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In order for welding work to proceed without unnecessary problems, you need to figure out how to connect welding machine. Before connecting the unit for welding, it must be placed in suitable place. It is very important that nothing obstructs the air flow to the openings on the equipment body. Cooling is often intentionally increased. To do this, when connecting the welding machine, install a fan behind it. It is very important to ensure that the unit does not come into contact with dust, as well as wet and aggressive vapors.
Before you are going to connect the welding machine, be sure to make sure that the frequency and voltage indicated on the equipment case match that of the network. Connecting such equipment requires a device correct connections. For this, the following wires are used: a phase or 2 phases in combination with a neutral and a grounding wire, which is usually green or yellow.
If the welding machine model you have chosen allows you to set the voltage yourself, you should fix the switch in a position that would correspond to the voltage in your network. The position is fixed using a locking screw.
A plug is used to connect the welding machine. It is very important that it matches established standards thermal throughput. This plug must have a grounding lug. It is to this that the corresponding cable will be connected. This plug cannot be plugged into a regular household outlet. A fused socket is suitable for connection. An auto switch is also suitable.
You will need to connect the return ground cable to the appropriate terminal. You need to connect at the shortest possible distance from the future seam. A specially designed clamp is used to attach the cable holder to the protruding fragment of the electrode.
Before connecting the welding unit directly to the network, be sure to check how securely the plugs are secured.
Due to poor contact, the device will not work at full capacity and will quickly fail.
Figure 1. Connection diagram of the welding machine: 1-welding station; 2—three-core hose cable; 3 - transformer; 4-regulator; 5-grounding clamps of the unit body; 6 - single-core hose cable; 7-electric holder; 8 - ground wires.
There are quite a lot of schemes according to which the welding unit is connected. The most common connection diagram is shown in Fig. 1.
- Position 1 is a welding station;
- number 2 indicates a three-core hose cable;
- 3 - transformer;
- 4th position - regulator;
- number 5 - grounding clamps of the unit body;
- 6 - single-core hose cable;
- 7th position - electric holder;
- number 8 - ground wires.
Remember and follow all these rules when connecting the welding machine to avoid injuries and other unpleasant consequences. Failure to comply with the safety system of the welding machine may result in fire or electric shock. If any of the power cables break, they must be replaced immediately. It is best to entrust this work to professionals. Any repair and maintenance work can be performed only after the welding machine is disconnected from the network.
When connecting the welding machine, be sure to check the quality of the permanently laid and flexible wires. Check their grounding, continuity and insulation to ensure compliance with established standards. Don't skimp too much on grounding. Best to use for it flexible wire from copper. If twists, cracks or other defects are detected, the wire must be replaced. The use of damaged wires leads to overheating and may cause damage to the welding machine. An important fact is the need to unwind the wires. If this requirement is neglected, inductance will occur and resistance will decrease.
The voltage for welding machines is not standardized, so pay attention to the characteristics of the particular model you will be working with. When assembling such equipment, it is given a certain voltage level. The resistance value is not taken into account.
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Step-by-step instructions for connecting a welding machine
Figure 2. Sequence diagram for connecting the welding machine.
After you have checked the integrity of the unit and all related components, and also established the voltage compliance, you can proceed directly to connecting your welding machine. For this you will need:
- the unit itself;
- extension;
- adapter for extension cord.
When connecting the device, you can refer to the diagram in Fig. 2.
The connection is made in a certain sequence, namely:
- First, a plug is prepared with the appropriate thermal throughput parameters.
- Select a socket with a circuit breaker or fuse.
- The return cable is connected to the terminal.
- The holder cable is connected to the electrode fragment using a clamp.
After you have done all this, the welding machine can be connected to the network. Most models have fairly short wires, so connecting them often requires the use of an extension cord. The extension cord must have a wire of sufficient cross-section. The reliability and safety of operation depends on the number of intermediate connections. The fewer there are, the better.
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Connection features depending on the type of device
Figure 3. A transformer-type welding machine can operate in a wide range of welding current. It is recommended to connect it to the shield.
The procedure for connecting the welding machine largely depends on the features of its device. So, if a two-phase model is used, the wires will be connected in an individual sequence. The first wire will need to be connected to the phase, the second to the neutral output, and the third wire to be connected to the protection. If you work with a three-phase welding machine, then you don’t have to follow a special sequence. The main thing is that the first 2 wires are connected to any phases, and the third wire is connected to the protection.
