ENGINE DRIVEN ELECTRICAL POWER GENERATION

Generator Type power sources convert mechanical energy or mechanical power that is obtained from an internal combustion engine into electrical power suitable for arc welding and/or auxiliary electrical power. For
welding, two basic types of rotating power sources are used, the generator and the alternator. Both designs
have a rotating member, called a rotor. A system of magnetic field excitation is needed for both types.
There are three essentials for electrical power generation:
1. Magnetic Lines of Force (Magnetic Field)
2. Electrical Current Carrying Conductor
3. Relative Motion Between the Magnetic Field and the Electrical Current Carrying Conductor.
In electrical power generation, there must be relative motion between a magnetic field and a current carrying
conductor. Whenever a wire moves through the lines of force of a magnetic field or whenever lines of force of
a magnetic field are moved through a wire, a voltage is induced in the wire. This induced voltage causes electric current to flow when the circuit is complete. Thus, the principle of any rotating power source is that electrical current is produced in electrical conductors (coil of wire) when they are moved through a magnetic field.
Physically, it makes no difference whether the magnetic field moves or the conductor moves, just so that the
coil experiences a changing magnetic field intensity.

Page 1

The amount of voltage generated depends upon the number lines of force cut per second. Three ways of
increasing the voltage from a generator are (1) by increasing the motion (speed/velocity)of the magnetic field
(or the coil), (2) by using a stronger magnet (or magnetic field), and (3) by increasing the number of turns of
wire in the coil.
A direct current generator consists of a rotor and a stator. The stator or the stationary portion of the generator,
within which the rotor assembly turns, holds the electromagnetic field coils which conduct a small amount of
direct current to maintain the necessary continuous electromagnetic field excitation required for power generation. Direct current is used to create the electromagnetic field. The direct current for the field windings of the
generator is called the exciting current, and the generator that supplies the direct current is called the exciter.
This direct current amperage is normally no more than 10 to 15 ampere and very often is less. Electromagnets
provide stronger magnetic fields and control the amount of induced current. This control is important, for
when the amount of current flowing through the electromagnets is changed, the strength of the magnetic field
is changed.
The rotor assembly consists of (1) a through shaft, (2) two end bearings to support the rotor and shaft load, (3)
an armature which includes the laminated armature iron core and the current-carrying armature coils. It is in
the armature coils that the electrical welding power is generated. And (4) a commutator brush arrangement for
mechanically rectifying or changing alternating current to direct current welding power.
In actual practice, the armature turns within the stator and its electromagnetic field system, and welding current is generated. The AC voltage produced by the armature coils moving through the magnetic field of the
stator is carried to the copper commutator bars through electrical conductors from the armature coils. The
commutator is located at one end of the armature. The commutator is a system of copper bars mounted on the
rotor shaft. The conductors are soft-soldered to individual commutator bars. The latter may be considered as
terminals, or "collector bars," for the alternating current generated from the armature. It is a group of conducting bars arranged parallel to the rotating shaft to make switching contact with a set of stationary carbon brushes (contact points). These bars are connected to the armature conductors. The whole arrangement is constructed in proper synchronization with the magnetic field. As the armature rotates, the commutator performs the
function of mechanical rectification.
Each copper bar has a machined and polished top surface. Carbon contact brushes ride on that top surface to
pick up each half-cycle of the generated alternating current. The carbon contact brushes pick up each halfPage 2

cycle of generated alternating current and direct it into a conductor as direct current. The purpose of the com
mutator is to carry both half-cycles of the generated AC sine wave, but on separate copper commutator bars.
Each of the copper commutator bars is insulated from all the other copper bars.

2 POLE
GENERATOR

VOLTAGE AT BRUSHES

TIME

AC
HERE

VOLTAGE
INDUCED

(+)
DC HERE
()

COMMUTATOR

The magnetic field is contained in the stator assembly of a generator. It is in the armature coils
that welding power is generated. The commutator-brush rectifies ac to dc welding power.

DC Generator
Normally, the direct current generator is a three-phase electrical device. Three-phase welding systems normally provide the smoothest welding power of any of the electromechanical welding power sources.

