Typical design A welding machine for electric arc welding includes two main parts: a power source, which receives voltage from the network, and a welding unit. the welding unit, in turn, consists of a holder, the electrode itself and neutral wire.
When the electrode briefly touches the place of the future connection, a spark jumps at this place (a breakdown occurs) in the gap from the air. This is where welding begins directly. The welder must have time to remove the heated end so that it does not stick to the metal surface. At the same time, you need to keep this minimum distance between the electrode and the metal, which allows you to maintain the electric arc.
Electric arc - this is a fairly long electrical discharge that occurs between the region of the future weld and the end of the electrode. The welding area is also called the arc zone. At the cathode region a temperature of over 30000C is formed. At the same time, the potential difference remains relatively small, only 20 - 25 V.
During arc formation, the air gap first breaks down with electrons. Afterwards, in a split second, the process stabilizes in the arc gap. Next comes the ionization of gas molecules by electrons, resulting in ionic conductivity. The arc combustion is stabilized with the help of melting and evaporating coating of the electrodes.
During welding, under the influence high temperature, the electrode begins to melt. A drop of molten metal appears at its end: it breaks off and falls onto metal surface details. Within 95% of the total mass of the electrode is transferred to the metal, the rest turns into steam and splashes. , electrode diameter, arc length and other factors affect the rate of droplet formation and their size. The shell that covers the electrodes forms a slag to hide the metal droplets. As a result, drops of metal passing through the arc do not close the arc gap.
The operating procedure of a typical welding transformer and its connection diagram
The main power source for the entire welding system. With its help, the single-phase mains voltage is reduced from 220V to a working value for welding of the order of 50 - 80V. Non-standard operating conditions require the greatest power output from the transformer during welding work. Design welding transformer involves the passage of large currents through it.
For improvement technical characteristics welding machine is used additional devices:
- To improve arc stability, ballast resistance is used. It is made from nichrome wire with good resistivity. The location of the electrode with less accuracy in relation to the metal is allowed;
- For stable operation device from AC voltage a throttle is used. At the same time, the weight of the welding machine increases significantly and use is possible mainly only in stationary conditions;
- Rectification using diode bridges. Welding arc at DC burns more stably, the quality of the seams is higher.
Typically, apartments and residential premises are powered from single-phase external electrical networks. Sometimes private households, garages, and cottages have three-phase power supply. In order to power three-phase (electric motors of pumps and machines, welding machines, compressors, electric stoves), a 380-volt socket (connector) is required.
As a rule, there is no difficulty in making all connections in a single-phase outlet. At the same time, it is somewhat more difficult to correctly connect a 380-volt connector - four or five cable cores are suitable for them. It is important to make all connections correctly to avoid damage electric shock and electrical equipment breakdowns.
How to properly connect a three-phase socket
Before you purchase a connector, you need to make sure it matches the plug electrical appliance. If necessary, it is possible to replace the plug of the electrical appliance.
Important! When purchasing a 380 connector, you need to pay attention to the current value for which the connector is designed. It must be greater than, or at least equal to, the current consumed by the connected electrical equipment.
Learn more about choosing connectors and plugs in the video
Connecting a 380 socket general guide
In Russia, the most common four- or five-pin sockets and connectors are RS 32, 115 (125). It makes sense to install foreign analogues only with appropriate plugs for electrical appliances or for aesthetic reasons.
PC 32 connection
PC32 is used only for stationary electrical equipment (electrical ovens, stationary water heating devices with heating elements, kitchen stoves).
Connect phase conductors A, B, C to terminals L1, L2, L3 in random order.
Connect the neutral conductor to the contact marked N (highlighted in blue in the figure).
To the terminal marked PE (shown in the diagram green), connect the grounding conductor.
To power a stationary electrical appliance, it is possible to use a four-pin socket without a grounding contact. In this case, the grounding of the metal housings of the devices is carried out bypassing the plug connector separate wire. The grounding conductor is connected under a bolt on the device body with the corresponding mark. According to current standards grounding metal parts stationary electrical appliances are required. It must be made unbroken, using stranded copper wire cross-section not less than the cross-section of the supply cable cores.