It is very important to know the basic features of connecting a transformer-type device. A typical representative is shown in Fig. 3. If such equipment is used, the connection is made in accordance with a number of special rules. Transformers can operate over a wide range of welding currents. When some of them are plugged into an outlet, a fairly powerful surge of current is generated, which can burn the outlet and turn off the circuit breaker. Therefore, it is recommended to connect such a welding machine to the shield. Detailed diagram connection of the welding transformer is shown in Fig. 4.
Be sure to follow these rules while working. If they are not followed, you risk injury that could easily be avoided. As a result of incorrect connection of the welding machine, you may receive an electric shock, a decrease in the quality of welding, fire, etc.
Until recently, the question of how to connect a welding machine was asked only by professional welders. Today this topic worries a large army of amateur craftsmen. Modern manufacturers have significantly expanded the scope of the concept “ Appliances and tools." Currently included in this list are: for various purposes machines and devices. Among this variety there is also a welding machine.
Connecting a welding machine can be a problem for those who purchased such a tool for the first time or asked it from a neighbor. You need to connect it correctly so as not to damage the electrical wiring, sockets, and the device itself during operation.. The equipment passport, as a rule, does not contain such recommendations.
Types of welding machine
You need to decide on the type of “welder” before starting work. There are two types of apparatus: inverter and transformer. The inverter welding machine is lightweight and compact and is equipped with many protections and adjustments. Exist different models, differing in power and output current, intended for real “pros” and “dummies”. Light weight(up to 5-6 kg) and modest dimensions allow the use similar devices as portable. You can simply hang them on your shoulder and work in the most difficult conditions. The device confidently cooks with electrodes with a diameter of up to 4-5 mm, and the price is quite reasonable.
The only drawback is maintainability. In the event of a breakdown, without knowledge of modern electronics, you will not be able to fix it yourself. Important tip for beginners from professionals - the “inverter” cannot be placed on the ground. Be sure to place a wooden or plastic board under the device.
Transformer welding machines are based on traditional scheme: mains transformer with copper windings. Hence the solid dimensions, decent weight and corresponding price. The undoubted advantages of such devices include the ability to work with metal of almost any thickness and ease of repair.
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Requirements for sockets and wiring
Welding is a serious and responsible matter. You need to be careful not to leave yourself and your neighbors without light, not to damage other electrical appliances, and to prevent a fire.
Before you begin, you need to make sure that the power supply allows you to connect the selected welding machine. You need to check the condition of traffic jams and machines, make sure there are no bugs. In houses old building electrical wiring and sockets are capable of operating at currents up to 10 A. The passport of any electrical appliance indicates its power and rated (operating) current. When turned on, an inrush current occurs (inrush current), which can exceed the rated current by 3 times.
The device is equipped with a soft start device that eliminates such surges. inverter device. It can be connected to a network rated for 16 A. For transformer models starting currents can reach 40 A. An ordinary household outlet will not withstand this - it may catch fire. It is better to connect to the electrical panel using an industrial outlet.
If the operating current of the device exceeds the permissible capabilities of the electrical network, the voltage in it will “sag” from 220 V to 140-150 V. This can lead to breakdown of household electrical appliances and cause “sticking” welding electrode. It will be impossible to work.
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How to use extension cords
The length of the power cord of a conventional “welder” does not exceed 2 m. Therefore, extension cords are often used in work. Their choice must also be approached carefully. It is known that through copper wire cross section of 1 sq. mm, you can “pass” a current of no more than 10 A (for aluminum - 8 A).
Knowing the starting and operating parameters of the welding machine, you can calculate what cross-section the extension cord should have. It is better to take with a small reserve to ensure yourself comfortable conditions work. You should not buy a cheaper extension cord on the market. Under a thick layer of insulation you can most often find thin wiring. It’s wiser to go to a specialized store and independently choose a wire with a suitable cross-sectional area, and look for an appropriate socket. It is desirable that it be made of thermosetting plastic, one that does not melt when heated.
It is important to remember that the extension cord must be completely unfolded when working. This way it cools better and does not create an additional inductive load.
It is also necessary to take care of safety. Electric wires must not have damage to the insulation, lie on a wet floor or touch operating mechanisms. Grounding must be used.
There are often cases when the output wires have to be extended. It is not recommended to make intermediate connections. High output currents can lead to large electrical losses in such places. Guided by the maximum operational parameters of the device, you should purchase a solid stranded copper wire of the required length. It is better to choose the cross-section using the rule: for every 8 A of current - 1 sq. mm wire area.
If the electrical network is “weak” and you need to cook, you can try to connect a gas generator to power the welding machine. It should be noted that its output voltage depends on the load size. You can calculate the minimum power that a generator must have to provide normal work. For welding with the most popular 3 mm electrode, the required current can reach 120 A at 40 V voltage. Thus, with a generator efficiency of 80%, its power should be at least 6 kW.