1. END VIEW OF THE ARMATURE AND

FIELD COILS OF GENERATOR

2. END VIEW OF FOUR POLE ROTOR

AND STATOR OF ALTERNATOR

Page 3

MILLER ALTERNATOR DESIGN VS. GENERATOR DESIGN

The entire line, of Miller Electric's engine driven power sources, uses a design concept called the "revolving
(electromagnetic) field design." This concept is commonly called an alternator design (often called an alternating current generator). This design in welding power sources is in direct contrast to how DC generator rotating
power sources are designed. There are distinct differences and advantages to using alternator design over the
DC generator design. It is very similar, except the alternator rotor assembly contains the electromagnetic field
coils instead of the stator coils as found in generators. The heavy current-carrying conductor windings are
wound into the stator. These machines are also called revolving or rotating field machines.
Slip rings are used to conduct low DC power into the rotating member to produce a rotating electromagnetic
field. An alternator usually has brushes and slip rings to provide the low direct current power to the field coils.
It is not usual practice in alternators to feed back part of the welding current to the field circuit. Rather the
alternator usually uses the brushes and slip rings to provide the low DC power to the field coils. The voltage
induced in the armature coil passes through a set of slip rings connected to the ends of the armature coil and
through a set of brushes making contact with the slip rings, to an external circuit. This configuration precludes
the necessity of the commutator and the brushes used with DC output generators.
The welding output is alternating current, which requires external rectification for direct current applications.
Rectification is usually done with a bridge rectifier using silicon diodes. Both single and three-phase alternators are available to supply AC to the necessary rectifier system. The DC welding characteristics are similar to
those of single and three-phase transformer-rectifier units.

Page 4

The alternator design presents several fundamental advantages. Some important facts are:
Miller Alternator Design
Generator Design
1. Higher duty cycle - 100%
- Design permits 100% duty cycle rating.

Lower duty cycle - 60%

- To obtain higher duty cycle requires heavier
windings in the armature.
- Small units are usually 30-50% duty cycle rated.

2. Operates cooler
- Most heat is generated in the weld windings.
located on the outside of the unit.
- Easy to cool.
- Minimum cold to hot drift.

Harder to cool
- Heat is generated in the armature. Must be cooled
by air movement and conduction to the outside of
the unit.
- More heat build up, greater cold to hot drift. Output
will drop off when unit heats up.

3. Low currents in moving parts

- Rotating field coils carry less than 10 amps.

High current in moving parts

- Armature carries full welding current. Heat builds
up internally.

4. No brush-commutator assembly
- Slip rings and brush carry less than 10 amps.
- Minimum brush wear.
- No chance of polarity changing.

Brush assembly and commutator bars

- Brushes must carry full welding current.
- Arcing occurs.
- Brushes wear, lowering efficiency, maintenance
required.
- Welding polarity may change during welding when
brushes lift off the commutator.
- Commutator will require maintenance.

5. Rotor is lighter
- Quicker to accelerate to speed.
- Rotates easier, engine easily handles 300 amp
power source.
- Less fuel consumption for same amperage
output.

Armature is a large mass of iron

- Slower to respond.
- Engine can only handle a 200 amp power source.
- More torque required to rotate. Harder on bearings,
etc.
- During heavy usage such as arc gouging, stress
relieving, etc. heat buildup will cause solder to be
thrown from commutator area.

6. No "kits" required for paralleling

- Hook any number of units together for increased
output.
- No current feedback can occur since diodes
block feedback.

Special kits required to parallel

- Adapter kits required to connect units together.
Current feedback from one unit to another causes
one to "drive" the other as a motor.