Connection 115 (125) 3P+PE+N
This type of connector is used to connect instruments and electrical equipment in workshops, garages, etc. They are suitable for mobile electrical appliances (for example, electric saws, welding machines, compressors). Mobile equipment must be connected to the network using flexible copper cable.
Phase conductors are connected to contacts L1, L2, L3.
Connect the neutral conductor to terminal N of the socket; it must be taken into account that the neutral contact in the plug is mirrored, as shown in the figure below.
The “ground” contact marked “PE” is located at the bottom near the groove that prevents the plug from being turned on incorrectly, to the left of the zero contact.
If stationary electrical equipment is powered from connector 115 (125) 3P+PE+N, it can also be four-pin. Then, according to the rules, the grounding of the housing is done with a separate copper stranded conductor.
To ensure that the welding process is as safe as possible and that no serious problems arise during it, you should figure out how to connect welding machine. This requires taking into account several key factors, such as location. Type of device, location of ventilation, etc. Ventilation is one of the most important points when placing the inverter, as they are highly susceptible to overheating. You also need to pay attention to contact with dust. Thus, connecting a welding machine can be a daunting process for beginners.
Connecting the welding machine begins with checking the network parameters. It must match the one indicated on the body of the equipment, since otherwise it cannot be used. Here you must comply with the devices correct connections. Here it is necessary to use grounding and phase wires, which can consist of one phase or two phases and a neutral.
If the model has a function for self-regulating the input voltage, then it should be placed in a position whose value will correspond to the network voltage. A fixing screw is usually used to secure the position.
The device is connected to the network using an ordinary plug. She should be in in good condition and match temperature standards, since heating will occur during operation. The plug must have a ground to which a special cable is connected. You also need to connect the ground cable to the appropriate terminal. The connection should occur close to the future seam, but at a safe distance. A special clamp is used to secure it to a metal surface.
Step-by-step instructions for connecting a welding machine
If you do not know how to connect the welding machine, then you should follow the sequence of steps below. Naturally, before connecting, you need to once again check the integrity of the device itself, the functionality of the components, and also find out the operating voltage. To connect you should have the following things:
- Welding machine;
- Extension;
- Adapter.
The step-by-step connection sequence is as follows:
- Preparing a plug for connection, which must have a certain set of parameters corresponding to the required thermal throughput;
- Select an outlet that has a fuse or circuit breaker;
- The return cable is connected to the terminal;
- The cable with the holder is connected to the electrode using a clamp.
Only after completing all these procedures can the equipment be connected to the network. Almost all models have short wires, so to connect them you need to use an additional extension cord. The wire in it must be large enough to withstand the specified voltage level.
Connection features depending on the type of device
Naturally, it’s also big professional model will have their own characteristics. If you need to connect a welding inverter with two phases, then the wires will be connected in an individual sequence. The first wire is put into phase immediately. The second wire is connected to the neutral output. The third wire is connected to the protection.
If you have to connect a three-phase device, then there is no longer a mandatory sequence. One of the main rules on how to connect a welding machine is to connect the first two wires to any phases, and one to the protection.
It is very important for specialists to know all the features of connecting various devices, especially such as. If this particular technique is used, then a number of special requirements must be taken into account. After all, the transformer is designed to work in a wide range of welding current parameters. This leads to a sharp surge in current in the network. Because of this, the circuit breaker may turn off or the socket may burn out. This type of equipment is connected to the panel.
Failure to comply with the above rules can lead to serious equipment breakdowns and also pose a risk to human life and health. Pre-inspection not only helps to avoid unnecessary injury, but also ensures good, stable welding conditions, not to mention a fire hazard.
Connecting an inverter welding machine is the simplest of the entire series, since most of them simply plug into a regular outlet without additional terminals, grounding, etc. The only question that may arise is how to connect. Here, too, everything is extremely simple, since the holder is placed on one terminal, and the clamp on the second. Most models even indicate the corresponding icons so that there is no confusion.