To be fair, it should be noted that there are devices that combine an electric generator and a welding machine. But the price for them is high for the home craftsman.
There are many types and models of welding equipment. At the dacha, in the garage and at home, you can use any.
The only indispensable condition is that the connection diagram must provide convenient and safe conditions work.
How to properly connect cables to a welding inverter
A welding machine is equipment that can be used to convert the current and voltage that are necessary to produce an arc between the electrode and the metal being welded. First of all, in the process quality work welding machine, the main factor is its power. So, for example, for welding gratings or fences, an electrode of up to 4 mm will be sufficient, welding current will fluctuate between 180-220 amperes. Tension also plays a significant role. idle move(Ux.x.). It is believed that the higher the voltage, the easier it is to ignite the arc. Often the no-load voltage is 30-80 V. The welding machine also has a current adjustment lever, with which you can increase or decrease the current. Basically, welding machines are designed for 220 or 380 V, and this must be taken into account when connecting the welding machine. If you have a single-phase welding machine, then the welding cable is connected to the power supply in next order- one core for the phase, the second for the neutral, and the third for the protective zero. The cables are connected in the same way if you have a three-phase welding inverter, but with one condition - you use a 5-core cable, 3 of which are connected to terminals L1, L2 and L3.
You can lengthen the welding cable on the inverter, taking into account the voltage loss and, accordingly, the current strength. The longer the cable, the higher the current must be set at the output. The technical documentation of some devices indicates a categorical prohibition on extension welding cable. When connecting cables to the Resanta welding machine, you need to keep this in mind. In practice, the performance of other devices does not noticeably deteriorate when the cables are extended to 5-6 meters. This is due to the power reserve and resource built into the welding machine by the manufacturers. In any case, connections on the welding cable are not allowed. The short cable is replaced with a longer piece with appropriate terminations.
How to choose welding equipment
Today, manufacturers offer big choice welding equipment. And what to choose best option, you must at least have an idea of what types of devices there are, what characteristics you should pay attention to, and what you need to know to properly connect the purchased device.
The range of welding machines is huge, but the main choice consists of:
Welding transformers;
. welding rectifiers;
. inverters.
There is a completely incorrect statement that the heavier and larger the device, the better - dimensions and weight do not determine it functionality. The weight of a conventional transformer does not exceed 30 kg, a welding rectifier - 20 kg, and an inverter - 10 kg. Naturally, the prices for the devices will be different.
One of the main conditions that you need to pay attention to is the parameters for welding current, PVR (percentage of operating time) or PV (on duration). To count the time, use an interval of 15 minutes. A fairly convenient arc ignition option, has large quantity devices. As for devices with welding current rectification, they produce very high quality seam, have the functions of starting the engine, charging the battery, heating and straightening the metal using a carbon electrode.
The question often arises: is it possible to connect a welding machine through a meter? It must be taken into account that new household meters designed for a current of 40-50 amperes, which equals ~8 kW active power. Therefore, it is necessary to select a welding machine that will consume a current less than that indicated on the meter and the input rating circuit breaker. If rated current welding machine will be selected correctly, then electric meter will not be harmed.
Cable for welding machine (cable for welding).
For productive work welding machine, it is necessary to select a welding cable so that its cross-sectional area, length and voltage drop of the welding circuit do not exceed 2 W. Welding cable KG is an insulated flexible current conductor with one or more cores woven from copper wires various diameters (from 0.18 mm to 0.2 mm). Such a cable performs the function of supplying current from the welding machine or voltage source to the device with which the electrode is held.
In conclusion, it should be noted that in order for your welding equipment to work smoothly and justify its service life, you must select a welding cable in accordance with the technical characteristics of the welding machine.
History of the problem
A welding machine has long become one of the indispensable devices in a summer resident’s household, especially since prices for household welding machines have dropped to 4-7 thousand rubles that are affordable for everyone.If you bought a welding machine for the first time or borrowed it from a neighbor, then the question naturally arises - how to turn it on correctly? To turn it on correctly means to turn it on in such a way as not to damage the sockets and wiring when using the device for its intended purpose, not to burn the device itself, and to carry out the welding process.
Unfortunately, the passport for the welding machine only provides general recommendations according to work-rest cycles, i.e. talks about the need to take breaks during the welding process and nothing or almost nothing is said about correct connection to the 220 V network.
What types of welders are there?
