5 Top Picks
4 Reviewers
18 Hours of Research
16 Products Considered
At A Glance: Our Top Picks for Welder Generators
- Miller Bobcat 250Our Top Pick
- Lincoln Electric Ranger 225Runner Up
- AMP TRIPLEX 9200RS (out of stock)
- Miller Trailblazer 325
What do you get when you cross a welder with a generator? You get a welder that does not have to rely on any external power sources.
A welder generator powers itself and can also produce enough continuous power for other items to be hooked up to it such as lights or another welder or even a plasma cutter.
There are many welder generators that can run multiple processes such as MIG, TIG, Stick and even Plasma Cutters.
Table of Contents
Some can be smaller portable units suitable for home workshop use while others can be large enough that you need to load them into the back of a flatbed pickup truck or onto an industrial trailer.
What type of engine driven welder generator you choose to purchase will depend on the intended use, the features you desire and your price threshold.
By Gregory Sanders: This article has been updated to reflect the most accurate information regarding welder generators available for those who are interested in welding. The best 4 available have changed, and information has been added to assist individuals in finding the best welder generator currently available on the market. The FAQ has also been updated.
Top 5 Welder Generators Reviews
Let's take a quick look at some of the best welder generators available to help with your welding needs in the field.
| IMAGE | PRODUCT | FEATURES | |
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Our Top Pick
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Runner Up
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AMP TRIPLEX 9200RS
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OUT OF STOCK |
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Miller Trailblazer 325
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VIEW LATEST PRICE → |
The Miller Bobcat engine driven welder can generate up to 11,000 watts of Accu-rated power output. This model has a good-sized fuel tank, at 12 gallons.
This engine driven welder also has their own “Smart Fuel Tank” design that helps reduce backsplash during refueling. It has a welding amp range of 40-250 AMPS with a 25V rated output at 100% duty cycle and I found it extremely consistent after 2.5 years of usage (it's still going strong, that's just how long I've had it).
The Miller Bobcat is available in an LP version, EFI version and Gas. Multi-function processes include Solid and Flux-Core, Stick, MIG, TIG, Air Carbon and Air Plasma Cutting.
Warranty
Miller is a longtime manufacturer of welding equipment and is one of the most trusted names in the business. They offer a TrueBlue 3-year warranty on parts and labor. The engine is warrantied separately by the engine manufacturer.
Miller Bobcat 250 Engine Driven Welder Pros
Miller Bobcat 250 Engine Driven Welder Cons
The Lincoln Electric Ranger 225 can generate up to 10,500 watts of AC power output, which is more than enough for most job sites, home and farm use.
It's a welder generator combo with a 12-gallon fuel tank allows the generator for run for up to 14 hours.
Totally enclosed case with 3 service access doors keeps the engine fully protected.
The welder is multi-process and includes Flux-Core, Stick, MIG & TIG. The stick DC can achieve very smooth welds.
Warranty
Lincoln Electric is also known as a trusted brand and offers 3 year manufacture warranty.
Lincoln Electric Ranger 225 Pros
Lincoln Electric Ranger 225 Cons
The 12,000 watt MIller Trailblazer 325 features a 23.5 hp motor. The amperage range is from 10-325.
The multi-process functions include flux core, plasma, MIG and stick TIG welding as well as a TIG pulse mode for out-of-position and lower heat welding jobs.
Infinite arc control feature for stick and solid wire welding functions to allow fine-tuning for difficult-to-weld materials and out-of-position welding ability. Its consistent power makes it one of the top options around.
Warranty
Miller is a longtime manufacturer of welding equipment and is one of the most trusted names in the business. They offer a TrueBlue 3-year warranty on parts and labor. The engine is warrantied separately by the engine manufacturer.
MILLER TRAILBLAZER 325 Pros
MILLER TRAILBLAZER 325 Cons
The Hobart Champion Elite can generate up to 11,000 Watts of generator power output, which is more than enough for most jobs sites, home and farm use.
The welding functions can handle materials up to ½ inch thick. It runs on a gas-powered 23HP Kohler engine and is perfect for those who are doing light welding work.