ROTOR COMPARISONS

ROTATING MAGNETIC
FIELD COIL DESIGN
OF AN ALTERNATOR
100% DUTY CYCLE
ROTATING ARMATURE
DESIGN OF A
GENERATOR
60% DUTY CYCLE

Page 5

The blocking nature of the rectifiers makes direct current alternator units easy to operate in parallel for obtaining increased welding current output by connecting two or more welding alternators (generators) in parallel.
Care should be taken to ensure that connections are the same polarity. All units paralleled must be set to deliver equal welding (amperage & polarity) outputs. Parallel connection is not advised unless the manufacturer's
specific instructions are followed. Such a precaution is necessary because successful paralleling depends upon
matching the output-voltage, output amperage setting, and polarity of each machine.
In the case of self-excited generators, the problem may be further complicated by the necessity to equalize the
excitation between the generators.
Both the generator and alternator type power sources generally provide welding current adjustment in broad
steps called ranges. A rheostat or other control is usually placed in the electromagnetic field circuit to adjust
the internal magnetic field strength for fine adjustment of power output. The fine adjustment of welding power
output regulates the strength of the magnetic field, and will also change the open circuit voltage. When the
rheostat is adjusted near the bottom of the range with a low rheostat setting, the open circuit voltage will normally be substantially lower than at the high end of the range.

Typical Engine Drive Amperage Control

With many alternator power supplies, broad ranges are obtained from taps on a reactor in the AC portion of
the circuit. As such, the basic machine does not often have the dynamic response required for shielded metal
arc welding. Thus, a suitable inductor is generally inserted in series connection in one leg of the DC output
from the rectifier. Welding generators do not normally require an inductor.
There is a limited range of overlap normally associated with rotating equipment where the desired welding
current can be obtained over a range of open circuit voltages. If welding is done in this area, welders have the
capability to fine tune or adjust the arc to the job. With a lower open circuit voltage, the slope of the voltampere curve is less. This allows the welder to regulate the welding current to some degree by varying the arc
length. This can assist in weld-pool control, particularly for out-of-position welding.
A generator or an alternator unit produces a maximum or a finite amount of power that is measured in kilowatts. As the voltage increases the amperage will decrease proportionately. Conversely as the voltage decreases the amperage will increase proportionately. In other words, if there is a relatively high open circuit voltage
at some particular setting on a power source, there must be a relatively limited amount of maximum short circuit current at the same time.

Page 6

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

100
Ranges
300Max
185425
125320
85190
5590

80

DC VOLTS

60

40

20

0
0

100

200

300

400

500

600

700

800

900

DC AMPERES

Volt-Amp Curves
Welding power sources are available that produce both constant current and constant voltage. These units are
used for field applications where both are needed at the job site when primary, utility power is not available.
Also, many new designs use electronic solid-state circuitry to obtain a variety of volt-ampere characteristics.
Saturable reactors and moving-core reactors may be used for output control of these machines. The normal
method is to provide a tapped reactor for broad control of current ranges, in combination with control of the
alternator magnetic field to produce fine control within these ranges.

ENGINE DRIVE AUXILIARY POWER

MILLER welding generators are combination welding and power generators specifically designed for the
welding application. An auxiliary power winding is included in the generator to provide convenience power
incidental to the welding operation for accessory equipment. Most auxiliary power generators are singlephase
and may be either two-wire or three-wire design depending upon the model. There is no significant advantage
of the two-wire system versus the three-wire except that the three-wire design is capable of supplying two different voltages simultaneously (120/240 VAC).
These machines are designed to provide nominal 120 or 240 volts, 60 Hertz power, which are the common
small load voltages in the United States. Different voltages and frequencies are found in various parts of the
world and optional auxiliary power generator designs are available for these requirements. These generators
can be used to power portable tools, lights, heaters, compressors, pumps, etc., within the capabilities of the
unit. They are not designed to power voltage and/or frequency sensitive electronic equipment which may be
damaged by voltage or frequency changes normal to the operation.
An alternator or generator may be either self-excited or separately-excited, depending on the source of the
field power. Either unit may use a small auxiliary alternator or generator, with the rotor on the same shaft as
the main rotor, to provide exciting power. On many engine-driven units, a portion of exciter field power is
available to operate tools or lights necessary to the welding operation. In the case of a generator, this auxiliary
power is usually 115 volts of direct current. With alternator-type power source, 120 or 120/240 volts of alternating current is usually available. Alternating Current Voltage frequency (hertz) depends upon the engine
Page 7

speed. The frequency of the output welding current is controlled by the rotation of the rotor assembly and by
the number of poles in the alternator design. A two-pole alternator must operate at 3600 rpm to produce
60 Hz alternating current, whereas a four-pole alternator design must operate at 1800 rpm to produce 60 Hz
alternating current.