Let's talk about the nuances in detail. First of all, determine what type of device you have and what type of electrical outlet. Welding machines can be divided into two large groups: transformer and inverter. Inverter ones are much lighter and more compact, have soft start devices, many adjustments and protections. With output currents of up to 140 A, they can be plugged into a 16 A power outlet without any problems.
Welding inverter.
Of course, inverter welding machines also have a transformer, but it operates at frequencies of 50-100 kHz, so it is very compact. The weight of a modern inverter welding machine is only 2.5-3 kilograms, and the dimensions are approximately 300x190x130 mm. An example is the Fubag IR160 inverter.
It has a MMA welding current range of 5-160 A. Welding current at 25% load is 160 A. Open circuit voltage is 65 V. Electrode diameter is 0.6-4.0 mm. Power factor 0.92. Productivity 85%. Air forced cooling.
Dimensions (LxWxH) 340x120x240 mm. Weight 5 kg. Price from 5118 rub. Typically, such inverters are equipped with convenient plastic cases.
Welding transformer.
Transformer welding machines, as a rule, are less modern devices and have fewer adjustments and protections. Since the transformer operates at 50 Hz, it is much bulkier and heavier. An example is the Telwin Bimax 4.195 Turbo welding machine.
Welding current range 30-160 A. Power 2.3-5.2 kW. The diameter of the welding electrode is 0.6-1.2 mm. Dimensions 600x340x430 mm, weight 28 kg, price 11,800 rubles! When you plug it into the network, a surge of current occurs, which can burn out the electrical outlet or turn off the circuit breaker. Therefore, it is better to connect such devices to the electrical panel using a special socket. For example, a very common socket for a three-phase electric stove RShVSh 40 (40A, 380V) is suitable.
The wiring is different.
Before using a welding machine, look at what outlets and wiring are installed in your home. If the house is old enough, then there may be sockets designed for maximum current 10 A. The wiring to these outlets is generally rated for the same amperage. Look at the traffic jams or the machines, and see if there are any bugs.
Welding is a very responsible process and must be approached seriously, otherwise you risk leaving yourself and your neighbors without electricity. By the way, if there is an overhead power line to your house, then the welding machine can load it so that the voltage “falls” below 150 V. This will lead to the fact that you will not be able to cook normally, and voltage fluctuations will occur in the network, dangerous for electrical appliances and electric lamps
How to use extension cords?
Typically, the welding machine has a network cable of no more than 1.8 - 2.5 meters. Therefore, when performing welding work, extension cords are used. The wire in the extension cord must be of sufficient cross-section. If the cross-section of the wire is 1.5 square millimeters, then the maximum current for which it is designed is 16A, 2.5 square millimeters - 25A.
Choose the wire cross-section with a margin and always unroll the wire from the extension cord, because...
in this case, it cools better and no additional inductive resistance of the coil with the wire is formed. Don't forget to use grounding for your safety.
If you need to extend the wires at the output of the welding machine, it is better not to make intermediate connections. You need to buy a multi-core solid cable of the required length. The cable cross-section for current up to 140A must be at least 35 square millimeters, i.e. The cross-sectional diameter of the copper core must be at least 7 millimeters.
Gasoline generator or welding generator?
As mentioned above, due to a voltage drop in the power line, welding is simply impossible. In this case, many try to use a low-power gas generator to power the welding machine. This is the wrong approach if the generator has a power of less than 5 kW. The output voltage of a low-power generator is highly dependent on the load power.
When welding with a 3 mm electrode, the current reaches 120A, at a voltage of 40 V. The output power is 120x40 = 4.8 kW. Even with an inverter efficiency of 0.8-0.9, the input power should be 4.8/0.8=6 kW. By the way, inverter welding machines are very sensitive to voltage surges at the input and can fail.
Therefore, with a “weak” network, it is better to use a welding machine combined with an electric generator. For example, Champion DW 180 AE, welding current up to 180 A, weight 110 kg, price from 42,000 rubles. There is another option, which is to use a stabilizer alternating current in front of the welder. True, if the network is very “weak”, such a solution will not help or you need to choose a stabilizer with a large range of adjustments, but it itself costs from 30,000 rubles.
Conclusions.
If possible, we told you about the problems that arise when using welding at home and in country life. In our opinion, it is better for you to choose an inverter welding machine for welding. It will pay for itself faster, and learning how to use it is much easier and more enjoyable. I hope now you know how to properly connect the welding machine. If we missed something, write and share your experience, and we will tell others about it. We wish you success.
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A welding inverter is a device that can greatly facilitate the arc welding process. Every year its use becomes more and more popular, because it allows welding of any structures quickly and efficiently. So that welding work takes place in the required modes, and the device has long term service, you need to properly connect the inverter to the power source. Therefore, further we will consider how to properly connect a welding inverter.