Possible connection problems
When was it committed? correct setting welding machine, but some problems may still occur. One of the most common problems is the strong hum of the transformer, which is often accompanied by overheating of the windings, so even forced and natural ventilation can not manage. The cause of the problem here lies in the turn short circuit that occurs in the primary winding. The only solution to this problem is to rewind the winding, which can pass partially or completely.
When the welding machine is connected to the network, they can give too much high current. This is also the reason short circuit, but this time its location becomes the secondary winding or the regulator winding. To correct the situation here, rewinding or eliminating the short circuit is also required.
If, when necessary, reduce the current value, nothing comes of it and the regulator spins in vain, then there is clearly a problem with the regulator terminals.
Periodically, a hum may occur on the device, which is not typical for normal operation. This situation may occur due to a weakened spring or due to a broken wire.
It may occur that the device does not turn on. Here you need to check all the connection contacts, since a contact may be broken, something may be disconnected, and so on. All inspections must be carried out only when completely disconnected from the network.
Thus, you should know not only how to connect an inverter welding machine, but also how to deal with its problems.
Video: connecting the welding machine to the generator
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In order for welding work to proceed without unnecessary problems, you need to figure out how to connect the 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 making the 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 carried out 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.
Today we will talk about how to independently connect a 380V welding machine for its further use. It’s worth warning right away that if the welding machine will be used at home, it is very important to know what load the machines in the electrical network of your house or apartment can withstand. And only after that choose an inverter the right type and power. When choosing a welding machine, of course, you need to take into account many important characteristics. We will describe the main points that you must pay attention to when choosing this rather expensive equipment. It is important to choose a unit that can be used to perform a maximum of tasks, but also that the cost corresponds to the stated parameters. So, what is it worth focusing on?
- Current consumption power. For example, in order to carry out welding work at home, a welding unit with a power of up to 5 kW is sufficient. Buying a device with a higher energy consumption threshold will be a waste of money.
- Resistant to power surges. Since in the power supply network there often occurs both a sharp drop and a sharp rise in current voltage.
- What network voltage range is the connected welding machine designed for?
After assessing all of the above parameters, as well as some others important conditions, you will already know how to properly connect the welding machine to the power supply. We will try to help a little with this and describe the technical key points.
Connecting equipment for welding work
Fundamental electrical diagram connections of the primary windings of the welding machine for voltage: a) 220 V; b) 380 V (secondary winding not specified).
At its core, a welding machine is a source of inverter welding current and a welding arc. It is clear that this arc occurs between the electrode and the metal. And the welding machine itself acts as a converter. To determine the permissible power of equipment for the type electrical wiring indoors, you need to multiply the voltage value in the network by the maximum current value, which is indicated on the automatic input panel of the unit for this type of work. To connect the 380 V unit itself, the output contacts must be correctly connected to it.
It is important to establish grounding to avoid electric shock when welding.
The connection diagram for welding equipment used in everyday life will be as follows:
- Define required power devices for performing welding in accordance with what will be welded.
- Using the current regulator knob, adjust the position of the transformer core. These actions decrease or increase the current strength.
- If necessary, set the switch on the unit body to the 380 V position
- Connect the two supply ends to the “phase”, and the third end to the “zero”.
Remember: the thick ends define the exit, and the thin ends define the entrance.
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Using cord extensions for the welding unit
As standard, such devices have a power cord ranging from 1.8 m to 2.5 m in length. But this length of the power cord may not be enough to carry out welding work on metal surfaces. But how to connect the welding unit in this case?
In such situations, extension cords are used. But using them uncontrollably is quite dangerous; preliminary calculations are required. So, with a wire cross-section of 1.5 sq. mm maximum current, which can be passed through such a wire, 16 A.
An important detail is that the extension cord must always be unrolled. This is due to the fact that this way the wire does not overheat under load and cools down faster, which reduces the risk of fire.
In addition, in this state no additional inductive reactance is formed.
By following these simple requirements, you will be able to properly connect the welding machine and weld safely.