S
TAPPED
REACTOR
AC HERE

FINE AMPERAGE
ADJUSTMENT

2 Pole Alternator With Tapped

Reactor For Coarse Current
Control And Adjustable Magnetic
Field Amperage For Fine Current
Output Control

Design:
1. Two Pole Alternator
2. Four Pole Alternator

Page 8

STABILIZER
(INDUCTOR)
DC
HERE

Two Pole Alternator

Four Pole Alternator

Considerations:
1. Generator Sizing
2. Load Analysis
Rated Output
Found on machine nameplate
E.G. Trailblazer 301:
9,500 Watts
120 Volts - 84 Amps
240 Volts - 42 Amps
kVA while welding is dependent on welding output

Page 9

1. Generator Sizing: How Much Power Can Generator Supply?

Limits of a Generator
MILLER welding generators are designed to operate at maximum load, but doing so allows very little reserve
engine horsepower to follow changes in load requirements. This makes itself known by noticeable voltage and
frequency changes (light bulbs flicker, etc.) Much improved voltage and frequency regulation can be realized
by not loading the generator to 100% of its capacity. For best performance and load handling, only use approximately 90% of the available output. The 10% margin allows for more satisfactory engine governor response
to changing load situations. The rule becomes simple: Always know the total load requirements and the generator's capability. Select a generator to adequately meet load requirements, or limit load requirements to the
capabilities of the existing generator.
2. Load Analysis: How Much Power Does Equipment Require?

Page 10

Load analysis and generator sizing are essential for satisfactory generator and equipment operation. The available auxiliary power is limited by engine horsepower and is a small, finite power system as compared to the
large, seemingly-infinite electric utility system. Any single load may represent usage of a large portion of the
total power available. It is necessary to carefully determine the total load that will be applied by adding up all
the individual loads. Some tools are rated in watts, others in amperes. Lights and heaters are rated in watts.
Most equipment will specify on its nameplate what its specific requirements will be.
For example, a drill requires 4.5 amperes at 115 volts. Watts equals volts times amperes. Therefore, this drill
requires approximately 520 watts. Add three 200 watt flood lamps, and requirements increase by 600 watts for
a total of 1120 watts. Continue in this fashion until all loads have been added. Be sure to add all motor running requirements to the total (motor starting requirements will be discussed later). Consider also that a load is
not always constant. To be sure, lights and resistance heaters are constant, but portable power tools are not.
One rarely grinds or drills with a constant, even pressure. Thus, the load requirements change greater than
anticipated. Induction motors normally power loads that require variable amounts of power from the generator
and will be discussed later.
VOLTS x AMPERES = WATTS
This equation provides an actual power requirement for resistive loads, or an approximate running requirement for nonresistive loads.
EXAMPLE 1: If a drill requires 4.5 amperes at 115 volts, calculate its running power requirement in watts.
115 V x 4.5 A = 520 W
Therefore, the individual load applied by the drill is 520 watts.

EXAMPLE 2: If a flood lamp is rated at 200 watts, the individual load applied by the lamp is 200 watts. If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.

Calculating Power Required To Run Equipment

Page 11

Starting Motors
Different types of loads require different types of output from the generator. When a nonmotor load is applied,
generator output goes to the ampere requirement of the equipment, but voltage remains near rated. The nonmotor load does not cause the voltage to drop significantly below its nominal rating. When a motor load is
applied, the generator will attempt to supply motor starting current causing output voltage to drop to nearly
zero volts because the starting current is many times the running current. For this reason, it is necessary to
determine the starting amperage required by the motor and verify the the generator can supply that amount of
amperage. This can be done using the formula shown below, or by using the charts shown on the following
pages.
4

AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1

1
3

1
2
3
4

Motor Start Code

Running Amperage
Motor HP
Motor Voltage

To find starting amperage:

Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motors running amperage.

