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If your generator has a 4-prong 240V 30A receptacle 8500W peak and your stick welder has a 3-prong 240V plug how do you make this work?

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2005-09-09 15:37:45
2005-09-09 15:37:45

Before you follow any of these instructions, make certain that you check with the documetation that came with the generator, since I can't be certain of what your generator is doing. The following assumes that the generator provides 220 output and is NOT 3 phase. If it's 3 phase, all of the following is wrong and don't do this! In general, 220 circuits have 2 110 "leg's" which are nothing more than a center-tap into the 220 source. It can be a center tap on a transformer or a generator. The center tap is designated with a white wire, and the two "hot" lines are usually designated with either black or red. In the case of your generator, if it is not a 3 phase circuit, the 4th wire is probably green which is the universal indicator for a ground wire. To be safe, it is a good idea to ground the generator using a long, copper grounding rod that has been driven into the ground and using a good sized wire (typically #10 or larger) connect it to the generator at the grounding lug, again, see instructions that came with the generator. To make the welder work with the generator, you can "get by" connecting the white wire to the white of the generator or if you're using a plug connect it to the silver screw. The two black wires or the black and red wires are connected to the two brass colored screws. Whenever a ground wire is provided on a wire it should be connected to grounding screw of the plug. I hope this is enough information. If you have any questions, contact the manufacturer or a local electrician.

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Yes as long as the generator has a 120 volt output it has the capacity of 36 amps. I = W/E. Current = 4400/120 = 36.6 amps. Your 120 volt receptacle on the generator will probably have a breaker rated at 15 amps to protect it. If your welder draws more than that it might trip the generator receptacle breaker when you use the welder. Check the nameplate on the welder to be sure the amperage is below 15 amps.

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When you refer to a 200 amp welder you are talking about the output side of the welder. What you have to do is find out what the input voltage and current of the welder is to calculate the size of a generator needed to operate the welder.

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As long as the amperage is the same (usually 30 amps) change the plug on the welder.

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You will have to check the amperage draw of the welder, it should be on the welder nameplate. Use this formula Amps = Watts / Volts. 5000/220 = 22.7 amps. If you welder draws more that this figure then the generator will overload.

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Generators are rated in watts or kilowatts. The formula for watts is W = Amps x Volts. To size a generator for the welder the voltage of the machine must be stated.

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Your welder needs 20A at 120V for full output. This is 2400W, but you should always add a little extra margin, so I would recommend a 3600W generator.

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