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How to connect a 380 volt welding machine
Welding is a responsible and potentially dangerous process, during which many factors must be taken into account, technology and safety rules must be observed. Incorrect connection of a 380 W welding machine is the cause of sudden voltage surges, which leads to failure of household appliances, “sticking” of the electrode and accidents.
Wiring and socket requirements
According to the principle of operation, a welding machine is a current converter into a welding arc. Operating current range (equipment power) is the main characteristic of the device that determines it technical specifications. It must be consistent with the building's electrical capabilities. To determine this, the network voltage is multiplied by the maximum permissible value current (indicated on the circuit breaker). Compare the obtained value with the data in the equipment data sheet.
From a 220 V household outlet, you can only power an inverter device, which is a more advanced device with many settings and safety parameters. In this case, it must have a built-in refractory fuse or circuit breaker. In old houses, the wiring is designed for a maximum current of 10 A, and when the device is started, there is a jump to 40 A - in such buildings you need to connect to the panel.
A transformer device, which is designed to operate from 380 V, is connected only through the electrical panel. If the wiring is weak, it is recommended to use a gas generator.
Unit connection sequence
General scheme connections are made in the following sequence:
- Conduct necessary calculations and ensure that the connection of welding equipment to the building network is acceptable.
- Check the machines and the condition of traffic jams, make sure there are no bugs.
- Set the operating voltage required for specific work depending on the complexity, volume and type of metal. The setting adjusts the position of the transformer core.
- Turn the device switch to the 220 V or 380 V position.
- If it is possible to connect to 220 V, insert the plug into the socket.
- To connect the welding machine to a 380V network, two supply ends are supplied to the “phase”, the third - to the “zero”. It is recommended to use an industrial socket and appropriate plug.
Using extension cords
The maximum length of the device cord is no more than 2.5 m; it is not enough for large-scale work. In this case, the use of an extension cord is allowed to connect the welding unit. When choosing it, you must comply with the following requirements:
- The cross-section of the wire must correspond to the rule: 1 sq. mm for every 8 A;
- total length supply wire – no more than 10 m.
During operation, the cable must be completely unrolled to prevent overheating and the formation of inductive reactance. Intermediate connections must be avoided - large current losses occur through them. The use of damaged wires is strictly prohibited.
Compliance with requirements and standards when connecting guarantees subsequent safe and efficient use equipment.
Related video: How to make 220 from 380 and where to connect the grounding
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How to connect a welding machine to a network at 220, 380: setup
To ensure that the welding process is as safe as possible and that no serious problems arise during it, you should figure out how to connect the welding machine. This requires taking into account several key factors, such as location. Type of device, location of ventilation, etc. Ventilation is one of the most important considerations when placing an inverter, as they are highly susceptible to overheating. You also need to pay attention to contact with dust. Thus, connecting a welding machine can be a daunting process for beginners.
Connecting the welding machine begins with checking the network parameters. It must match the one indicated on the body of the equipment, since otherwise it cannot be used. Here it is necessary to observe the correct connection devices. Here it is necessary to use grounding and phase wires, which can consist of one phase or two phases and a neutral.
If the model has a function for self-regulating the input voltage, then it should be placed in a position whose value will correspond to the network voltage. A fixing screw is usually used to secure the position.
The device is connected to the network using an ordinary plug. It must be in good condition and meet temperature standards, as heating will occur during operation. The plug must have a ground to which a special cable is connected. You also need to connect the ground cable to the appropriate terminal. The connection should occur close to the future seam, but at a safe distance. A special clamp is used to secure it to a metal surface.
Step-by-step instructions for connecting a welding machine
If you do not know how to connect the welding machine, then you should follow the sequence of steps below. Naturally, before connecting, you need to once again check the integrity of the device itself, the functionality of the components, and also find out the operating voltage. To connect you should have the following things:
- Welding machine;
- Extension;
- Adapter.
The step-by-step connection sequence is as follows:
- Preparing a plug for connection, which must have a certain set of parameters corresponding to the required thermal throughput;
- Select an outlet that has a fuse or circuit breaker;
- The return cable is connected to the terminal;
- The cable with the holder is connected to the electrode using a clamp.