Single-Phase Induction Motor Starting Requirements

Motor Start
Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

kVA/HP x HP x 1000
VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.
Volts = 230

HP = 1/4

Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000

= 12.2 A Starting the motor requires 12.2 amperes.
230

Caculating Motor Starting Requirements

Page 12

S-0624

Approximate Power Requirements for Industrail Motors

Industrial Motors
Split Phase

Capacitor Start-Induction Run

Capacitor Start-Capacitor Run

Fan Duty

Rating

Starting Watts

Running Watts

1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP

800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500

300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100

Starting Watts

Running Watts

1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200

1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050

Approximate Power Requirements for Farm/Home Equipment

Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)

High Torque (e.g. Barn

Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump

Rating

1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP

Page 13

Approximate Power Requirements for Contractor equipment

Contractor
Hand Drill

Circular Saw

Table Saw
Band Saw
Bench Grinder

Air Compressor

Electric Chain Saw

Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights

Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer

55 gal Drum Mixer

Wet & Dry Vac

Rating

Starting Watts

Running Watts

1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP

350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300

350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250

Page 14

1000
200
500
1400
1600
950
1400
1600
700
900
1300

Auxiliary Power While Welding

Weld Current
in Amperes
0
90
125
180
250

Total Power
in Watts
10,000
8000
5200
3500
2200

120 V Receptacle
Amperes
84*
66*
43*
29*
18

240 V Receptacle
Amperes
42*
33
21
14
9

Bobcat 250 Power While Welding

Weld Current
In Amperes

Total Power
in Watts

120 V
Receptacle
Amperes

240 V
Receptacle
Amperes

300

1000

10

250

3500

31

15

200

5200

46

23

150

6700

60

30

100

8000

70

35

10000

84

42

Trailblazer 301 Power While Welding

Typical Connections To Supply Standby Power

Generators may be used to provide emergency power to systems normally supplied by other sources of electricity, but extreme caution must be exercised to properly install the generator. The specific rules for installation and use of auxiliary generators are established by the National Electrical Code, state, local, and in some
cases OSHA codes. These codes were developed to assure personnel safety - vitally important for any user. It
is the responsibility of the installer to be familiar with and meet all installation requirements. Major requirements of the National Electrical Code (1990 edition) for auxiliary power plant installations are (1) overcurrent
protection as required for the generator, (2) proper grounding of the generator, and (3) isolation of the generator from other sources of power. Additional requirements may be established by state and local codes.
Overcurrent protection is required if a generator is supplying a permanent installation. Fuses or circuit breakers are adequate for small auxiliary power plants. Overcurrent protection is generally not required for generators supplying portable, cord-connected equipment through receptacles mounted on the generator.

Page 15

Customer-supplied equipment is required if generator is to supply standby power during emergencies or power
outages. Locate the power company service meter (Item 1), and main and branch overcurrent protection (Item
2), and install equipment as shown below.

Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
1
2

 Customer-supplied equipment is required if

generator is to supply standby power during

emergencies or power outages.

Obtain and install correct switch.

Switch rating must be same as or
greater than the branch overcurrent
protection.

1
240 V

120/240 Volt
60 Hz
Three-Wire
Service

120 V
5

Extension Cord

Select as shown in Section 13-11.

Neutral

Circuit Breakers or Fused

Disconnect Switch

Obtain and install correct switch.

120 V

Generator Connections

Connect terminals or plug of adequate amperage capacity to cord.

Follow all applicable codes and
safety practices.

240 V

Turn off or unplug all equipment

connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.

