Quick Answer
For off-grid welding, a 5-7 kW solar panel array is recommended, consisting of 10-14 high-efficiency panels, to provide a stable 30-40 amp DC power supply for a 115V DC welder.
Welder Power Requirements
To determine the number of solar panels required, we need to consider the power draw of the DC welder. A typical 115V DC welder requires a 30-40 amp DC power supply. We’ll use 35 amps as a baseline. For a 12-hour welding session, the total power consumption would be 35 amps x 12 hours = 420 watt-hours.
Solar Panel Selection and Array Sizing
We recommend high-efficiency solar panels with a minimum of 400 watts of power per panel. A 10-14 panel array would provide a total power output of 4-5.6 kW. To account for inefficiencies in the charging system and ensure a stable power supply, we’ll size the array to 6-7 kW. This will provide a 20-30% buffer to account for cloud cover, shading, and other factors.
Battery Bank Sizing and Charging System
A 12V 400Ah battery bank is a good starting point for off-grid welding. This will provide a 4.8 kWh storage capacity, which can supply the welder for 12 hours. The charging system should be sized to recharge the battery bank within 4-6 hours. We recommend a 30A MPPT solar charge controller and a 200A DC-DC charger to ensure efficient recharging and minimize battery wear.
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