This lightweight design weighs 10-20% less than competitive units and is just over 3' long.
It has a single knob current control for easy set up.
Warranty
Hobart offers a 5/3/1 limited warranty on the Hobart Champion Elite. Engines, batteries and tires are warrantied separately by those manufacturers.
Hobart Champion Elite Pros
Hobart Champion Elite Cons
5. TOMAHAWK 15 HP ENGINE DRIVEN Portable GENERATOR - 2,000 WATT
Tomahawk 15 HP Engine Driven Portable Generator is the best engine driven generator on the market with its versatility and awesome output.
It weights 154 pounds, and is 23 x 21 x 28 in dimensions. The wattage is 3,000 with 120V and 210 rated amps with a 2 year warranty.
You can reliably do a few different types of welds with this option. It comes ready out of the box so you don't need to spend time setting it up.
It comes in as advertised and is extremely consistent. This engine driven generator is fairly light weight at about 150 pounds. With its wheels it is decently portable, but you won't be bringing this around if you move job sites a lot.
To get started simply finish assembling the handles and wheel kit, then add an inline filter to the fuel line to get it chugging along. You might want to consider getting longer cables since they can be fairly short, but regardless it's still great for small jobs if you're doing MMA or TIG welding.
It has a good-sized gas tank that can hold a fair amount, but the bag it comes with is fairly cheap.
The muffler and and regular bolts might need tightening every 6-9 months but apart from that it requires no maintenance. Overall it is a powerful engine driven generator.
Tomahawk 15 HP Engine Driven Portable Generator Pros
Tomahawk 15 HP Engine Driven Portable Generator Cons
What Are The Uses Of A Welder Generator
All welding machines require a power source. Most machines rely on an external power source such as a wall outlet in a welding shop or a home garage.
A generator has its own built-in power source. This comes in very handy for instances where an electrical connection is not available.
Farmers can make good use of a generator for repairs to the metal on combines, tractors and other farm equipment; irrigation pipes, seeders and spreaders; metal components and frames on fencing and pens and barns; and hitches and trailers.
A generator comes in handy on a ranch for constructing fences and holding pens, wagons and trailers, as well as the various types of equipment used on a ranch.
Those in the construction trades would make use of a generator for structural steel supports and framing on buildings.
Any industry or trade that uses welding out in the field where no external source of power is available will require a engine driven welder generator in order to construct or repair metal structures, equipment or items with a metal component to it.
Welder generators and welder generator combos are useful not just for the welding features. They also offer many benefits in emergency power situations.
After a natural disaster such as a hurricane, tornado, ice storm, or flood has occurred, homes and businesses can be left without power for long periods of time.
A welders generator is designed with a fairly large fuel tank so it can run for many hours under a continuous watt load without the need to refuel.
Some generators can provide output power up to 12,000 watts, which is enough to provide power needs for a house or small business. Many generators can deliver peak power capability to start the motors of big appliances such as an air conditioner, water heater or furnace.
What To Look For In A Welder Generator
Welding machines can require a fairly significant outlay of money, so you want to make sure you get the biggest bang for your buck.
Many welding operators are interested in welding machines that can run multiple types of processes. Most reputable generators can run MIG, TIG and Stick welder processes and many can also run a plasma cutter.
The more power your welder generator has, the more processes it can handle. Thus, one of the more significant things to look for in a generator is how much amperage it can provide.
The more demanding the type of projects you regularly undertake, the more amperage you will require. The fuel capacity or fuel tank size of the engine driven welder generator will determine how long it will run for.
For example, a 5-gallon fuel tank can allow the generator to run on about 7 hours while a 12-gallon fuel tank would allow 13-14 hours. Of course, that return will lower if you’re also supplying power for other devices.
Some generators can be portable and lightweight. Most welder generators; however, are much bigger than a stand-alone welding machine and can be quite heavy.
They will often require a truck or trailer to haul them to and from job sites. How large a truck or trailer you will need will depend on how large and heavy the generator is.
Fuel Efficiency In A Welder Generator
The fuel type you require will depend on the model of welder generator you purchase and other factors based on how it will be used. Most generators are engine-driven and will run on either gasoline, diesel or liquid propane.
