder plug used by almost all welders is a 50 amp plug so I wonder if Lincoln is just trying to standardize the input plugs in garages since the AC225 does not need 50 amps of 220.

The AC welder is just a big fat transformer that takes 220 volt input power and lowers the voltage to about 25 volts. So when you set the welder to the 200 amp setting for thick steel you are using 200 * 25 = 5000 watts. There might be some efficiency penalty so say 5500. Most welding for me is done in the 120 amp range so 3000 watts is all I needed.

I made an adapter cable just like the one posted here and ran my AC225 from a Coleman 6850 surge/5500 continuous rated genset for quite some time. I performed jobs like welding the reinforcement plate to my tractor bucket for the toothbar or adding beads of weld to the grousers on my old bulldozer.

[Iron Horse]

Just had a look at my welder . This is word for word off the machine . Rated input - 240 volt @ 50hz........Rating of supply lead 15amp........Maximum short circuit input current 40amp (probably where i went wrong , this is what you guys are refering too i presume) Our house power is 240 volt 50hz 10amp single phase . Most welders and compressors etc have a 15amp plug which has an enlarged earth pin and require a seperate supply . My 4.5 horse power air con unit has an even bigger earth pin and is a 20amp plug (the biggest ive ever seen) .

[npaden]

Well, I sold my 3,000 watt generator for $300 so my net upgrade cost was $300 to go from a 6 hp 3,000 watt pull start generator with 2 110v outlets to an electric start 13hp 6,300 watt generator with a 30 amp 220v outlet and 4 110v outlets.

I need to switch out the plug on the welder and I'll give it a try!