Sizing a stick welder

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We live 35 miles from the nearest general store, and about 2 miles from the nearest electrical grid.  We have lived on solar for about 15 years, and when I need to arch anything, I must start up a 7500 Watt generator – solar and arc welding don’t mix.  The generator is adequate for flux core wire, but when I get into a stick welder, I’m not so sure the 7500 generator will be able to pull the weight.  Say, I need to weld ½ to ¼ plate steel – any ideas as to the minimum size sick welder I will need( don’t want something so big as to require Hover Dam to power), and the size of its power source?   When they size a stick welder, do they measure the amps from the 230V input side, or the DC output side?
Reply:An inverter type stick welder is better suited to a generator (if it has relatively clean power) because they tend to have a reasonable power factor and efficiency.  In layman's terms, that means they aren't amp hogs like old style transformer welders. Welders are spec'd as Amps out to the welding leads (and arc voltage).  Amps in depends on the type of welder and the efficiency. I'll let experienced people chime in, but I'd be thinking on the order of an inverter stick welder that could do 200 Amps."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Get a rechargeable welderhttp://www.waspsupplies.com/new-lorc...red-4610-p.aspBubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:I would get an engine driven welder for your needs and it sounds like you need something like the  Miller Wildcat 200Lincoln pro core 125 14''chop saw7 inch grinder,2-4.5 inch grinders,electric die grinder.Half inch drillAnd alot of hand tools
Reply:This thread might help you out. Welders are sized by output amps.http://weldingweb.com/vbb/showthread.php...-size-and-makeAirco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Originally Posted by SquirmyPugThis thread might help you out. Welders are sized by output amps.http://weldingweb.com/vbb/showthread.php...-size-and-make
Reply:I also vote for an inverter welder.The Thermal arc 161 will put out up to 160 amps on 230 volts, or 90 amps on 110V.  Not sure how many power it will draw on 230V, probably around 5 KW.  This would probably be the most cost effective solution.The Miller Maxstar 150 is very similar, more expensive, draws about 5KW at full power on 230 volts.  Unfortunately the spec sheet does not list a minimum generator size, perhaps the manual addresses this.   The Maxstar 200 has more power, but your generator only puts out 7.5 KW.Realistically, you need to look through the owners manuals before you buy, and see if the manual addresses the minimum generator size.  I would note that if you don't use full power, you need less power in, so if your generator bogs down at 160 amps out, maybe it would be happy at 125 amps.   Perhaps a local welding shop might loan you a demo unit to try one out with your own generator.Personally, I think that 150 amps is adequate for most work.  150 amps is more than enough for 1/8 inch 6010 or 6013 rod, probably marginal for 1/8 inch diameter 7014 or 7108.   The Miller stick calculator says 110 to 165 amps for 1/8 inch 7014 or 7018, 3/32 inch needs 80-125 amps.    I know that I seldom turn up my welder past 150 amps.  You are not going to be welding bulldozers or 1 inch plate.My two cents, don't confuse me with a real expert.RichardLast edited by raferguson; 02-22-2014 at 06:03 PM.Reason: add more info.Sculptures in copper and other metalshttp://www.fergusonsculpture.comSyncrowave 200 Millermatic 211Readywelder spoolgunHypertherm 600 plasma cutterThermal Arc GMS300 Victor OA torchHomemade Blacksmith propane forge
Reply:Originally Posted by BistineauWhen I first started reading this thread, I was thinking about doing the same thing you did and reference that post. But you beat me to it.Dennis, why are you starting a new thread asking the same question again? Not getting enough responses on the first thread or not the answers you were looking for?  I still say your best bet is going to be an engine drive, like I said before. That's my story and I'm sticking to it.
Reply:Originally Posted by rafergusonPersonally, I think that 150 amps is adequate for most work.  150 amps is more than enough for 1/8 inch 6010 or 6013 rod, probably marginal for 1/8 inch diameter 7014 or 7108.   The Miller stick calculator says 110 to 165 amps for 1/8 inch 7014 or 7018, 3/32 inch needs 80-125 amps.    I know that I seldom turn up my welder past 150 amps.  You are not going to be welding bulldozers or 1 inch plate.
Reply:A 7500 watt generator should run a buzz box up to around 200 amps.An inverter will give you a few more welding amps.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Originally Posted by mad welder 4A 7500 watt generator should run a buzz box up to around 200 amps.
Reply:Is there any possibility they just want you to buy a larger generator?old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Why? They don't sell generators. If you could use one off a smaller gen set, it would cause them to sell more welders. They'd look really stupid if they recommended a 15 KW genny and it turned out the units would run off 7Kw ones. There is no logical reason for them to recommend something that is unnecessary. The reality is transformer units are simply inefficient.  Trying to run one off a genny is a poor way to go. Engine drives skip all the  issues by directly making the power that's required. They don't make power, then try to convert it to something else on average..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I have a 5000 watt Honda Brand Generator.  It will NOT run a buzz box in the real world off its 30 amp 230 v receptical. I tried it when I didn't have power to my garage.  At 100 amps DC, I could run around 1" of bead until the breaker would pop.   Put power in shortly thereafter.  My TA161S run off a 20 amp 110 outlet on the same Genny can weld at 100 amps all day without an issue.  Bought the outlets to add it to the 230 feed but haven't needed to.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Is that honda one of the inverter types?This is the whole reason I wanted to add some power factor correction to my buzz box and people said I was crazy.Last edited by mad welder 4; 02-23-2014 at 01:25 PM.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Mine is not an inverter type.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Originally Posted by DSWWhy? They don't sell generators. If you could use one off a smaller gen set, it would cause them to sell more welders. They'd look really stupid if they recommended a 15 KW genny and it turned out the units would run off 7Kw ones. There is no logical reason for them to recommend something that is unnecessary. The reality is transformer units are simply inefficient.  Trying to run one off a genny is a poor way to go. Engine drives skip all the  issues by directly making the power that's required. They don't make power, then try to convert it to something else on average.