Connecting a welding inverter
The welding machine can be connected to an external network with a voltage of 220 V or 380 V, or to a generator set of a certain power. The connecting cable with plug corresponds to the maximum power of the unit, so there should be no questions here. The main difficulties may arise from external source power supply, especially if the electrical wiring is summer cottage old and has an unknown cross-section.
Modern wiring, plugs and sockets are designed for a current of no more than 16 A. Total power, which is consumed by all devices in the house, can be greater than this value, so it is limited by an automatic safety device or a regular plug. To make a connection welding inverter, first you need to make sure that its input power will not cut off protective device home network.
One of the advantages of this type of welding devices is that they electrical circuit has several types of protection. In case of network overload, the protection automatically turns off the device by low voltage. This situation can occur when the input voltage is low, or in the case of insufficient electrical wiring, the resistance of which will reduce the voltage when a load in the form of welding current occurs.
If electrical wiring If the fixed network does not allow connecting an inverter, you need to use other power sources, which will be discussed below. If the maximum power of the device fully matches the external wiring, you can connect the inverter to the mains and carry out test welding.
If possible, you need to control the voltage drop when igniting the arc. Severe subsidence may be the result of a small cross-section of wires.
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Connecting a welding inverter to an electric generator
Due to poor parameters of the external electrical network, in some situations it is simply impossible to carry out welding. Then you can use the power plant. At the same time, it is very important that the power of the power plant allows for full-scale welding work.
When choosing a generator, you should first familiarize yourself with the basic technical characteristics of the welding machine. As an example, we will take a conventional inverter with an operating current of 160 A. Modern inverters have smooth adjustment of the welding current from minimum to maximum value. This allows welding to be carried out at both medium and maximum power of the equipment. But manufacturers often write only power consumption, without saying anything about its maximum value.
Figure 1. KG brand wires are different and differ in maximum load, depending on the cross-section.
To independently calculate the maximum power, you need to multiply the maximum operating current of the device by the arc voltage (usually it is 25 V), and then divide the resulting figure by the efficiency of the inverter (approximately 90%). As a result maximum power will be equal to: 160x25/0.9=4444 W.
After making the calculations, you can begin to select an electric generator. In this case, you should focus on the maximum power consumption, adding a reserve of 25% to it, so as not to use the power plant to its maximum capacity.
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Therefore, for a welding inverter with an operating current of 160 A, you need to buy a generator with an output power of at least: 4444+4444x0.25=5555 W, or 5.5 kW.
Gasoline generator or electric generator? In some cases, if it is impossible to use an external power supply, welders try to connect inverter welding
through a low-power gas generator. This approach is incorrect if its power is less than 5 kW. The operating voltage in such generators strongly depends on the load size. Inverter devices are sensitive to voltage changes, so if the output voltage of the gas generator changes frequently, the welding machine may fail.
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When welding with a 3 mm electrode, the operating current reaches 120 A at a voltage of 40 V. In this case, the output power will be: 120x40 = 4800 W, or 4.8 kW, that is, the gas generator will operate at maximum power, which will also lead to its premature exit building. Therefore, if the network is poor, it is better to connect the welding machine to an electric generator.
Selecting a cable to connect the inverter To carry out high-quality welding, it is very important to choose the right connecting wires. Welding wires
- are selected according to the following indicators:
- length;
- cross-sectional area;
The inverter cable is a flexible current conductor with good insulation. In most cases, such a wire is made of copper wires 0.18-0.2 mm thick, woven together. Such cables are used to connect the inverter to the electrical holder, as well as to ground the device. The choice of wires depends on their technical characteristics and characteristics of the welding unit itself.
Among welders, the most popular is the KG brand wire (Fig. 1). Manufacturers of this type of cable recommend its use in AC circuits with a voltage of no more than 600 V or when DC with a voltage of no more than 1000 V.
KG brand wires vary in maximum load, depending on the cross-section. Ratio maximum load the cable and its brand are presented in the table:
In addition to the KG brand, KOG1 brand wire is also used, which is more flexible than the first option. It is used in cases where the welder needs to constantly move to perform work.
Connecting the welding cable is carried out taking into account certain rules:
- Connections should be made using pressed or soldered lugs.
- The cable is connected to the power connectors of the unit (+) and to the electrode holder in reverse polarity (-). The polarity can only be changed when the current parameters have been changed.
- When carrying out welding work, the welder is prohibited from pulling the inverter towards himself with wires.
- Under no circumstances should the rated power of the cable be exceeded.