Only after completing all these procedures can the equipment be connected to the network. Almost all models have short wires, so to connect them you need to use an additional extension cord. The wire in it must be large enough to withstand the specified voltage level.
Connection features depending on the type of device
Naturally, a mini welding machine and a large professional model will have their own characteristics. If you need to connect a welding inverter with two phases, then the wires will be connected in an individual sequence. The first wire is put into phase immediately. The second wire is connected to the neutral output. The third wire is connected to the protection.
If you have to connect a three-phase device, then there is no longer a mandatory sequence. One of the main rules on how to connect a welding machine is to connect the first two wires to any phases, and one to the protection.
It is very important for specialists to know all the features of connecting various devices, especially such as a welding transformer. If this particular technique is used, then a number of special requirements must be taken into account. After all, the transformer is designed to work in a wide range of welding current parameters. This leads to a sharp surge in current in the network. Because of this, the circuit breaker may turn off or the socket may burn out. This type of equipment is connected to the panel.
Failure to comply with the above rules can lead to serious equipment breakdowns and also pose a risk to human life and health. Pre-inspection not only helps to avoid unnecessary injury, but also ensures good, stable welding conditions, not to mention a fire hazard.
Connecting an inverter welding machine is the simplest of the entire series, since most of them simply plug into a regular outlet without additional terminals, grounding, etc. The only question that may arise is how to connect welding wires to the welding inverter. Here, too, everything is extremely simple, since the holder is placed on one terminal, and the clamp on the second. Most models even indicate the corresponding icons so that there is no confusion.
Possible connection problems
When the welding machine has been correctly configured, problems may still occur. One of the most common problems is the strong hum of the transformer, which is often accompanied by overheating of the windings, so that even forced and natural ventilation cannot cope. The cause of the problem here lies in the turn short circuit that occurs in the primary winding. The only solution to this problem is to rewind the winding, which can pass partially or completely.
When the welding machine is connected to the network, they may produce too high a current. This is also the reason for the short circuit, but this time its location is the secondary winding or the regulator winding. To correct the situation here, rewinding or eliminating the short circuit is also required.
If, when necessary, reduce the current value, nothing comes of it and the regulator spins in vain, then there is clearly a problem with the regulator terminals.
From time to time, a hum may occur on the device, which is not typical for normal operation. This situation may occur due to a weakened spring or due to a broken wire.
It may occur that the device does not turn on. Here you need to check all the connection contacts, since a contact may be broken, something may be disconnected, and so on. All inspections must be carried out only when completely disconnected from the network.
Thus, you should know not only how to connect an inverter welding machine, but also how to deal with its problems.
Video: connecting the welding machine to the generator
svarkaipayka.ru
Connecting the welding machine | Electricdom.ru
A welding machine is a voltage and current converter that are necessary to produce an arc between the electrode and the metal. Manufacturers of welding machines are trying to create as much as possible Better conditions specialist during his work.
First of all, the welding current range (figuratively speaking, the power of the device) plays a role in the work. For welding fences, gratings and other structures, an electrode of up to 4 mm is sufficient, and welding current in this case it will fluctuate between 180-220 A. Ux.x also plays a role. (voltage idle move), the higher it is, the easier it is to ignite the arc. Usually it is 35-80 V. But many devices already have an arc ignition function, which is convenient. If the machine has a function for rectifying the welding current, the seam will be of better quality and smoother.
The welding machine has a knob for adjusting the current (the core of the transformer is adjusted), the current decreases or increases. There are fewer turns on the secondary winding of a welding transformer than on the primary winding, this is necessary to increase the current.
When connecting the welding machine, you need to look at what voltage it is designed for; if it is both 220 V and 380 V, you need to switch the corresponding switch.
To connect a 220V welding machine to a 380V network, you need to connect the power supply to one wire per phase, the other to the neutral, and the third wire to the protective neutral conductor to protect the housing. To connect a 380 V household welding machine to the machine (you must make sure that the machine is rated current sufficient for the operation of the welding machine) connect the supply ends to any two phases, and also connect the third wire to the protective neutral conductor to protect the housing. If you can’t see where the input and where the output of the welding transformer is - thick welding ends (output), thinner ends (input). In fact, a certain number of turns are simply added to the primary winding of the transformer and the supply voltage is increased from 220 to 380V.
