What is a Welder Generator?
A welder generator is a standalone machine that combines an internal combustion engine, an electrical alternator, and a built-in welding circuit. This integrationgenerator power and welding capability from a single unit, eliminating the need to transport separate equipment. The engine burns fuel to create mechanical energy, which spins the alternator to generate electrical energy for your welding applications and auxiliary tools.
Where Welder Generators Work Best
Construction sites often lack proper electrical infrastructure, making welder generators essential equipment for professionals. They’re perfect for structural steel erection, where workers join massive I-beams and steel trusses in locations where utility power simply doesn’t reach. Field fabrication work requires high precision and heavy metal manipulation away from traditional workshops, and a portable welder generator makes this possible.
Workers rely on welder generators for quick, on-site repairs of heavy equipment and structural components. You’ll find them mounted on trucks and trailers, performing welding on pipelines in remote areas where there’s no access to mains power. The portability of these machines allows use in hard-to-reach locations and during power outages, giving you flexibility that fixed equipment simply cannot provide.
Selecting Your Welder Generator
When selecting a machine, consider your specific welding applications. Stick welding is the most common use for welder generators because of its suitability in outdoor environments. High-end models support multiple welding processes, including Stick, TIG, MIG, and Flux-Cored, providing versatility across various job types.
Diesel engines are typically preferred for heavy-duty applications due to better fuel efficiency and higher torque. This makes them ideal if you’re running extended operations or working in demanding construction environments. At Crommelins, we’ve tested our range across Australian conditions to ensure you get equipment built for local jobs.
Power Quality
Not all generator power is created equal. Generator power can be characteristically dirty, which may damage sensitive electronic components inside inverter welding machines, especially with smaller generator sets. When choosing equipment, this is crucial to understand.
If you’re powering an inverter welder, the generator must provide clean power. Look for units with a low Total Harmonic Distortion (THD) output of 6% or less to ensure a clean power supply and prevent damage to your inverter equipment. Generators with a brushed alternator and Automatic Voltage Regulation (AVR) technology are recommended for frequent use, providing superior voltage regulation and cleaner output.
Modern inverter welders require clean power with a smooth sine wave to avoid damaging components. The continuous auxiliary power (kVA) must be capable of supporting the required tools, with specific amp matching between the generator capacity and welding output.
Sizing It Correctly
Sizing is essential for optimal performance. A generator that is sized appropriately avoids voltage spikes and ensures your welding machine performs at its best. A suggested minimum generator size for running welders up to 160A is 7 kVA, while for 250A welders, a minimum of 13 kVA is recommended.