In terms of economics, gas is typically going to be the lowest-cost alternative. However, fuel price is not the only consideration in determining what type of fuel to choose.
GASOLINE
In general gas provides a lower fuel consumption and is cheaper than diesel or propane. Most smaller, portable engine driven welder generator welder generators run on gasoline. Additionally, gas engines start easier in cold weather. However, the use of gasoline requires a well-ventilated area as it is susceptible to ignition.
DIESEL
Many larger jobs where the fuel is being provided on-site require the use of diesel fuel. Diesel offers a longer run time than either Gas or Propane. So for jobs that will require a long run time, it can be a more economical choice.
Diesel does not ignite as fast or as easily as gasoline so it may be a more attractive option when using around other spark-generating equipment.
Diesel, however, gives off noxious emissions and is not well-suited for indoor applications. It can be harder to start in cold weather conditions and may require additional starting aids.
PROPANE OR LPG
Propane can be stored forever as it doesn’t go stale while gasoline will. It can also be used in areas that are not well-ventilated or where exhaust emission are not permitted.
Propane burns cleaner than either gas or diesel. Propane is not commonly used because it is the costliest of the three fuel options.
Accessories For Your Welder Generator
Almost all of the accessories that would be required for a stand-alone welding function like MIG, TIG or stick welding are also required for use with a welder generator if it incorporates that function into the unit. But there are some additional accessories that may be handy to may work on the job site easier.
Remote control operation of the welder generator can be handy on the job site. Many come with an extension cable and can be used up to a range of 400 ft. to start or stop the engine, activate the idle function, change the current control for stick TIG welding etc.
For larger/heavier generators, a welding cart or trailer may be necessary in order to haul the unit to the job site and/or provide portability around the job site.
If you plan to use LP Gas, you will need a cylinder tank rack that includes a hose assembly for your generator.
To use a MIG function you may want to consider purchasing a portable wire feeder and a welding gun and connector kit.
To use a TIG welding function on your welder generator, you will likely want to purchase a TIG torch complete with collets, nozzles and tungsten electrodes in a variety of sizes.
Additionally a foot control pedal and/or a hand amptrol for use with the TIG torch can be handy to control the current.
To use a stick welding function, a stick welding cable set that includes an electrode cable with holder and a work cable with clamp can provide between 20 to 50 feet of portability for the stick welding function with a 100% duty cycle.
Heavy-duty extension cords can be handy for jobs that may require the unit to be many feet from an electricity source. Often these cords can add an additional 20 feet of flexibility for your unit and can handle up to 230V of current running through them.
Conclusion
A welder generator is an essential piece of equipment for welding needs where an external source of power is not readily available or you need a reliable, long-running source of power.
In addition, these generators offer the ability to run several welding functions from one machine. Any of the generators reviewed here would be an excellent choice for your needs.
FAQs
1. How do I choose a welding generator?
At the moment, some models feature independent welding and generator power, while others provide enough generator power to avoid interference.
Another factor to consider when selecting a welder generator is the generator's capacity to power both the welding arc and power tools.
2. Why are welder generators so expensive?
The majority of welder/generators generate an excessive amount of energy. This means you can also connect a grinder and a couple of lights to the same machine. The catch is that the higher the output of these welder/generators, the more expensive they are.
3. How big of a generator do I need to run a 250 amp welder?
Everlast recommends a minimum 6000-watt surge generator in the 140 STi owner's manual. “The Westinghouse generator is an affordable option for transformer welders operating on 120V or small 240V. The more powerful model should be capable of welding at a maximum current of 250 amps when used with a 240V transformer welder.”
4. What is the main disadvantage of a generator welding machine?
The other significant disadvantage of engine-driven welders is their extreme weight. While they are technically portable, they weigh between 300 and 2000 pounds.
5. Will a 7000 watt generator run a welder?
Can a 7000-watt generator power a welder? It should work fine in conjunction with the MIG. However, instabilities can occur between a generator and a load, such as a welder equipped with an active rectifier section. The factory-built units are tested as a welder/generator combination, but all bets are off in the others.