120 V
Load

Power Company Service

Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch

120 V

4
7

Load Connections

CB
Item 4 is not necessary if circuit
protection is already present in
welding generator auxiliary
power output circuit.

or
F1

5
240 V

120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection

120 V
120 V
Ground

Standby Power Equipment And Connections

Page 16

Selecting Extension Cords

Use the tables below to select extension cords. Use shortest cords possible because long cords may reduce output or cause unit overload.
Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

600

840

10

1200

15

10

12

14

350 (106)

225 (68)

137 (42)

100 (30)

400 (122)

250 (76)

150 (46)

100 (30)

62 (19)

400 (122)

275 (84)

175 (53)

112 (34)

62 (19)

50 (15)

1800

300 (91)

175 (53)

112 (34)

75 (23)

37 (11)

30 (9)

20

2400

225 (68)

137 (42)

87 (26)

50 (15)

30 (9)

25

3000

175 (53)

112 (34)

62 (19)

37 (11)

30

3600

150 (46)

87 (26)

50 (15)

37 (11)

35

4200

125 (38)

75 (23)

50 (15)

40

4800

112 (34)

62 (19)

37 (11)

45

5400

100 (30)

62 (19)

50

6000

87 (26)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)

Load (Watts)

1200

1680

10

2400

15

10

12

14

700 (213)

450 (137)

225 (84)

200 (61)

800 (244)

500 (152)

300 (91)

200 (61)

125 (38)

800 (244)

550 (168)

350 (107)

225 (69)

125 (38)

100 (31)

3600

600 (183)

350 (107)

225 (69)

150 (46)

75 (23)

60 (18)

20

4800

450 (137)

275 (84)

175 (53)

100 (31)

60 (18)

25

6000

350 (107)

225 (69)

125 (38)

75 (23)

30

7000

300 (91)

175 (53)

100 (31)

75 (23)

35

8400

250 (76)

150 (46)

100 (31)

40

9600

225 (69)

125 (38)

75 (23)

45

10,800

200 (61)

125 (38)

50

12,000

175 (53)

100 (31)

*Conductor size is based on maximum 2% voltage drop

Page 17

Engine and Fuel Choices

Rotating type power supplies are used for field erection and fabrication work when no electric power is available. For this use, a wide variety of internal combustion engines are available. Both liquid-cooled and aircooled engines are used. Gasoline is the most popular fuel because of price and availability. Diesel fuel is popular because of its high flash point. Also, some regulations will permit only diesel fuel for engines used in specific applications. A good example is the use of diesel engines for welding power sources on offshore drilling
rigs and marine applications. Propane and natural gas are used in some applications because it is cleaner burning than gasoline. However, they require a special carburetion system. An example of the need for these cleaner burning fuels is "in plant" maintenance welding.
Engine driven power sources are often equipped with idling devices to save fuel. These devices are automatic
in that the engine will run at a set idle speed until the electrode is touched to the work or a load is sensed on
the auxiliary power outlet. Under idling conditions, the open circuit voltage of the alternator/generator is low.
Touching the electrode to the work energizes a sensing circuit that automatically accelerates the engine to the
operating speed. When the arc is broken, the engine will return to its idle speed after a set time.
The curve shows typical fuel use
under weld or power loads.

1800 RPM

IDLE

50

100 150 200 250 300 350 400 450 500

DC WELD AMPERES AT 100% DUTY CYCLE

193 093

Fuel Consumption
Engine driven power sources are available with many auxiliary features. Units may be equipped with a remote
output control attachment. It may be either fingertip, hand, or foot control operated so that the operator may
take the power source adjustment (contactor, voltage and/or amperage) to the work area while welding.
Other auxiliary features that can be obtained on the engine driven welding machines are: polarity switches (to
easily change from DCEN to DCEP), running hour meters, fuel gauges, battery chargers, high-frequency arc
starters, and volt/ampere meters. Some larger units are equipped with an air compressor for carbon arc air cutting and gouging, plasma arc cutting and gouging, and operating pneumatic hand tools.
Page 18

Why Buy A Diesel Engine Powered Welder?

- It uses approximately half as much fuel as a similar sized gasoline engine.
- It has no points, plugs, condenser or carburetor, which means no downtime from costly tune-ups and
adjustments.
- It doesn't have carburetor icing problems in severe cold climates or fuel and vapor lock problems in severe
warm climates.
- It is less apt to be pilfered for personal use than gasoline due to lack of diesel fueled automobiles, and it's a
more common fuel for the large construction machinery.
- It will be running long after a gasoline engine has had to be overhauled.
- It is safer fuel to use than gasoline, which is very important on construction job sites, on offshore rigs and in
the oil fields.

Page 19