Welding transformer NORDIKA 3200 is designed for manual arc welding with alternating current of low-carbon and low-alloy steels. The device is equipped with a fan and overheating protection, equipped with cables, an electrode holder, a grounding terminal, a mask, a brush and a hammer. Manufacturer: TELWIN.
Characteristics: Supply voltage, 220-380 V Power consumption, 3.5 kW Maximum current consumption, 16 A No-load voltage, 48 V Welding current, 55-190 AD Electrode diameter, 2-4 mm Weight, 20 kg Dimensions, 650x325x425 mm
On a core made of transformer steel, there are two windings - primary and secondary. In devices of this type, one winding is fixed statically, and the second moves relative to the first along the core. It is this movement that regulates the current strength.
To determine the permissible power of the welding machine for a specific electrical wiring, you need to multiply the mains voltage by the maximum current value indicated on the input panel.
When the current (welding) on the secondary winding of the transformer increases, the voltage decreases, the power must remain the same (property of the transformer).
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Connecting the welding machine and operating rules
In order to use the welding machine correctly and safely, it is necessary to ensure its connection in accordance with all the features of handling this equipment. It is important to connect the welding machine correctly.
Attention must be paid to every little detail, including the choice of power cable for the device. To work with a welding machine, you must have experience, since this equipment is potentially dangerous; you cannot start work without experience and protection.
Rules for connecting a welding machine
To use welding correctly, you must follow all the requirements and recommendations for turning on the welding machine:
- The first thing to do is check the frequency and voltage. The data is indicated by the manufacturer on the equipment housing. They must match the network indicators. The connection itself can be made in one of several ways: using two phases, one phase and neutral, using separate grounding.
- If the model of welding equipment allows it, you must immediately select the required voltage for the supply network. The switch is fixed in the selected position. It is important to determine which network will work with, otherwise the device will fail.
- To connect, you must use a plug whose characteristics comply with all standards. Plugs can be easily purchased either separately or together with extension cables, which makes connection much easier. The plug must have a grounding lug, through which the connection will be made. A regular socket is no longer suitable; you must use a special fuse; you can also use an auto switch to make the connection simple and safe.
- The welding machine is turned on by means of a return ground cable, which is attached to the terminals at the required operating point. In this case, the distance from the future seam should be as minimal as possible. The cable holder must be fixed to a special fragment of the housing using a reliable clamp.
- Before you begin connecting to the network, you must re-check that all plugs and cables are connected securely and firmly. If there is poor contact, this may cause the equipment to stop, creating a dangerous situation.
Before you start working, you need to prepare gloves and a special welding mask with eye protection. This required condition, since a high-temperature arc is formed during welding. It can seriously damage your eyes if you don't protect them.
Wiring for welding machine
If the welding machine will be used at home, then you must immediately check what type of wiring is installed and inspect the sockets. This happens due to the fact that weak wiring can lead to failure of the welding machine. Typically, in older homes, outlets are rated at 10 A, which may not be sufficient for welding work. In this case, the use of special generators may be required. It is necessary to inspect the condition of the meter; under no circumstances should there be so-called bugs on it.
If these requirements are not taken into account, then when the welding machine is turned on, a sharp voltage surge may occur, and the light may well go out not only in the apartment, but throughout the entire house. Strong drops of up to 150 V lead to the fact that welding becomes impossible, and vibrations occur in the room, which are dangerous for any electrical equipment, lighting fixtures.
Can I use an extension cord?
When connecting the welding machine, it is important to use the correct power cord; its length should be up to 1.8-2.5 m. Therefore, the question arises whether an extension cord can be used if required. There are no special restrictions, but you cannot use such equipment uncontrollably. This requires a calculation; it is not recommended to connect the extension cord without it.
