Comparison EnerSol EPG-7500SE vs Tesla Weld WG 185

The rated power of the generator is the highest power supply that the unit is capable of delivering without problems for an unlimited time. In the “weakest” models this figure is less than 1 kW, in the most powerful – 50 – 100 kW or even more ; and generators with welding capabilities (see below) typically have power ratings ranging from 1 – 2 kW to 8 – 10 kW.

The main rule of choice in this case is this: the rated power must not be lower than the total power consumption of the entire connected load. Otherwise, the generator simply will not be able to produce a sufficient amount of energy, or it will work with overloads. However, to determine the minimum required generator power, it is not enough to simply add up the number of watts indicated in the characteristics of each connected device - the calculation method is somewhat more complicated. Firstly, you need to take into account that only the active power of various equipment is usually indicated in watts; In addition, many AC electrical appliances consume reactive power (the "waste" power consumed by coils and capacitors when operating at that power). And the actual load on the generator depends precisely on the total power (active plus reactive), indicated in volt-amperes. There are special coefficients and formulas for its calculation.

...The second nuance is related to the power supply of devices in which the starting power (and, accordingly, the power consumption at the moment of switching on) is significantly higher than the rated one - these are mainly devices with electric motors such as vacuum cleaners, refrigerators, air conditioners, power tools, etc. You can determine the starting power by multiplying the standard power by the so-called starting coefficient. For one type of equipment it is more or less the same - for example, 1.2 - 1.3 for most power tools, 2 for a microwave, 3.5 for an air conditioner, etc.; More detailed data is available in special sources. Starting characteristics of the load are necessary, first of all, to assess the required maximum power of the generator (see below) - however, this power is not always given in the characteristics; often the manufacturer indicates only the rated power of the unit. In such cases, when calculating for equipment with a starting coefficient of more than 1, it is worth using the starting power, and not the rated power.

Also note that if there are several outlets, the specific division of the total power among them may be different. This point should be clarified separately - in particular, for specific types of sockets (for more details, see “230 V sockets”, “400 V sockets”).

The maximum power supply that the generator can provide.

This power is slightly higher than the rated power (see above), but the maximum performance mode can only be maintained for a very short time - otherwise overload occurs. Therefore, the practical meaning of this characteristic is mainly to describe the efficiency of the generator when operating with increased starting currents.

Let us remind you that some types of electrical appliances at the moment of startup consume many times more power (and, accordingly, power) than in normal mode; this is typical mainly for devices with electric motors, such as power tools, refrigerators, etc. However, increased power for such equipment is needed only for a short time; normal operation is restored in just a few seconds. And you can evaluate the starting characteristics by multiplying the rated power by the so-called starting coefficient. For one type of equipment it is more or less the same (1.2 - 1.3 for most power tools, 2 for a microwave, 3.5 for an air conditioner, etc.); More detailed data is available in special sources.

Ideally, the maximum power of the generator should be no lower than the total peak power of the connected load - that is, the starting power of equipment with a starting factor above 1 plus the rated power of all other equipment. This will minimize the likelihood of overloads.

— Copper. Copper winding is typical for advanced class generators. The copper alternator is characterized by high conductivity and low resistance. The conductivity of copper is 1.7 times higher than the conductivity of aluminium, such a winding heats up less, and compounds made of this metal endure temperature drops and vibration loads. Among the disadvantages of the copper winding, one can only note the high cost of the alternator. Otherwise, generators with copper winding have high reliability and durability.

— Aluminium. The aluminium winding of the alternator is typical for low-cost-class generators. The main advantages of aluminium are light weight and low price; otherwise, such a winding is usually inferior to copper counterparts. An oxide film is created on the surface of aluminium, it appears everywhere, even in the places of contact soldering. The oxide film undermines the contacts and does not allow the outer protective braid to securely hold the aluminium conductors.

The type of current supplied by the welding generator to the electrodes during welding.

— Variable (AC). Current with constantly changing polarity — as in ordinary household sockets; however, when welding, higher frequencies are usually used — not 50 – 60 Hz, but on the order of several tens of kilohertz. The key advantage of alternating current is that it does not have a fixed polarity — in other words, it is basically impossible to confuse plus and minus when connecting electrodes. On the other hand, constantly reversing the current direction increases the amount of spatter and reduces the quality of the seam compared to using direct current. As a result, this option is relatively rare and is intended for relatively rough work.

— Permanent (DC). Current having a fixed polarity and constantly flowing in one direction, without changing it. This allows you to achieve a more accurate seam with less spatter than with alternating current; as a consequence, it is direct current that most modern welding generators use. At the same time, when working with such a device, you need to carefully control the polarity of the connection — and, depending on the features of the work, both “direct” (“minus” to the electrode) and “reverse” (“minus” to the material) polarity may be required. In addition, additional circuits are required for direct current, which slightly increases the cost of generators.

The maximum current that the welding generator (see above) is capable of delivering to the electrodes during welding.

For different materials, different thicknesses of the parts to be welded and different types of welding itself, the optimal welding current will also be different; there are special tables that allow you to determine this value. The general rule is this: the maximum generator current must not be lower than the required welding current, otherwise the unit will either work with an overload or not be able to provide the necessary welding efficiency.

The maximum diameter of the welding electrodes that the welding generator can work with (see above).

The thicker the material being processed and the wider the seam, the thicker the electrodes should be used for welding; and a thicker electrode generally implies higher currents. There are special tables that allow you to determine the optimal electrode diameter depending on the type and thickness of the material, type of welding, etc. However, anyway, the thickness of the electrode used should not be higher than the maximum allowable — this is fraught with overloads and breakdowns, and at best the generator is simply will not be able to provide the desired efficiency.

Model name of the engine installed in the generator. Knowing this name, you can, if necessary, find detailed data on the engine and clarify how it meets your requirements. In addition, model data may be needed for some specific tasks, including maintenance and repair.

Note that modern generators are often equipped with branded engines from famous manufacturers: Honda, John Deere, Mitsubishi, Volvo, etc. Such engines are more expensive than similar units from little-known brands, but this is offset by higher quality and/or solid warranty conditions , and in many cases, the ease of finding spare parts and additional documentation (such as manuals for special maintenance and minor repairs).

The working volume of the engine in a gasoline or diesel generator (see "Fuel"). Theoretically, more volume usually means more power, but in fact, everything is not so clear. Firstly, the specific power strongly depends on the type of fuel, and in gasoline units, also on the type of internal combustion engine (see above). Secondly, similar engines of the same power can have different volumes, and there is a practical point here: with the same power, a larger engine consumes more fuel, but by itself it can cost less.

The operating power of the engine installed in the generator. Traditionally stated in horsepower; 1 HP approximately equal to 735 watts.

First of all, the rated power of the generator directly depends on this indicator (see above): in principle, it cannot be higher than the engine power, moreover, part of the engine power is spent on heat, friction and other losses. And the smaller the difference between these capacities, the higher the efficiency of the generator and the more economical it is. However high efficiency affects the cost, but this difference can pay off with regular use due to fuel savings.