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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.
Page 3
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.
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.
4. No brush-commutator assembly
- Slip rings and brush carry less than 10 amps.
- Minimum brush wear.
- No chance of polarity changing.
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.
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.
Page 6
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.
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
Design:
1. Two Pole Alternator
2. Four Pole Alternator
Page 8
STABILIZER
(INDUCTOR)
DC
HERE
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
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.
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
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
HP = 1/4
Page 12
S-0624
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
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
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
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
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
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
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
1
240 V
120/240 Volt
60 Hz
Three-Wire
Service
120 V
5
Extension Cord
Neutral
120 V
Generator Connections
240 V
120 V
Load
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
Page 16
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)
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)
Page 17
1800 RPM
IDLE
50
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
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