You need to start with a section electric cable. For a product of 1.5 m², you can use a current with a maximum value of 16 A. For equipment with a cable cross-section of 2.5 m², the current value is already higher - up to 25 A. It is necessary to take into account what type of welding equipment will be used, what conditions for its applications exist. Manufacturers of welding machines themselves indicate all the necessary values; all that remains is to purchase an extension cord that meets all the requirements.
When using an extension cord, it is necessary to completely unroll the wire so that it cools quickly and easily and does not form inductive resistance. It is important to use grounding; operational safety depends on it.
Sometimes it becomes necessary to extend the cable near the entrance of the welding machine. It is better not to make intermediate connections; you should use the whole multi-core cable with the required section. For a current of 140 A, the cross-section should not be less than 35 mm². It is best to use copper conductors with a diameter of 7 mm or more.
Welding generator or gas generator?
For correct use equipment, it is important to choose a generator. It often happens that when the voltage drops during welding, the process stops and becomes impossible. Many people make the mistake of using a gas generator for work, which will provide power to the welding equipment. Its power is small quality work he simply cannot provide.
You cannot use generators whose power is less than 5 kW, as they will not withstand the required voltage.
The output voltage value will be very different from the total power.
When using a 3 mm electrode, the current is 120 A, the voltage should be 40 V. The output power will be 120x40 = 4.8 kW. If efficiency welding inverter is 0.8-0.9, then the input power should be 4.8/0.8/=6 kW. It is important to remember that an inverter-type welding machine is sensitive to any voltage surges at the input. If not provided normal conditions work, the equipment will quickly fail.
If the network is weak, then it is better to use a welding machine that is connected not to a gas generator, but to an electric generator. The Champion DW 180 AE model is perfect here, for which a welding current of 180 A is possible. If necessary, you can use a special stabilizer alternating current, which is mounted in front of the welding equipment. The cost of such equipment is significant, but its use is necessary for high-quality work and safety.
For safe use welding machine, it is important to ensure that it is switched on correctly. To do this you need to follow quite simple recommendations, use only correctly selected cables for connection, and if necessary, purchase a generator to power the device.
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A typical design of a welding machine for electric arc welding includes two main parts: a power source, which receives voltage from the mains, and a welding unit. The welding unit, in turn, consists of a holder, the electrode itself and the neutral wire. When the electrode briefly touches the place of the future connection, a spark jumps at this place (a breakdown occurs) in the gap from the air. This is where welding begins directly. The welder must have time to remove the heated end so that it does not stick to the metal surface. At the same time, it is necessary to maintain such a minimum distance between the electrode and the metal that allows maintaining the electric arc. An electric arc is a fairly long-lasting electrical discharge that occurs between the area of the future weld and the end of the electrode. The welding area is also called the arc zone. At the cathode region a temperature of over 30000C is formed. At the same time, the potential difference remains relatively small, only 20 - 25 V. During arc formation, the air gap first breaks down with electrons. Afterwards, in a split second, the process stabilizes in the arc gap. Next comes the ionization of gas molecules by electrons, resulting in ionic conductivity. The arc combustion is stabilized with the help of melting and evaporating coating of the electrodes. During welding, under the influence of high temperature, the electrode begins to melt. A drop of molten metal appears at its end: it breaks off and falls onto the metal surface of the part. Within 95% of the total mass of the electrode is transferred to the metal, the rest turns into steam and splashes. Current strength, electrode diameter, arc length and other factors affect the rate of droplet formation and their size. The shell that covers the electrodes forms a slag to hide the metal droplets. As a result, drops of metal passing through the arc do not close the arc gap. The operating procedure of a typical welding transformer and its connection diagramThe transformer is the main power source of the entire welding system. With its help, the single-phase mains voltage is reduced from 220V to a working value for welding of the order of 50 - 80V. Non-standard operating conditions require the greatest power output from the transformer during welding work. The design of the welding transformer involves the passage of large currents through it. To improve the technical characteristics of the welding machine, additional devices are used:
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How to connect a welding machine: requirements
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 that during operation you do not damage the electrical wiring, sockets, and the device itself. 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.